Patent Publication Number: US-9905892-B2

Title: Battery module and method of coupling first and second electrical terminals of first and second battery cells to first and second voltage sense members of an interconnect assembly

Description:
BACKGROUND 
     The inventors herein have recognized a need for an improved battery module and a method of coupling first and second terminals of first and second battery cells, respectively, to first and second voltage sense members, respectively, of an interconnect assembly. 
     SUMMARY 
     A battery module in accordance with an exemplary embodiment is provided. The battery module includes a first battery cell having a first electrical terminal. The battery module further includes a second battery cell having a second electrical terminal. The battery module further includes an interconnect assembly having a plate portion, first and second finger portions, a blade portion, and first and second voltage sense members. The first finger portion is coupled to and extends from a first end of the plate portion. The first finger portion has first and second side surfaces and a first flat outer surface. The first flat outer surface of the first finger portion is disposed between the first and second side surfaces of the first finger portion. The first voltage sense member is coupled to the first finger portion. The first voltage sense member has a first voltage sense wall disposed directly on the first flat outer surface of the first finger portion. The second finger portion is coupled to and extends from the first end of the plate portion. The second finger portion extends substantially parallel to the first finger portion and is spaced apart from the first finger portion. The second finger portion has first and second side surfaces and a first flat outer surface. The first flat outer surface of the second finger portion is disposed between the first and second side surfaces of the second finger portion. The second voltage sense member is coupled to the second finger portion. The second voltage sense member has a first voltage sense wall disposed directly on the first flat outer surface of the second finger portion. The blade portion is coupled to and extends from the first end of the plate portion. The blade portion extends substantially parallel to the first and second finger portions and is disposed between the first and second finger portions such that a first gap is defined between the first finger portion and the blade portion, and a second gap is defined between the second finger portion and the blade portion. The first electrical terminal extends through the first gap and has a first terminal portion disposed directly on and coupled to the first voltage sense wall of the first voltage sense member. The second electrical terminal extends through the second gap and has a first terminal portion disposed directly on and coupled to the first voltage sense wall of the second voltage sense member such that the blade portion electrically isolates the first electrical terminal from the second electrical terminal. 
     A method for coupling first and second electrical terminals of first and second battery cells, respectively, to first and second voltage sense members, respectively, of an interconnect assembly, in accordance with another exemplary embodiment is provided. The method includes providing the interconnect assembly having a plate portion, first and second finger portions, a blade portion, and the first and second voltage sense members. The first finger portion is coupled to and extends from a first end of the plate portion. The first finger portion has first and second side surfaces and a first flat outer surface. The first flat outer surface of the first finger portion is disposed between the first and second side surfaces of the first finger portion. The first voltage sense member is coupled to the first finger portion. The first voltage sense member has a first voltage sense wall disposed directly on the first flat outer surface of the first finger portion. The second finger portion is coupled to and extends from the first end of the plate portion. The second finger portion extends substantially parallel to the first finger portion and is spaced apart from the first finger portion. The second finger portion has first and second side surfaces and a first flat outer surface. The first flat outer surface of the second finger portion is disposed between the first and second side surfaces of the second finger portion. The second voltage sense member is coupled to the second finger portion. The second voltage sense member has a first voltage sense wall disposed directly on the first flat outer surface of the second finger portion. The blade portion is coupled to and extends from the first end of the plate portion. The blade portion extends substantially parallel to the first and second finger portions and is disposed between the first and second finger portions such that a first gap is defined between the first finger portion and the blade portion, and a second gap is defined between the second finger portion and the blade portion. The method further includes disposing the first electrical terminal through the first gap and further disposing a first terminal portion of the first electrically terminal directly on the first voltage sense wall of the first voltage sense member. The method further includes welding the first terminal portion of the first electrical terminal to the first voltage sense wall of the first voltage sense member. The method further includes disposing the second electrical terminal through the second gap and further disposing a first terminal portion of the second electrically terminal directly on the first voltage sense wall of the second voltage sense member. The method further includes welding the first terminal portion of the second electrical terminal to the first voltage sense wall of the second voltage sense member, such that the blade portion electrically isolates the first electrical terminal from the second electrical terminal. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic of a battery module in accordance with an exemplary embodiment; 
