Method of ultrasonically welding together two conductors

An improved method of ultrasonically welding together an electrical lead from a sensing element and an extension conductor wherein the extension conductor has a lateral dimension which is greater than the lateral dimension of the electrical lead comprising the steps of:

• (a) selecting a welding capture fixture having lateral sides which are spaced apart by a distance substantially equal to the lateral dimension of the extension conductor;
• (b) placing the extension conductor into the selected fixture so that the extension conductor is proximate to or substantially engages both lateral sides of the fixture;
• (c) forming the electrical lead of the sensing element into a pattern so that at least a first portion of the electrical lead extends laterally beyond a second portion of the electrical lead;
• (d) placing the electrical lead into the selected fixture so that the first portion of the electrical lead is proximate to or substantially engages one of the lateral sides of the fixture and the second portion of the electrical lead is proximate to or substantially engages the other lateral side of the fixture and so that both the first and second portions of the electrical lead substantially engage the extension conductor;
• and
• (e) applying ultrasonic energy to one of the electrical lead and the extension conductor for movement with respect to the other of the electrical lead and the extension conductor for welding the electrical lead to the extension conductor.