Method and apparatus for ultrasonic welding of terminals

A method for welding of battery terminals to an interconnect comprising;

• juxtaposing two or more battery cell terminals to each other to create a terminal stack including an innermost terminal and an outermost terminal;
• juxtaposing a battery cell interconnect with the innermost terminal of the stack;
• positioning an anvil in contact with the interconnect;
• after positioning the anvil, directing an air stream against the outermost terminal so that the air stream compresses the terminal stack and urges the innermost terminal into contact with the interconnect, said air stream being provided by an air knife mounted below the sonotrode horn so that the air stream is directed at the terminal stack at a line of contact vertically below the sonotrode horn so that the air stream provides an air curtain to capture any debris created during the ultrasonic welding and prevent the debris from falling downwardly;
• after directing the air stream, positioning a sonotrode horn in contact with the outermost terminal;
• and energizing the sonotrode horn to vibrate the terminal stack and thereby make an ultrasonic weld between the stacked terminals of the terminal stack and the interconnect.