         FIG. 2  is another schematic of the battery module of  FIG. 1 ; 
         FIG. 3  is another schematic of the battery module of  FIG. 1 ; 
         FIG. 4  is another schematic of the battery module of  FIG. 1 ; 
         FIG. 5  is a cross-sectional schematic of the battery module of  FIG. 3  taken along lines  5 - 5 ; 
         FIG. 6  is an enlarged view of a portion of the cross-sectional schematic of the battery module of  FIG. 5 ; 
         FIG. 7  is an enlarged view of another portion of the cross-sectional schematic of the battery module of  FIG. 5 ; 
         FIG. 8  is a schematic of a frame member utilized in the battery module of  FIG. 1 ; 
         FIG. 9  is a top view of the frame member of  FIG. 8 ; 
         FIG. 10  is a bottom view of the frame member of  FIG. 8 ; 
         FIG. 11  is a side view of the frame member of  FIG. 8 ; 
         FIG. 12  is a cross-sectional schematic of the frame member of  FIG. 8 ; 
         FIG. 13  is a schematic of a first interconnect assembly utilized in the battery module of  FIG. 1 ; 
         FIG. 14  is a top view of the first interconnect assembly of  FIG. 13 ; 
         FIG. 15  is a bottom view of the first interconnect assembly of  FIG. 13 ; 
         FIG. 16  is a cross-sectional view of a portion of the first interconnect assembly of  FIG. 13  before electrical terminals are coupled to the first interconnect assembly; 
         FIG. 17  is a schematic of a voltage sense member utilized in the battery module of  FIG. 1 ; 
         FIG. 18  is another schematic of the voltage sense member of  FIG. 17 ; 
         FIG. 19  is a schematic of a second interconnect assembly utilized in the battery module of  FIG. 1 ; 
         FIG. 20  is a top view of the second interconnect assembly of  FIG. 19 ; 
         FIG. 21  is a bottom view of the second interconnect assembly of  FIG. 19 ; 
         FIG. 22  is a cross-sectional view of a portion of the second interconnect assembly of  FIG. 19  before electrical terminals are coupled to the second interconnect assembly; 
         FIGS. 23-25  are flowcharts of coupling electrical terminals of battery cells to the first interconnect assembly of  FIG. 13  in accordance with another exemplary embodiment; 
         FIGS. 26-28  are flowcharts of a method of coupling electrical terminals of battery cells to the second interconnect assembly of  FIG. 19  in accordance with another exemplary embodiment; and 
         FIG. 29  is a block diagram of a system of coupling electrical terminals of battery cells to the first and second interconnect assemblies of  FIGS. 13 and 19 . 
     
    
    
     DETAILED DESCRIPTION 
     Referring to  FIGS. 1-5 , a battery module  10  in accordance with an exemplary embodiment is provided. The battery module  10  includes frame members  20 ,  22 ,  24 ,  26 ,  28 ,  30 , battery cells  40 ,  42 ,  44 ,  46 ,  48 ,  50 ,  52 ,  54 ,  56 ,  58 ,  60 ,  62 , an interconnect assembly  90 , a removable wire harness assembly  92 , an interconnect assembly  94 , a removable wire harness assembly  96 , and end plates  100 ,  102 . An advantage of the battery module  10  is that the module  10  utilizes interconnect assemblies  90 ,  94  each having voltage sense members which can be readily laser welded to electrical terminals of battery cells. 
     Further, the battery module  10  utilizes frame extension portions on frame members and blade portions on an interconnect assembly to electrically isolate each pair of electrical terminals disposed proximate to one another that are separated by an air gap to prevent electrical discharges across the air gap. In particular, when a frame extension portion of a frame member electrically isolates a first electrical terminal from a second electrical terminal, the frame extension portion disposed between the first and second electrical terminals is adapted to prevent an electrical discharge across an air gap between the first and second electrical terminals. Also, when a blade portion electrically isolates a first electrical terminal from a second electrical terminal, the blade portion disposed between the first and second electrical terminals is adapted to prevent an electrical discharge across an air gap between the first and second electrical terminals. 
     Referring to  FIGS. 1, 5 and 8-12 , the frame members  20 ,  22 ,  24 ,  26 ,  28 ,  30  are provided to hold the battery cells  40 - 62  therebetween. The frame member  20  is coupled to and between the frame member  22  and the end plate  100 . The frame member  22  is coupled to and between the frame members  20 ,  24 . The frame member  26  is coupled to and between frame members  24 ,  28 . Further, the frame member  28  is coupled to and between frame members  26 ,  30 . The frame member  30  is coupled to and between the frame member  28  and the end plate  102 . The structure of each of the frame members  20 - 30  are identical to one another. 
     Referring to  FIGS. 8-12 , the frame member  20  has substantially rectangular ring-shaped outer plastic frame  130 , a frame extension portion  132 , and a heat exchanger  134 . Referring to  FIG. 12 , the heat exchanger  134  has first and second thermally conductive plates  200 ,  202  that are coupled together and define a flow path portion  204  that extends therethrough. The flow path portion  204  has flow path subportions  205 ,  206 ,  207 ,  208  each extending through the first and second thermally conductive plates  200 ,  202 . 
     Referring to  FIGS. 8-12 , the substantially rectangular ring-shaped outer plastic frame  130  is coupled around an outer peripheral region of the first and second thermally conductive plates  200 ,  202 . The rectangular ring-shaped outer plastic frame  130  has first, second, third, and fourth side walls  140 ,  142 ,  144 ,  146 . The first and second side walls  140 ,  142  extend substantially parallel to one another. The third and fourth side walls  144 ,  146  are coupled between the first and second side walls  140 ,  142  and extend substantially parallel to one another and perpendicular to the first and second side walls  140 ,  142 . 
