Ultrasonic Wire Splicer utilizes two welding heads.

Press Release Summary:

Able to accommodate tinned or heavily oxidized wires, Dual Head SpliceRite(TM) welds wire bundles that have cross-sectional areas of up to 100 mm². It comes with 3,500 W power supply and utilizes Wedge-Reed system, which directs high frequency ultrasonic energy via welding tips to wires to be welded. Welding heads on each side of weld area enables accelerated splicing of large wire bundles. Up to 250 jobs can be stored/recalled, and welds may be controlled by height, energy, or time.

Original Press Release:

Sonobond Announces it will Introduce its Dual Head SpliceRite(TM) Ultrasonic Wire Splicer at the National Electrical Wire Processing Technology Expo in Milwaukee

This new unit welds bundles with a cross-sectional area of up to 100 sq. mm. Expo attendees can see this innovative wire splicing technology at Booth #1513, May 20-21.

WEST CHESTER, Pennsylvania, March 10, 2009-Sonobond Ultrasonics, a leader in ultrasonic metal welding technology since 1960, announced today that it will be introducing its Dual Head SpliceRite(TM) Ultrasonic Wire Splicer at the National Electrical Wire Processing Technology Expo in Milwaukee, May 20-21. In making the announcement, Melissa Alleman, Sonobond's Vice President, said, "This new machine represents a significant breakthrough in ultrasonic wire splicing technology. Like the current SpliceRite(TM) Ultrasonic Wire Splicer, this unit accommodates tinned or heavily oxidized wires that can otherwise stall the welding process. However, the breakthrough is the ability of the Dual Head SpliceRite(TM) Ultrasonic Splicer to weld wire bundles that have cross-sectional areas of up to 100 square millimeters. No other ultrasonic bonder can equal this capacity in a single hit. This makes the Dual Head SpliceRite(TM) suitable for applications involving heavy-duty cables for cars, trucks, and industrial machinery."

The dual-headed welder, with appropriate tooling, has also extended the capacity of ultrasonic welding to weld multiple layers of foils for batteries.

Dual Head Technology
As the name suggests, the new Sonobond wire splicer has two welding heads, one on each side of the weld area. This increases the welding capacity, enabling larger wire bundles to be spliced quickly, in one step. The resulting welds have low voltage drop.

The ultrasonic welding process creates solid-state metallurgical bonds without producing arcs, sparks, or fumes, or melting wires. Ultrasonic technology eliminates any need for filler metal materials or for clipping, soldering, crimping, or dipping. The new Dual Head SpliceRite(TM) Ultrasonic Wire Splicer has a microprocessor controller with the ability to store and recall up to 250 jobs. It can control welds by height, by energy, or by time. The unit comes with a 3500 watt power supply.

Uses the Patented Wedge-Reed System
The Dual Head SpliceRite(TM) Ultrasonic Wire Splicer-like other Sonobond metal welders-utilizes the patented Wedge-Reed system. This system combines high vibratory force with low amplitude coupling. It enables the unit to direct high frequency ultrasonic energy via welding tips to the wires to be welded. The vibratory energy disperses the oxides and surface films between the wires. A true metallurgical bond is then created without melting the materials. This process is environmentally friendly, produces no waste, and consumes a minimum of energy.

All Sonobond metal welders feature heat-treated, tool steel taper lock tips. These tips last for as many as 100,000 welds and permit quick tooling changes and fail-proof placement. Sonobond units have the additional benefit of being easy to operate with only minimal training.

Expo Attendees Encouraged to Visit Booth #1513
Vice President Alleman encourages Expo attendees to come to Booth #1513 in Milwaukee to discuss the merits of the Dual Head SpliceRite(TM) Ultrasonic Wire Splicer. "This new technology is another example of our continuing commitment to the wiring industry. The Dual Head SpliceRite(TM) successfully accommodates wire bundles much larger than other ultrasonic bonders can handle and can be used even when wires are tinned or heavily oxidized. So we invite Expo visitors to stop by and discuss their company's requirements with us. They will find that Sonobond is second to none in providing customized solutions that are backed by truly exceptional customer support."

A Record of Pioneering Accomplishment
Sonobond is a worldwide leader in the application of ultrasonic welding and bonding technology. In 1960, Sonobond-then known as Aeroprojects-received the first patent ever awarded for ultrasonic metal welding. During the intervening 49 years, Sonobond has earned an outstanding reputation for its pioneering work and quality-engineered products. Today Sonobond manufactures a complete line of ultrasonic bonding and welding equipment for a wide variety of customers in the electrical, automotive, appliance, HVAC, aerospace, filtration, medical, and apparel industries.
Additional Information

To learn more about Sonobond products-as well as for information about its free, no-obligation Ultrasonic Welding Viability Test-visit the company's website at SonobondUltrasonic.com or call toll free 1-800-323-1269.

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