Melissa Alleman, vice president of Sonobond Ultrasonics, announced that the company will be exhibiting two examples of its innovative technology at the 2011 Assembly & Automation Expo in Chicago, Sept. 20-22.
Alleman says, “The Dual Head SpliceRite represents a major breakthrough in fast, dependable wire splicing. The SeamMaster High Profile Ultrasonic Bonder, on the other hand, demonstrates the important role that ultrasonic technology plays in a variety of textile applications, including the assembly of filters, medical disposables, and body armor.”
Dual Head SpliceRite Provides Largest Ultrasonic Wire Splicing Capacity
The Dual Head SpliceRite Ultrasonic Wire Splicer, one of the two units to be exhibited in Chicago, can easily accommodate wire bundles with cross-sectional areas of 48 to 100 sq. mm. It can even weld tinned wires up to 60 sq. mm. No other ultrasonic unit can equal this capacity with just one hit. This ultrasonic wire splicer is especially suited for assembling the heavy cables used for cars, trucks, and industrial machinery.
As its name implies, the unit has two welding heads, one on each side of the weld area. Non-ferrous similar and dissimilar metals can be welded with repeated accuracy. The welds produced have excellent conductivity. According to Alleman, “Manufacturers are discovering that the Dual Head SpliceRite offers significant advantages by creating solid-state metallurgical bonds without the need for filler materials or for clipping, soldering, crimping, or dipping. It’s an environmentally-friendly, cost-effective process that produces no waste. And it consumes only minimal energy.”
Unique Advantages of Sonobond’s Wedge-Reed System
All Sonobond spot welders, including the Dual Head SpliceRite, use the unique, patented Wedge-Reed bonding system of high vibratory force and low amplitude coupling. Shear mode vibration, parallel to the welding surface, is utilized while the line of force is directly over the parts to be welded. This creates precise, dependable welds without bending stress or stalling. It also enables most oxidized and tinned metals to be spliced without pre-cleaning.
Among the many outstanding features of the Dual Head SpliceRite are heat-treated, tool steel taper lock tips that can last for 100,000 welds or more. These are designed for quick tooling changes and fool-proof placement. The unit has a 3,500-watt power supply with a microprocessor that stores and recalls up to 250 jobs. Welds can be controlled by height, by energy, or by time. The entire process is fast and does not melt the material.
SeamMaster Bonders: Four Times Faster Than Traditional Sewing Machines
The other Sonobond unit to be exhibited at the Assembly & Automation Technology Expo in Chicago will be the SeamMaster High Profile Textile Bonder.
The SeamMaster series of ultrasonic bonders is similar in appearance and operation to traditional sewing machines. However, these units use no thread, glue, or other consumables. Instead, they seal, “sew,” and trim nonwoven and synthetic fabrics with ultrasonic vibrations. This eliminates concerns about stitch holes and glue gaps. Fraying and/or unraveling of bonded edges and seams are also virtually eliminated.
SeamMaster units save time and money for manufacturers by performing several labor-intensive operations in one pass. They operate four times faster than conventional sewing machines and up to ten times faster than adhesive methods. They are frequently used in assembling filters and protective products, including medical disposables that must comply with OSHA regulations for barrier seams.
Sonobond offers a variety of interchangeable pattern rollers for slitting, embossing, and “stitching.” Among the many other products produced with this technology are window shades, draperies, garments, blankets, awnings, automotive seats and carpets, athletic accessories, banners, safety garments, ballistic vests, aviation insulation panels, netting, and ribbons.
Easily Integrated Into Production Lines
The SeamMaster High Profile Ultrasonic Bonder is ideal for hand-guided applications with tight tolerances, for heavy and bulky materials, and for working around curves. That’s because it has a higher clearance between the wheel and horn than do Sonobond’s other SeamMaster units. As a result, the machine is especially useful for specialized applications in the textile, apparel, and engineered fabrics industry. It is available with a special fixture for sewing pleated filters. The machine has the additional advantage of being easily integrated into production lines as a modular unit.
Increasingly Popular with Body Armor Manufacturers
Another important application for the SeamMaster High Profile Ultrasonic Bonder is in the assembly of ballistic vests. The unit is highly effective in sealing the outer nylon shell of the body armor with the ballistic-resistant materials inside. This helps manufacturers comply with the latest National Institute of Justice (NIJ) submersion standards (NIJ 0101.06). These standards were recently revised and made more stringent to require a leak-tight seam, even after full immersion in water for 30 minutes. Prior to this, NIJ standards only required protection from a spray shower.
Half-Century of Leadership
Sonobond has been a respected, worldwide leader in the application of ultrasonic welding and bonding equipment since 1960. It was in that year that the company—then known as Aeroprojects—received the first patent ever awarded for ultrasonic metal welding. Over the intervening years, Sonobond has earned an outstanding reputation for its pioneering work and quality-engineered products. The company currently manufactures a complete line of ultrasonic bonding and welding equipment for a wide variety of companies in the filtration, electrical, automotive, appliance, solar, aerospace, medical, body armor, and apparel industries. Sonobond equipment is easy to operate and requires only minimal training.
The company provides a free Ultrasonic Welding/Bonding Viability Test to help confirm which unit is best for any particular application. In addition, Sonobond backs its products with exceptional technical support and outstanding customer service before, during, and after installation.
For Additional Information
To learn more about Sonobond products — or for information about the free, no-obligation Ultrasonic Welding Viability Test — visit www.SonobondUltrasonics.com or call 1-800-323-1269.