     Referring to  FIGS. 8 and 12 , the first side wall  140  has apertures  160 ,  162 ,  164  extending therethrough. The aperture  160  fluidly communicates with the flow path subportions  205 . Also, the aperture  162  fluidly communicates with the flow path subportions  206 ,  207 . Further, the aperture  164  fluidly communicates with the flow path subportion  208 . Referring to  FIGS. 11 and 12 , the second side wall  142  has apertures  170 ,  172 ,  174  extending therethrough. The aperture  170  fluidly communicates with the flow path subportion  205 . Also, the aperture  172  fluidly communicates with the flow path subportions  206 ,  207 . Further, the aperture  174  fluidly communicates with the flow path subportion  208 . The third side wall  144  has a groove  180  extending therein, and the fourth side wall  146  has a groove  186  extending therein. The grooves  180 ,  186  are configured to receive first and second electrical terminals of a battery cell therethrough. 
     Referring to  FIGS. 6 and 8 , the frame extension portion  132  is coupled to and extends outwardly from the fourth side wall  144  of the substantially rectangular ring-shaped outer plastic frame  130 . Further, the frame extension portion  132  extends outwardly from the frame  130  through a gap between the finger portions  620 ,  622 . In an exemplary embodiment, the frame extension portion  132  is constructed of plastic. 
     Referring to  FIG. 12 , the heat exchanger  134  includes first and second thermally conductive plates  200 ,  202  that are coupled together and define the flow path portion  204  defined between the plates  200 ,  202 . The first thermally conductive plate  200  has a first side  210  and a second side  212 . The first thermally conductive plate  200  further includes elongated depressed portions  220 ,  222 ,  224  and depressed edge portions  230 ,  232 . In an exemplary embodiment, the first thermally conductive plate  200  is constructed of aluminum and is substantially rectangular-shaped. The second thermally conductive plate  202  has a first side  240  and a second side  242 . The second thermally conductive plate  202  further includes elongated depressed portions  250 ,  252 ,  254  and depressed edge portions  260 ,  262 . In an exemplary embodiment, the second thermally conductive plate  202  is constructed of aluminum and is substantially rectangular-shaped. The first thermally conductive plate  200  is coupled to the second thermally conductive plate  202  such that the elongated depressed portions  220 ,  222 ,  224  contact and are coupled to the elongated depressed portions  250 ,  252 ,  254 , respectively and the depressed edge portions  230 ,  232  contact and are coupled to the depressed edge portions  260 ,  262 . The plates  200 ,  202  define the flow path portion  204  having the flow path subportions  205 ,  206 ,  207 ,  208  that extend entirely through a longitudinal length of the plates  200 ,  202  that receives air therethrough for cooling the adjacent battery cells. 
     Referring to  FIGS. 1, 5 and 6 , the frame member  22  has a substantially rectangular ring-shaped outer plastic frame  330 , a frame extension portion  332 , and a heat exchanger  334 . The frame extension portion  332  extends outwardly from the frame  330  through a gap between the finger portions  622 ,  624 . 
     The frame member  24  has a substantially rectangular ring-shaped outer plastic frame  350 , a frame extension portion  352 , and a heat exchanger  354 . The frame extension portion  352  extends outwardly from the frame  350  through a gap between the finger portions  624 ,  626 . 
     The frame member  26  has a substantially rectangular ring-shaped outer plastic frame  370 , a frame extension portion  372 , and a heat exchanger  374 . The frame extension portion  372  extends outwardly from the frame  370  through a gap between the finger portions  626 ,  628 . 
     The frame member  28  has a substantially rectangular ring-shaped outer plastic frame  390 , a frame extension portion  392 , and a heat exchanger  394 . The frame extension portion  392  extends outwardly from the frame  390  through a gap between the finger portions  628 ,  630 . 
     The frame member  30  has a substantially rectangular ring-shaped outer plastic frame  410 , a frame extension portion  412 , and a heat exchanger  414 . The frame extension portion  412  extends outwardly from the frame  410  through a gap between the finger portions  630 ,  632 . 
     Referring to  FIG. 5 , the frame member  20  and the end plate  100  are configured to hold the battery cell  40  therebetween. Further, the heat exchanger  134  of the frame member  20  is disposed between and contacts the battery cells  40 ,  42 . 
     The frame members  20 ,  22  are configured to hold the battery cells  42 ,  44  therebetween. Further, the heat exchanger  334  of the frame member  22  is disposed between and contacts the battery cells  44 ,  46 . 
     The frame members  22 ,  24  are configured to hold the battery cells  46 ,  48  therebetween. Further, the heat exchanger  354  of the frame member  24  is disposed between and contacts the battery cells  48 ,  50 . 
     The frame members  24 ,  26  are configured to hold the battery cells  50 ,  52  therebetween. Further, the heat exchanger  374  of the frame member  26  is disposed between and contacts the battery cells  52 ,  54 . 
     The frame members  26 ,  28  are configured to hold the battery cells  54 ,  56  therebetween. Further, the heat exchanger  394  of the frame member  28  is disposed between and contacts the battery cells  56 ,  58 . 
     The frame members  28 ,  30  are configured to hold the battery cells  58 ,  60  therebetween. Further, the heat exchanger  414  of the frame member  30  is disposed between and contacts the battery cells  60 ,  62 . The battery cell  62  is disposed and held between the frame member  30  and the end plate  102 . 
