Increased trade show participation parallels expected spike in demand for innovative energy storage.

WEST CHESTER, Pennsylvania, July 28, 2016 – Sonobond’s ultrasonic battery assembly prowess will be featured at trade shows in China and Michigan this year. The company’s participation in two events is indicative of growing worldwide interest in battery solutions for renewable energy storage, notes Sonobond President Janet Devine.

Sonobond’s ultrasonic metal welding technology provides a cost-effective, environmentally friendly method for attaching multiple layers of foil to battery terminals, even for the assembly of new, innovative, rechargeable batteries designed to store electrical energy from alternative and conventional sources.“Increased demand for affordable and efficient battery storage, as well as for rechargeable batteries, has stimulated manufacturers’ awareness of our reliable, eco-friendly, high-conductivity, ultrasonic assembly methods,” explains Devine.

The China International Battery Industry Fair takes place August 23 – 25, at the Shanghai New International Expo Center, in Shanghai, while The Battery Show Exhibition & Conference occurs September 13 – 15, at the Suburban Collection Showplace, in Novi, Michigan. Both trade shows attract leading global suppliers of materials and equipment related to the battery industry.

Providing Eco-friendly Assembly for Alternative Energy Storage

Sonobond is already supplying ultrasonic assembly solutions to manufacturers developing new and innovative battery storage systems.

“Currently, wind and solar account for only about 6 percent1 of the United States’ electrical power generation. But, as reliance on alternative sources of energy increases, storage batteries will become essential as backup, providing power when there is no wind or sun,” says Devine. “In fact, some battery manufacturers are developing new formats for home and utility-sized energy storage systems that could eventually make wind and solar more consistent power resources. And some battery manufacturers hoping to commercialize new types of rechargeable batteries – that may eventually provide backup power, as well as grid-scale distributive storage to maintain peak power – are employing Sonobond’s ultrasonic assembly technology.”

She adds that the company continues to provide welding units to manufacturers seeking environmentally friendly methods for assembling existing lithium-ion and NiMH rechargeable batteries used in applications such as all-electric and hybrid automobiles, medical technology, and military and telecommunication fields.

Unique System Ensures Reliable Welds

Sonobond’s ultrasonic metal spot welders require no external heat, current, fluxes or fillers and produce no arcs, sparks or fumes. Instead, the welders create durable bonds by employing the company’s unique, patented Wedge-Reed ultrasonic bonding system that combines high vibratory force and low amplitude coupling. Using shear mode vibration parallel to the welding surface – while the line of force is directly over the parts to be welded – achieves precise, dependable, solid-state and highly conductive welds. Sonobond’s is also the only ultrasonic assembly system that can weld most oxidized and tinned metals in one pulse without pre-cleaning.

Ultrasonic Spot Welding Equipment

In addition to assembling newly designed rechargeable batteries, Sonobond’s Dual Head Ultrasonic Spot Welder is ideal for manufacturing existing lithium-ion, NiMH rechargeable batteries and pouch cells.  The machine can weld foils as thin as seven microns without tearing, is the first ultrasonic machine that can join up to 100 layers of copper or aluminum foil, and welds most oxidized and tinned metals in one pulse without pre-cleaning.Sonobond offers two ultrasonic spot welder models that weld multiple layers of foils to tabs or terminals, accommodate battery pouch assembly and HV termination welding. The SonoWeld® 1600 and Dual Head Spot (DHS) Welders weld foils as thin as seven microns. Also, the Dual Head Spot Welder is the first ultrasonic welder that can join up to 100 layers of copper or aluminum foil without tearing, and in just one pulse. The units use outputs of 1,500, 2,500 or 3,500 watts. Both models have digital displays that allow weld control to be selected by time, energy, or distance. Each unit has a power supply with a built-in microprocessor featuring automatic frequency control, overload protection, and storage and recall of up to 250 protocols.

The SonoWeld® 1600 and Dual Head Spot Welders employ heat-treated, tool steel Taper Lock Tips that can perform up to 30,000 welds before redressing is required and as many as 100,000 welds before being easily removed and replaced. As with all Sonobond equipment, the spot welders require only minimal training.

Achieving New Electrical Grid Storage Capability

“It’s estimated that the market for batteries providing stationary energy storage will increase from about $1 billion today, to approximately $6 billion by 20202,” notes Devine. “Sonobond fully expects to help manufacturers achieve that goal, which potentially promises to make our energy grid cleaner and more resilient.”

Free Ultrasonic Viability Test

To assist battery manufacturers in determining the benefits of ultrasonic welding for their particular applications and requirements, Sonobond offers a free Ultrasonic Welding Viability Test. Using materials provided by the manufacturer, Sonobond produces no-cost, no-obligation sample welds. If Sonobond’s equipment is incorporated into the customer’s production process, service and technical support are provided before, during and after installation.

Leading the Industry in Ultrasonic Innovation

For 56 years, innovation, performance and service have made Sonobond the industry leader in ultrasonic welding technology. Founded in 1960, Sonobond (then known as Aeroprojects) earned the first patent for ultrasonic metal welding. Since then, the company has received more than 150 additional patents for metal welders and custom-engineered ultrasonic bonders of all types used by manufacturers in the automotive, appliance, filtration, HVAC, apparel, aerospace, medical, electronic, electrical, photovoltaic and ballistic vest/body armor fields.

See Sonobond Technology on Display

Domestic manufacturers will discover how Sonobond can assist them with battery assembly, by visiting Booth #1729 at the Battery Show, in Michigan, where the capabilities of the SonoWeld® 1600 and Dual Head Spot Welders will be featured.

Learn More

For more immediate information or details on submitting materials for a free Ultrasonic Welding Viability Test, please call 800-323-1269, click this link, or contact President Janet Devine at This email address is being protected from spambots. You need JavaScript enabled to view it..

1,2,3 Murray, Charles “Renewable Energy’s Secret Weapon,” Design News, December 29. 2015, www.designnews.com