Ultrasonic Spot Welders work with foils as thin as 7 microns.

Press Release Summary:

Able to weld multiple layers and/or delicate foils to tabs or terminals, SonoWeld® 1600 and Dual Head Spot Welders also accommodate battery pouch assembly and HV termination welding. Durable bonds are created in one operation that takes seconds; does not employ any heat, current, fluxes, or filler; and does not produce any arcs, sparks, or fumes. Dual Head Spot Welder can join up to 100 layers of copper or aluminum foil in one pulse. Systems offer outputs of 1,500 and 2,500 W.

Original Press Release:

Sonobond's New Generation of Battery Assembly Technology Featured at Upcoming 2014 Battery Show

Ultrasonic spot welders achieve environmentally friendly, high-performance welding with unique and patented features.

WEST CHESTER, Pennsylvania –The capabilities of the SonoWeld® 1600 and Dual Head Spot Welders will be the focus of Sonobond Ultrasonics’ display at the 2014 Battery Show in Novi/Detroit, Michigan, September 16 –18.

“Our units require no consumables and use lower vibration amplitude than competitors’ ultrasonic equipment to weld foils as thin as seven microns without tearing, notes Vice President Melissa Alleman.  “Plus, our Dual Head Spot Welder is the first ultrasonic welder that can join up to 100 layers of copper or aluminum foil in just one pulse.  Both machines provide a fast, efficient, environmentally friendly and cost-effective way to weld multiple layers and/or delicate foils to tabs or terminals.  They also can accommodate battery pouch assembly and HV termination welding.”

Assembly Capability to Meet Growing Demand for Batteries

“The use of batteries in all-electric and hybrid automobiles, as well as in advanced utility and renewable energy storage, medical technology, military applications and telecommunications is expanding,” Alleman adds.  “Demand for batteries, especially lithium-ion and NiMH rechargeable batteries, in consumer products has also grown.  Our equipment can be used in the assembly of many of these battery products.”

Fast, Reliable Welds with a Unique Ultrasonic System

Sonobond’s spot welders create durable bonds in a single operation that takes only seconds and employs no heat, current, fluxes or filler and produces no arcs, sparks, or fumes.  Instead, the units use Sonobond’s unique, patented Wedge-Reed bonding system that combines high vibratory force and low amplitude coupling.  By utilizing sheer mode vibration parallel to the welding surface, while the line of force is directly over the parts to be welded, precise, dependable, solid-state and highly conductive welds are created without bending stress or stalling.  This ultrasonic system is also the only one capable of providing one-pulse welding of most oxidized and tinned metals without pre-cleaning.

The SonoWeld® 1600 and Dual Head Spot Welders use outputs of 1,500 and 2,500 watts to weld non-ferrous similar or dissimilar assemblies, including copper to aluminum.  Both have a power supply with a built-in microprocessor that features automatic frequency control, overload protection, and storage and recall of up to 250 weld protocols.  The units also have digital displays that allow weld control to be selected by time, energy, or distance.  Easily removed and replaceable heat-treated steel Taper Lock Tips can perform up to 100,000 welds.  Like all Sonobond equipment, the spot welders require only minimal training for operation.

Free Ultrasonic Welding Viability Test

To ensure that manufacturers get the spot welder that’s appropriate for their particular applications and requirements, Sonobond offers a free Ultrasonic Welding Viability Test.  Potential customers provide their materials to Sonobond for no-cost, no-obligation sample welds.   And our assistance doesn’t end there; if Sonobond’s equipment is incorporated into the customer’s production process, service and technical support is available before, during and after installation.

Industry Leadership for More Than a Half-Century

A pioneer in ultrasonic technology, Sonobond holds more than 150 patents, including the first – in 1960, when the company was known as Aeroprojects – for ultrasonic metal welding.  In the ensuing 54 years, Sonobond has established and maintained a well-earned reputation for innovative and quality-engineered products.  Today, the company manufactures a complete line of ultrasonic welding and bonding equipment used by leading firms in the electrical, automotive, appliance, HVAC, solar, aerospace, filtration, medical and apparel industries.

Learn More

“Attendees at this year’s Battery Show are encouraged to stop by our Booth #1540 to learn how our SonoWeld® 1600 and Dual Head Spot Welders can help them achieve dependable and cost-effective solutions to their battery assembly needs,” says Alleman.

For more immediate information about Sonobond’s products or details on submitting materials for a free, no-obligation Ultrasonic Welding Viability Test, please visit www.sonobondultrasonics.com, call 800-323-1269, or contact Vice President Melissa Alleman at MAlleman@sonobondultrasonics.com.

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