     The battery cells  40 ,  42 ,  44 ,  46 ,  48 ,  50 ,  52 ,  54 ,  56 ,  58 ,  60 ,  62  are each configured to generate an operational voltage. In one exemplary embodiment, the battery cells  40 - 62  are pouch-type lithium-ion battery cells that have a substantially rectangular-shaped body portion and a pair of electrical terminals. In an exemplary embodiment, the battery cells  40 - 62  are electrically coupled in series with one another utilizing the interconnect assemblies  90 ,  94 . Further, in an exemplary embodiment, the electrical terminals of the battery cells  40 - 62  are coupled to the interconnect assemblies  90 ,  94  by welding the electrical terminals of the battery cells  40 - 62  to the interconnect assemblies  90 ,  94  utilizing a laser. In an exemplary embodiment, the structure of the battery cells  40 - 62  are identical to one another. 
     Referring to  FIGS. 5-7 , the battery cell  40  has a rectangular-shaped housing  430  with electrical terminals  432 ,  434 , extending from first and second ends, respectively, of the housing  430 . The electrical terminal  432  includes terminal portions  435 ,  436 . Further, the electrical terminal  434  includes terminal portions  437 ,  438 . 
     The battery cell  42  has a rectangular-shaped housing  440  with electrical terminals  442 ,  444 , extending from first and second ends, respectively, of the housing  440 . The electrical terminal  442  includes terminal portions  445 ,  446 . Further, the electrical terminal  444  includes terminal portions  447 ,  448 . 
     The battery cell  44  has a rectangular-shaped housing  450  with electrical terminals  452 ,  454 , extending from first and second ends, respectively, of the housing  450 . The electrical terminal  452  includes terminal portions  455 ,  456 . Further, the electrical terminal  454  includes terminal portions  457 ,  458 . 
     The battery cell  46  has a rectangular-shaped housing  460  with electrical terminals  462 ,  464 , extending from first and second ends, respectively, of the housing  460 . The electrical terminal  462  includes terminal portions  465 ,  466 . Further, the electrical terminal  464  includes terminal portions  467 ,  468 . 
     The battery cell  48  has a rectangular-shaped housing  470  with electrical terminals  472 ,  474 , extending from first and second ends, respectively, of the housing  470 . The electrical terminal  472  includes terminal portions  475 ,  476 . Further, the electrical terminal  474  includes terminal portions  477 ,  478 . 
     The battery cell  50  has a rectangular-shaped housing  480  with electrical terminals  482 ,  484 , extending from first and second ends, respectively, of the housing  480 . The electrical terminal  482  includes terminal portions  485 ,  486 . Further, the electrical terminal  484  includes terminal portions  487 ,  488 . 
     The battery cell  52  has a rectangular-shaped housing  490  with electrical terminals  492 ,  494 , extending from first and second ends, respectively, of the housing  490 . The electrical terminal  492  includes terminal portions  495 ,  496 . Further, the electrical terminal  494  includes terminal portions  497 ,  498 . 
     The battery cell  54  has a rectangular-shaped housing  500  with electrical terminals  502 ,  504  extending from first and second ends, respectively, of the housing  500 . The electrical terminal  502  includes terminal portions  505 ,  506 . Further, the electrical terminal  504  includes terminal portions  507 ,  508 . 
     The battery cell  56  has a rectangular-shaped housing  510  with electrical terminals  512 ,  514  extending from first and second ends, respectively, of the housing  510 . The electrical terminal  512  includes terminal portions  515 ,  516 . Further, the electrical terminal  514  includes terminal portions  517 ,  518 . 
     The battery cell  58  has a rectangular-shaped housing  520  with electrical terminals  522 ,  524  extending from first and second ends, respectively, of the housing  520 . The electrical terminal  522  includes terminal portions  525 ,  526 . Further, the electrical terminal  524  includes terminal portions  527 ,  528 . 
     The battery cell  60  has a rectangular-shaped housing  530  with electrical terminals  532 ,  534  extending from first and second ends, respectively, of the housing  530 . The electrical terminal  532  includes terminal portions  535 ,  536 . Further, the electrical terminal  534  includes terminal portions  537 ,  538 . 
     The battery cell  62  has a rectangular-shaped housing  540  with electrical terminals  542 ,  544  extending from first and second ends, respectively, of the housing  540 . The electrical terminal  542  includes terminal portions  545 ,  546 . Further, the electrical terminal  544  includes terminal portions  547 ,  548 . 
     Referring to  FIGS. 13-16 , the interconnect assembly  90  is adapted to be electrically coupled to the battery cells  40 - 62 . The interconnect assembly  90  includes a plate portion  600 , finger portions  620 ,  622 ,  624 ,  626 ,  628 ,  630 ,  632 , voltage sense members  642 ,  644 ,  646 ,  648 ,  650 , and electrical terminals  660 ,  662 . 
     The plate portion  600  includes a first side  680  and a second side  682 . Further, the plate portion  600  includes a first end  684  and a second end  686 . In an exemplary embodiment, the plate portion  600  is substantially rectangular shaped. Further, in an exemplary embodiment, the plate portion  600  is constructed of plastic. 
