The Unique Capabilities of Sonobond's Dual Head SpliceRite(TM) Ultrasonic Wire Splicer

The machine confidently handles stranded copper wire bundles-with crosssectional areas up to 100 square millimeters-all in one pulse. Even tinned and oxidized wires can be accommodated. This exceptional equipment will be exhibited at Booth #1540 at the 2012 National Electrical Wire Processing Technology Expo in Milwaukee, May 9-10.

WEST CHESTER, Pennsylvania - Sonobond's Dual Head SpliceRite(TM) continues to be the industry leader for ultrasonic splicing of wire harness assemblies. According to Sonobond's Vice President, Melissa Alleman, the Dual Head SpliceRite is unequalled in its handling of large wire bundles. She says, "This ultrasonic wire splicer is the latest in our SpliceRite(TM) series. It can reliably weld stranded copper wire bundles having cross-sections of 48 to 100 square millimeters. It even accommodates lightly tinned or oxidized wires up to 60 square millimeters without pre-cleaning. No other ultrasonic metal welder can accomplish these splices in a single pulse. All this makes the Dual Head SpliceRite ideal for fast, dependable, cost-efficient ultrasonic splicing of the heavy-duty cables used in wire harnesses for cars, trucks, trains, industrial machinery, and similar applications.

Sonobond's Dual Head SpliceRite(TM) Ultrasonic Wire Splicer

"Sonobond is looking forward to exhibiting the Dual Head SpliceRite at the 2012 National Electrical Wire Processing Expo in Milwaukee this May. Expo attendees are invited to come to Booth #1540 to see this equipment in operation and inspect sample welds. Once they witness a demonstration of the machine's wire splicing capabilities, they'll understand why the Dual Head SpliceRite is the ultrasonic metal welder of choice for so many wire harness assemblers."

Superior to Other Ultrasonic Metal Wire Splicers

Ultrasonic metal welding is now a well-accepted and frequently used method of assembling wire harnesses. It creates solid-state metallurgical bonds with high conductivity. This is accomplished without the need for filler metal materials and without clipping, soldering, crimping, or dipping. The process does not produce arcs, sparks, or fumes and does not result in melting of the weldment.

However, the Sonobond Dual Head SpliceRite(TM) is truly unique among ultrasonic wire splicers. It consists of two ultrasonic transducers and couplers-one above and one below the weld area-plus a set of pneumatically driven jaws. These jaws gather the wires tightly to a preset width. The upper tip then descends to complete the compressing of the bundle and ultrasonic power is applied. When the cycle ends, the jaws open so the wires can be removed. A support for the wire array can also be integrated into the tooling system if necessary. This cost-effective process produces no waste, consumes only minimal energy, and is environmentally-friendly.

Accommodates Even Oxidized or Tinned Surfaces

All Sonobond metal spot welders, including the Dual Head SpliceRite, are made in the U.S.A. and use the unique, patented Wedge-Reed bonding system of high vibratory force and low amplitude coupling. Shear mode vibration, parallel to the welding surface, is utilized while the line of force is directly over the parts to be welded.

Sonobond's Dual Head SpliceRite(TM) Ultrasonic Wire Splicer

This creates precise, dependable welds without bending stress or stalling. It also permits splicing of most oxidized and tinned metals with just one pulse and without pre-cleaning. No other ultrasonic metal welding system can weld oxidized or tinned surfaces.

Taper Lock Tips Last for 100,000 Welds or More

Sonobond's Dual Head SpliceRite features heat-treated, tool steel taper lock tips that can last for 100,000 welds or more. These are designed for quick tooling changes and fool-proof placement. The equipment has a 3500-watt power supply with a microprocessor that stores and recalls up to 250 jobs. Welds can be controlled by height, by energy, or by time. The entire process is completed in one quick step without melting the material. Like Sonobond's other ultrasonic welders and bonders, the Dual Head SpliceRite can be operated easily and requires only a minimal amount of training.

An Invitation to Expo Attendees

In speaking of Sonobond's participation in the upcoming 2012 National Electrical Wire Processing Technology Expo, Vice President Alleman says, "We are very much looking forward to attending this important event in Milwaukee, May 9th and 10th. Our Dual Head SpliceRite(TM) Ultrasonic Wire Splicer represents a significant breakthrough in the field of wire harness assembly. So I encourage Expo attendees to take the opportunity to see this machine in operation and inspect the sample welds we will have on hand. We'll be at Booth #1540 in the Frontier Airlines Center. Visitors will find us ready to answer their questions and discuss the ways in which Sonobond equipment and expertise can provide practical, cost-effective solutions to their specific needs."

Over 50 Years of Innovation and Leadership

In 1960, Sonobond-then known as Aeroprojects-received the first patent ever awarded for ultrasonic metal welding. Over the intervening 52 years, the company has continued to enjoy a well-earned reputation for innovative leadership and qualityengineered products. Sonobond currently manufactures a complete line of ultrasonic Page 4. Sonobond's Dual Head SpliceRite(TM) Ultrasonic Wire Splicer welding and bonding equipment for firms in the automotive, appliance, solar, electrical, filtration, aerospace, medical, body armor, and apparel industries.

Free Ultrasonic Welding Viability Test

Sonobond offers a no-cost, no-obligation way for companies to determine which machine is right for a specific application. To take advantage of this Free Ultrasonic Welding Viability Test, companies are encouraged to submit their materials so that sample welds can be made. Once a manufacturer decides to introduce Sonobond equipment into its production process, every effort is made to assure this is accomplished in as seamless a manner as possible. Customers can confidently rely on Sonobond for superior customer service and for prompt, dependable technical support before, during, and after installation.

Additional Information

To find out more about the Dual Head SpliceRite Ultrasonic Wire Splicer and other Sonobond equipment-or to take advantage of the free Ultrasonic Welding Viability Test-please visit or call 1-800-323-1269. For immediate service, contact Sonobond's Vice President, Melissa Alleman, at

© 2012 Sonobond Ultrasonics

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