Sonobond Ultrasonics is claiming success as battery assemblers choose its SonoWeld^® 1600 digital metal spot-welder and its dual-head SpliceRite^™ ultrasonic unit. “Our technology is especially important to companies that produce rechargeable lithium-ion batteries,” according to Melissa Alleman, Sonobond's vice president. “These types of batteries are in high demand today because they are used in everything from laptops to cell phones, and power tools to hybrid electric cars. However, manufacturing lithium-ion, as well NiMH batteries, often requires the welding of multiple layers and/or delicate foils to tabs or terminals.”

The SonoWeld^® 1600 can weld up to 20 layers of foil, and the dual-head SpliceRite^™ unit welds up to 80 layers of foil.

Sonobond's (www.SonobondUltrasonics.com) ultrasonic welding technology creates a fast, durable bond without using heat, current, fluxes, or fillers. This means there are no consumables costs and no cleaning requirements after assembly. The patented Wedge-Reed coupling system directs high-frequency ultrasonic energy to the metals being welded. The energy disperses oxides and surface films between the workpieces to create a true metallurgical bond, without melting the materials. The one-step process takes only seconds. There is no damage to foils or mesh.

The SonoWeld^® 1600 digital metal spot welder, available in 1500 and 2500 power levels, welds dissimilar metals to tabs or terminals. It handles copper, aluminum, lithium, nickel, and other nonferrous materials, creating bonds that have greater electrical conductivity and weld strength than those created by conductive adhesives. In addition to lithium-ion and NiMH batteries, the SonoWeld^® 1600 can be used to assemble pouch cells and for a variety of other terminal-joining operations.

At the same time, the dual-head SpliceRite^™ ultrasonic unit uses the patented Wedge Reed System. The design has two welding heads, one on each side of the weld area, which increases its capacity for welding up to 80 levels of foil.