     The finger portions  620 - 632  are coupled and extend from the first end  684  of the plate portion  600  and are spaced apart from one another. Further, the finger portions  620 - 632  extend substantially parallel to one another. Each of the finger portions  620 - 632  have a T-shaped cross-sectional profile along a plane extending through the finger portions  620 - 632  that is substantially parallel to the first end  684  of the plate portion  600 . In an exemplary embodiment, the finger portions  620 - 632  are constructed of plastic. 
     Referring to  FIG. 16 , the finger portion  620  has a flat outer surface  700  and side surfaces  702 ,  704 . The flat outer surface  700  is disposed between the first and second side surfaces  702 ,  704 . Further, the first and second side surfaces  702 ,  704  extend substantially perpendicular to the flat outer surface  700  in a first direction. 
     The finger portion  622  has a flat outer surface  710  and side surfaces  712 ,  714 . The flat outer surface  710  is disposed between the first and second side surfaces  712 ,  714 . Further, the first and second side surfaces  712 ,  714  extend substantially perpendicular to the flat outer surface  710  in the first direction. 
     The finger portion  624  has a flat outer surface  720  and side surfaces  722 ,  724 . The flat outer surface  720  is disposed between the first and second side surfaces  722 ,  724 . Further, the first and second side surfaces  722 ,  724  extend substantially perpendicular to the flat outer surface  720  in the first direction. 
     The finger portion  626  has a flat outer surface  730  and side surfaces  732 ,  734 . The flat outer surface  730  is disposed between the first and second side surfaces  732 ,  734 . Further, the first and second side surfaces  732 ,  734  extend substantially perpendicular to the flat outer surface  730  in the first direction. 
     The finger portion  628  has a flat outer surface  740  and side surfaces  742 ,  744 . The flat outer surface  740  is disposed between the first and second side surfaces  742 ,  744 . Further, the first and second side surfaces  742 ,  744  extend substantially perpendicular to the flat outer surface  740  in the first direction. 
     The finger portion  630  has a flat outer surface  750  and side surfaces  752 ,  754 . The flat outer surface  750  is disposed between the first and second side surfaces  752 ,  754 . Further, the first and second side surfaces  752 ,  754  extend substantially perpendicular to the flat outer surface  750  in the first direction. 
     The finger portion  632  has a flat outer surface  760  and side surfaces  762 ,  764 . The flat outer surface  760  is disposed between the first and second side surfaces  762 ,  764 . Further, the first and second side surfaces  762 ,  764  extend substantially perpendicular to the flat outer surface  760  in the first direction. 
     Referring to  FIGS. 13-18 , the voltage sense members  642 ,  644 ,  646 ,  648 ,  650  are adapted to be electrically coupled to electrical terminals of the battery cells. In an exemplary embodiment, the voltage sense members  642 - 650  are constructed of steel. Of course, in an alternative embodiment, the voltage sense members  642 - 650  could be constructed of other metals such as copper or aluminum for example. The structure of the voltage sense members  642 - 650  are identical to one another. 
     Referring to  FIGS. 6, 16 and 17 , the voltage sense member  642  is coupled to the finger portion  622 . The voltage sense member  642  has voltage sense walls  770 ,  772 ,  774  and coupler members  776 ,  778 . The voltage sense walls  772 ,  774  are coupled to and extend from first and second ends, respectively, of the voltage sense wall  770 . The voltage sense walls  772 ,  774  extend substantially perpendicular to the voltage sense wall  770 . The voltage sense wall  770  is disposed directly on the flat outer surface  710  of the finger portion  622 . The voltage sense walls  772 ,  774  are disposed directly on the side surfaces  712 ,  714 , respectively, of the finger portion  622 . 
     The voltage sense wall  772  defines an electrical tab connector  780  adapted to be coupled to a spade clip of the removable wire harness assembly  92 . 
     The coupler members  776 ,  778  are coupled to and extend from first and second ends, respectively, of the voltage sense wall  770 . The coupler members  776 ,  778  are adapted to be received in respective apertures in the finger portion  622  and to hold the voltage sense member  642  on the finger portion  622 . 
     Referring to  FIGS. 6 and 16 , the electrical terminal  442  has the terminal portion  445  disposed directly on the voltage sense wall  772  of the voltage sense member  642 , and the terminal portion  446  disposed directly on and coupled to the voltage sense wall  710  of the voltage sense member  642 . 
     The electrical terminal  452  has the terminal portion  455  disposed directly on the voltage sense wall  774  of the voltage sense member  642 , and the terminal portion  456  disposed directly on and coupled to the terminal portion  446  of the electrical terminal  442 . The terminal portion  446  is sandwiched between the voltage sense wall  770  and the terminal portion  456 . 
     Referring to  FIGS. 6, 14 and 16 , the voltage sense member  644  is coupled to the finger portion  624 . The voltage sense member  644  has voltage sense walls  790 ,  792 ,  794 . The voltage sense walls  792 ,  794  are coupled to and extend from first and second ends, respectively, of the voltage sense wall  790 . The voltage sense walls  792 ,  794  extend substantially perpendicular to the voltage sense wall  790 . The voltage sense wall  790  is disposed directly on the flat outer surface  720  of the finger portion  624 . The voltage sense walls  792 ,  794  are disposed directly on the side surfaces  722 ,  724 , respectively, of the finger portion  624 . 
