As a leader in capacitor technology since its founding in 1909, Cornell Dubilier is committed to maintaining the highest standards of product performance. That’s a primary reason why it relies on Sonobond equipment to ultrasonically weld multiple layers of foil to its capacitor posts.

Cornell Dubilier has found that Sonobond equipment enables it to produce its capacitors quickly, while assuring maximum reliability. Cornell Dubilier has been so pleased by the effectiveness of its Sonobond’s units—and the commitment of Sonobond personnel to providing customized welding solutions—that the company is now in the process of adding a SonoWeld 1600 Spot Welder to its Liberty, South Carolina plant. This new unit will enable Cornell Dubilier to increase the number of layers of foil it can weld to its capacitor posts—and still accomplish this procedure in a single pulse.

Outstanding Performance and Strong Technical Support

According to Tom Crumpton, Production Superintendent at Cornell Dubilier, Sonobond technology is quick and dependable and delivers repeatably excellent welds. Mr. Crumpton says that the exceptional quality of the ultrasonic welding—plus the strong, hands-on technical support he receives—cause him to rate Sonobond as "practically a 10." And he adds, "You can’t do better than that!"

Ultrasonic metal welding is fast, cost-effective, and environmentally-friendly. It creates solid-state metallurgical bonds without the use of heat, current, fluxes, or fillers. In this process, high-frequency ultrasonic energy is directed to the surface between the metals being welded to produce a reliable bond without melting the materials.

Patented Wedge-Reed Coupling System

Sonobond ultrasonic metal spot welders, such as those at Cornell Dubilier, have a significant added advantage. They use the patented Wedge-Reed bonding system that combines high vibratory force with low amplitude coupling for maximum metal welding effectiveness. Highly dependable welds are achieved by utilizing shear mode vibration that is parallel to the welding surface. Bending stress is eliminated by positioning the line of force directly over the welding surface. Non-ferrous similar or dissimilar metal assemblies can be confidently welded with this system, including copper to aluminum. Even lightly tinned or oxidized metals can be accommodated.

SonoWeld 1600 Digital Metal Spot Welder Series

According to Scott Day, Electronic Technician at Cornell Dubilier, the decision to add a 2,500-watt SonoWeld 1600 metal spot welder to their production line was made after careful consideration. It was based on the well-established speed, design, and ease of maintenance of their other Sonobond units, as well as the excellent customer service provided by Sonobond personnel, especially Vice President Melissa Alleman.

The SonoWeld 1600 offers multi-function capabilities never before available in an ultrasonic metal welder. It performs spot welds in a single pulse and with repeatable accuracy. This includes welding multiple layers and/or delicate foils to tabs or terminals. The addition of special tooling enables the unit to provide wire-to-terminal welding. Although the company currently welds a maximum of four layers to capacitor posts, the SonoWeld 1600 Digital Metal Spot Welder is capable of welding up to eight layers of foil.

Sets Weld Parameters by Time, Energy, or Weld Thickness

The power supply of the SonoWeld 1600 features a built-in microprocessor that can store and recall up to 250 weld protocols. Weld parameters can be set by time, energy, or final weld thickness. Available as a 1,500-watt or 2,500-watt model, the unit has an RS232 port to transfer weld data to a computer. Automatic control monitoring detects when variables exceed preset power and time limits. It also senses if a part height is different from that originally set, as well as wrong-part or no-part welding.

Free Ultrasonic Welding Viability Test

Sonobond has been a worldwide leader in ultrasonic welding technology for over 50 years. We offer a free, no-obligation Ultrasonic Welding Viability Test to determine the right unit for your specific needs. We will also work with you to develop custom solutions for your particular application(s). We are dedicated to providing exceptional technical support and fast, reliable customer service before, during, and after installation.

Click the links below to learn more about the SonoWeld 1600 or our other ultrasonic metal welders. For immediate service, please call Sonobond's Vice President, Melissa Alleman, at 800-323-1269 or 610-696-4710 or email MAlleman@SonobondUltrasonics.com. You’ll find us ready to answer your questions and eager to assist you in any way possible.

Learn more about Cornell Dubilier and its products at www.cde.com.