DualHead cable weld close upThis machine represents a significant breakthrough in ultrasonic wire splicing technology.  Like the current SpliceRite™ Ultrasonic Wire Splicer, this unit can bond most tinned or oxidized wires that can otherwise stall the welding process.  DualHead cable weldsHowever, the breakthrough is the ability of the Dual Head SpliceRite™ 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™ 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 large wires to terminals and multiple layers of foils for batteries. 

Dual Head Technology 

As the name suggests, this 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 minimum resistivity. 

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 Dual Head SpliceRite™ 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™—like other Sonobond metal spot 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 spot 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.   

This technology is another example of our continuing commitment to the wiring industry.  The Dual Head SpliceRite™ successfully accommodates wire bundles much larger than other ultrasonic bonders can handle and can be used even when wires are tinned or heavily oxidized. 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 53 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 www.SonobondUltrasonics.com or call toll free 1-800-323-1269.