     The electrical terminal  462  has the terminal portion  465  disposed directly on the voltage sense wall  792  of the voltage sense member  644 , and the terminal portion  466  disposed directly on and coupled to the voltage sense wall  790  of the voltage sense member  644 . 
     The electrical terminal  472  has the terminal portion  475  disposed directly on the voltage sense wall  794  of the voltage sense member  644 , and the terminal portion  476  disposed directly on and coupled to the terminal portion  466  of the electrical terminal  462 . The terminal portion  466  is sandwiched between the voltage sense wall  790  and the terminal portion  476 . 
     The voltage sense member  646  is coupled to the finger portion  626 . The voltage sense member  646  has voltage sense walls  810 ,  812 ,  814 . The voltage sense walls  812 ,  814  are coupled to and extend from first and second ends, respectively, of the voltage sense wall  810 . The voltage sense walls  812 ,  814  extend substantially perpendicular to the voltage sense wall  810 . The voltage sense wall  810  is disposed directly on the flat outer surface  730  of the finger portion  626 . The voltage sense walls  812 ,  814  are disposed directly on the side surfaces  732 ,  734 , respectively, of the finger portion  626 . 
     The electrical terminal  482  has the terminal portion  485  disposed directly on the voltage sense wall  812  of the voltage sense member  646 , and the terminal portion  486  disposed directly on and coupled to the voltage sense wall  810  of the voltage sense member  646 . 
     The electrical terminal  492  has the terminal portion  495  disposed directly on the voltage sense wall  814  of the voltage sense member  646 , and the terminal portion  496  disposed directly on and coupled to the terminal portion  486  of the electrical terminal  482 . The terminal portion  486  is sandwiched between the voltage sense wall  810  and the terminal portion  496 . 
     The voltage sense member  648  is coupled to the finger portion  628 . The voltage sense member  648  has voltage sense walls  830 ,  832 ,  834 . The voltage sense walls  832 ,  834  are coupled to and extend from first and second ends, respectively, of the voltage sense wall  830 . The voltage sense walls  832 ,  834  extend substantially perpendicular to the voltage sense wall  830 . The voltage sense wall  830  is disposed directly on the flat outer surface  740  of the finger portion  628 . The voltage sense walls  832 ,  834  are disposed directly on the side surfaces  742 ,  744 , respectively, of the finger portion  628 . 
     The electrical terminal  502  has the terminal portion  505  disposed directly on the voltage sense wall  832  of the voltage sense member  648 , and the terminal portion  506  disposed directly on and coupled to the voltage sense wall  830  of the voltage sense member  648 . 
     The electrical terminal  512  has the terminal portion  515  disposed directly on the voltage sense wall  834  of the voltage sense member  648 , and the terminal portion  516  disposed directly on and coupled to the terminal portion  506  of the electrical terminal  502 . The terminal portion  506  is sandwiched between the voltage sense wall  830  and the terminal portion  516 . 
     The voltage sense member  650  is coupled to the finger portion  630 . The voltage sense member  650  has voltage sense walls  850 ,  852 ,  854 . The voltage sense walls  852 ,  854  are coupled to and extend from first and second ends, respectively, of the voltage sense wall  850 . The voltage sense walls  852 ,  854  extend substantially perpendicular to the voltage sense wall  850 . The voltage sense wall  850  is disposed directly on the flat outer surface  750  of the finger portion  630 . The voltage sense walls  852 ,  854  are disposed directly on the side surfaces  752 ,  754 , respectively, of the finger portion  630 . 
     The electrical terminal  522  has the terminal portion  525  disposed directly on the voltage sense wall  852  of the voltage sense member  650 , and the terminal portion  526  disposed directly on and coupled to the voltage sense wall  850  of the voltage sense member  650 . 
     The electrical terminal  532  has the terminal portion  535  disposed directly on the voltage sense wall  854  of the voltage sense member  650 , and the terminal portion  536  disposed directly on and coupled to the terminal portion  526  of the electrical terminal  522 . The terminal portion  526  is sandwiched between the voltage sense wall  850  and the terminal portion  536 . 
     Referring to  FIGS. 6 and 13 , the electrical terminal  660  is adapted to be coupled to the finger portion  620  of the interconnect assembly  90 . The electrical terminal  660  includes terminal walls  870 ,  872 ,  874 ,  876 ,  878 ,  880 ,  882 . The terminal wall  872  is coupled to and extends substantially perpendicular to the terminal walls  870 ,  874 . The terminal wall  876  extends substantially perpendicular to the terminal wall  874 . The terminal wall  880  is coupled to and extends substantially perpendicular to the terminal walls  874 ,  880 . The terminal wall  880  defines an electrical tab connector that is configured to hold a spade clip of the removable wire harness assembly  92  thereon. The terminal wall  876  is disposed on a coupled to the flat outer surface  700  of the finger portion  620 . In an exemplary embodiment, the electrical terminal  660  is constructed of steel. However, in an alternative embodiment, the electrical terminal  660  could be constructed of other metals such as aluminum or copper for example. 
