Sonobond Ultrasonics Solves Assembly Demands of Complex Components

Sonobond Ultrasonics’ Wire-to-Terminal Assembly Solutions Satisfy Requirements of Today’s Complex Electronic Components

WEST CHESTER, Pennsylvania, March 31, 2016 – Sonobond Ultrasonics’ metal welding technology is keeping pace with the growing number of increasingly complex electronic components used in automotive and other circuitry. The company even offers wire-to-terminal welders that produce single point ground terminals, and can also accommodate a variety of specialty applications through its custom tooling capabilities.

“Today’s automotive circuitry is particularly susceptible to electrical noise caused by multiple ground connections,” explains Melissa Alleman, Sonobond vice president. “Our Single Point Ground Welder is a microprocessor-controlled, spot-welding system that ultrasonically welds as many as 18 wires onto a single terminal with just one pulse. Then, it automatically folds over the terminal arms to provide stress relief for the joint. Ground loops, that generate electrical noise, are eliminated.”

Ultrasonic Welding and the Wedge-Reed Bonding System

The ultrasonic metal welding technique, as employed by the Single Point Ground Welder and other Sonobond metal welding equipment, uses a welding tip to direct high frequency, ultrasonic vibratory energy to the surface between the metals being welded. That vibratory energy disperses the oxides and surface films between the work pieces, creating a true metallurgical bond. No materials are melted and no heat, current, fluxes or fillers are used, making the welding process particularly energy efficient and environmentally responsible.

But Sonobond’s unique, patented Wedge-Reed bonding system takes ultrasonic welding technology a step farther to assure precise, ultra-reliable welds are achieved by all its metal welding units. Shear mode vibration parallel to the welding surface is essential for metal welding to occur. Sonobond’s system generates the shear mode with high vibratory force and low amplitude while the line of force is directly over the parts to be welded. This creates maximum ultrasonic metal welding effectiveness without bending stress or stalling and exclusively enables most oxidized and lightly tinned metals to be welded.

“Our Wedge-Reed bonding system definitely gives us a competitive edge by providing our customers with the means to achieve exceptionally efficient and precise wire-to-terminal assemblies,” notes Alleman.

Features of the Sonobond Single Point Ground Welder

In addition to welding up to 18 wires, Sonobond’s Single Point Ground Welder can also weld wire bundles up to 20 square millimeters to a single terminal in one pulse. It utilizes heat-treated, tool steel, easily removed and replaced Taper Lock Tips that can be readily redressed and can perform up to 100,000 welds before being discarded. The 2,500-watt unit includes a microprocessor that stores and recalls up to 250 protocols. A digital display allows welding modes to be selected by time or energy and provides automatic frequency control and overload protection. Automatic control monitoring can also detect variations from preset limits. Plus, weld data can be transferred to or from a computer via the unit’s RS232 port.

Additional Wire-to-Terminal and Wire-to-Wire Welders and Applications

For other spot and wire-to-terminal welding applications, Sonobond offers the SonoWeld® 1600 Metal Spot Welder. This equipment welds foils, as well as foils to tabs for batteries and capacitors, and can join dissimilar metals, such as copper to aluminum. Its microprocessor stores and recalls up to 250 weld protocols. Sonobond’s Dual Head Spot Welder can accommodate up to 100 layers of foil for battery and capacitor applications. It can also weld non-ferrous sheet metal, including aluminum, up to 3mm in thickness.

In addition to machinery for wire-to-terminal and battery welding applications, Sonobond has its ultrasonic SpliceRite™ series for wire-to-wire welding of bare copper wire up to 100mm2 and tinned wire to 60mm2. These metal spot and wire welders – all made in the U.S.A. – ultrasonically assemble electrical wire harnesses; bus bars; electrical contacts; fuses and circuit breakers; ignition modules; starter motors; assembly boards; circuit analyzers; and connectors, terminals and switches.

Accommodating Assembly Applications through Custom Tooling

“We are especially sensitive to the fact that every application is unique and every company has different production requirements,” says Alleman.

She notes that Sonobond takes a step-by-step approach to custom tooling. First, it determines whether its ultrasonic metal welding is appropriate for the customer’s application. “For example, we always test tinned materials and ensure that our equipment can handle an unusual part configuration,” Alleman explains.

Next, Sonobond considers the geometry and specification of the finished part to determine what tooling adjustments are needed. Then, tooling is designed to hold the various pieces to be welded in the proper configuration while the weld is being completed. “We’re always mindful not to unnecessarily complicate load and unload operations,” says Alleman.

Finally, finished welds are checked to ensure that dimensional tolerances and electrical and mechanical requirements are met. Customers are welcome to review the operation and have parts delivered to their facility so they can run their own tests. Sonobond’s technicians can also be at the customer’s site for final approval. “Throughout the process, we work closely with our customers’ plant engineers and manufacturing personnel,” explains Alleman.

Order a Free Ultrasonic Welding Viability Test

To ensure that Sonobond equipment can meet your welding needs and assembly specifications, take advantage of our free, no-obligation Ultrasonic Welding Viability Test, using materials supplied by you to provide sample welds. If you decide to incorporate Sonobond equipment into your assembly process, you’re assured of receiving comprehensive customer service and technical support, before, during and after installation.

An Industry Leader

A pioneer in ultrasonic technology, Sonobond holds more than 150 patents, including the first for ultrasonic metal welding in 1960, when the company was known as Aeroprojects. In the ensuing decades, 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, body armor and apparel industries.

Additional Information

For more information on Sonobond’s ultrasonic metal welding technology and equipment, stop by Booth #1544, at the WPE Show, May 11 and 12, at the Wisconsin Center, in Milwaukee. To obtain information now or submit materials for a free Ultrasonic Welding Viability Test, please click this link. For immediate assistance, call 800-323-1269, 610-696-4710, or email skarmilowicz@sonobondultrasonics.com