     The electrical terminal  662  is adapted to be coupled to the finger portion  632  of the interconnect assembly  90 . The electrical terminal  662  includes terminal walls  890 ,  892 ,  894 ,  896 ,  898 ,  890 . The terminal wall  892  is coupled to and extends substantially perpendicular to the terminal walls  890 ,  894 . The terminal wall  896  extends substantially perpendicular to the terminal wall  894 . The terminal wall  898  is coupled to and extends substantially perpendicular to the terminal walls  894 ,  900 . The terminal wall  900  defines an electrical tab connector that is configured to hold a spade clip of the removable wire harness assembly  92  thereon. The terminal wall  896  is disposed on a coupled to the flat outer surface  760  of the finger portion  632 . In an exemplary embodiment, the electrical terminal  662  is constructed of steel. However, in an alternative embodiment, the electrical terminal  662  could be constructed of other metals such as aluminum or copper for example. 
     Referring to  FIGS. 2, 13 and 14 , the removable wire harness assembly  92  is provided to route voltages from the voltage sense members  642 ,  644 ,  646 ,  648 ,  650  and the electrical terminals  660 ,  662  to a battery management system. The removable wire harness assembly  92  includes spade clips  940 ,  942 ,  944 ,  946 ,  948 ,  950 ,  952 , electrical cables  960 ,  962 ,  964 ,  966 ,  968 ,  970 ,  972 , and an electrical connector  980 . 
     The spade clip  940  is coupled to the electrical cable  960  and is further removably physically and electrically coupled to the electrical connector  660 . The electrical cable  960  is further coupled to the electrical connector  980 . 
     The spade clip  942  is coupled to the electrical cable  962  and is further removably physically and electrically coupled to an electrical tab member of the voltage sense member  642 . The electrical cable  962  is further coupled to the electrical connector  980 . 
     The spade clip  944  is coupled to the electrical cable  964  and is further removably physically and electrically coupled to an electrical tab member of the voltage sense member  644 . The electrical cable  964  is further coupled to the electrical connector  980 . 
     The spade clip  946  is coupled to the electrical cable  966  and is further removably physically and electrically coupled to an electrical tab member of the voltage sense member  646 . The electrical cable  966  is further coupled to the electrical connector  980 . 
     The spade clip  948  is coupled to the electrical cable  968  and is further removably physically and electrically coupled to an electrical tab member of the voltage sense member  648 . The electrical cable  968  is further coupled to the electrical connector  980 . 
     The spade clip  950  is coupled to the electrical cable  970  and is further removably physically and electrically coupled to an electrical tab member of the voltage sense member  650 . The electrical cable  970  is further coupled to the electrical connector  980 . 
     The spade clip  952  is coupled to the electrical cable  972  and is further removably physically and electrically coupled to the electrical connector  662 . The electrical cable  972  is further coupled to the electrical connector  980 . 
     Referring to  FIGS. 5 and 19-22 , the interconnect assembly  94  is adapted to be electrically coupled to the battery cells  40 - 62 . The interconnect assembly  94  includes a plate portion  1600 , finger portions  1620 ,  1622 ,  1624 ,  1626 ,  1628 ,  1630 , blade portions  1633 ,  1634 ,  1635 ,  1636 ,  1637 , and voltage sense members  1640 ,  1642 ,  1644 ,  1646 ,  1648 ,  1650 . 
     The plate portion  1600  includes a first side  1680  and a second side  1682 . Further, the plate portion  1600  includes a first end  1684  and a second end  1686 . In an exemplary embodiment, the plate portion  1600  is substantially rectangular shaped. Further, in an exemplary embodiment, the plate portion  1600  is constructed of plastic. 
     The finger portions  1620 - 1630  are coupled and extend from the first end  1684  of the plate portion  1600  and are spaced apart from one another. Further, the finger portions  1620 - 1630  extend substantially parallel to one another. Each of the finger portions  1620 - 1630  have a T-shaped cross-sectional profile along a plane extending through the finger portions  1620 - 1630  that is substantially parallel to the first end  1684  of the plate portion  1600 . In an exemplary embodiment, the finger portions  1620 - 1630  are constructed of plastic. 
     Referring to  FIG. 22 , the finger portion  1620  has a flat outer surface  1700  and side surfaces  1702 ,  1704 . The flat outer surface  1700  is disposed between the first and second side surfaces  1702 ,  1704 . Further, the first and second side surfaces  1702 ,  1704  extend substantially perpendicular to the flat outer surface  1700  in a second direction. 
     The finger portion  1622  has a flat outer surface  1710  and side surfaces  1712 ,  1714 . The flat outer surface  1710  is disposed between the first and second side surfaces  1712 ,  1714 . Further, the first and second side surfaces  1712 ,  1714  extend substantially perpendicular to the flat outer surface  1710  in the second direction. 
     The finger portion  1624  has a flat outer surface  1720  and side surfaces  1722 ,  1724 . The flat outer surface  1720  is disposed between the first and second side surfaces  1722 ,  1724 . Further, the first and second side surfaces  1722 ,  1724  extend substantially perpendicular to the flat outer surface  1720  in the second direction. 
     The finger portion  1626  has a flat outer surface  1730  and side surfaces  1732 ,  1734 . The flat outer surface  1730  is disposed between the first and second side surfaces  1732 ,  1734 . Further, the first and second side surfaces  1732 ,  1734  extend substantially perpendicular to the flat outer surface  1730  in the second direction. 
     The finger portion  1628  has a flat outer surface  1740  and side surfaces  1742 ,  1744 . The flat outer surface  1740  is disposed between the first and second side surfaces  1742 ,  1744 . Further, the first and second side surfaces  1742 ,  1744  extend substantially perpendicular to the flat outer surface  1740  in the second direction. 
     The finger portion  1630  has a flat outer surface  1750  and side surfaces  1752 ,  1754 . The flat outer surface  1750  is disposed between the first and second side surfaces  1752 ,  1754 . Further, the first and second side surfaces  1752 ,  1754  extend substantially perpendicular to the flat outer surface  1750  in the second direction. 
     Referring to  FIGS. 7, 20 and 22 , the blade portions  1633 - 1637  will now be described. In an exemplary embodiment, the blade portions  1633 - 1637  are constructed of plastic. The blade portion  1633  is coupled to and extends from the first end  1684  of the plate portion  1600 . The blade portion  1633  extends substantially parallel to the finger portions  1620 ,  1622  and is disposed between the finger portions  1620 ,  1622  such that a gap is defined between the finger portion  1620  and the blade portion  1633 , and another gap is defined between the finger portion  1622  and the blade portion  1633 . A length of the blade portion  1633  is greater than a length of each of the finger portions  1620 ,  1622 . Further, a length of the blade portion  1633  is greater than a length of each of the voltage sense members  1640 ,  1642 . 
     The blade portion  1634  is coupled to and extends from the first end  1684  of the plate portion  1600 . The blade portion  1634  extends substantially parallel to the finger portions  1622 ,  1624  and is disposed between the finger portions  1622 ,  1624  such that a gap is defined between the finger portion  1622  and the blade portion  1634 , and another gap is defined between the finger portion  1624  and the blade portion  1634 . A length of the blade portion  1634  is greater than a length of each of the finger portions  1622 ,  1624 . Further, a length of the blade portion  1634  is greater than a length of each of the voltage sense members  1642 ,  1644 . 
     The blade portion  1635  is coupled to and extends from the first end  1684  of the plate portion  1600 . The blade portion  1635  extends substantially parallel to the finger portions  1624 ,  1626  and is disposed between the finger portions  1624 ,  1626  such that a gap is defined between the finger portion  1624  and the blade portion  1635 , and another gap is defined between the finger portion  1626  and the blade portion  1635 . A length of the blade portion  1635  is greater than a length of each of the finger portions  1624 ,  1626 . Further, a length of the blade portion  1635  is greater than a length of each of the voltage sense members  1644 ,  1646 . 
     The blade portion  1636  is coupled to and extends from the first end  1684  of the plate portion  1600 . The blade portion  1636  extends substantially parallel to the finger portions  1626 ,  1628  and is disposed between the finger portions  1626 ,  1628  such that a gap is defined between the finger portion  1626  and the blade portion  1636 , and another gap is defined between the finger portion  1628  and the blade portion  1636 . A length of the blade portion  1636  is greater than a length of each of the finger portions  1626 ,  1628 . Further, a length of the blade portion  1636  is greater than a length of each of the voltage sense members  1646 ,  1648 . 
     The blade portion  1637  is coupled to and extends from the first end  1684  of the plate portion  1600 . The blade portion  1637  extends substantially parallel to the finger portions  1628 ,  1630  and is disposed between the finger portions  1628 ,  1630  such that a gap is defined between the finger portion  1628  and the blade portion  1637 , and another gap is defined between the finger portion  1630  and the blade portion  1637 . A length of the blade portion  1637  is greater than a length of each of the finger portions  1628 ,  1630 . Further, a length of the blade portion  1637  is greater than a length of each of the voltage sense members  1648 ,  1650 . 
     Referring to  FIGS. 7 and 22 , the voltage sense members  1640 ,  1642 ,  1644 ,  1646 ,  1648 ,  1650  are adapted to be electrically coupled to electrical terminals of the battery cells. In an exemplary embodiment, the voltage sense members  1640 - 1650  are constructed of steel. Of course, in an alternative embodiment, the voltage sense members  1640 - 1650  could be constructed of other materials such as copper or aluminum for example. The structure of the voltage sense members  1640 - 1650  are identical to one another and have a structure identical to the voltage sense member  642  discussed above. 
     The voltage sense member  1640  is coupled to the finger portion  1620 . The voltage sense member  1640  has voltage sense walls  1760 ,  1762 ,  1764 . The voltage sense walls  1762 ,  1764  are coupled to and extend from first and second ends, respectively, of the voltage sense wall  1760 . The voltage sense walls  1762 ,  1764  extend substantially perpendicular to the voltage sense wall  1760 . The voltage sense wall  1760  is disposed directly on the flat outer surface  1700  of the finger portion  1620 . The voltage sense walls  1762 ,  1764  are disposed directly on the side surfaces  1702 ,  1704 , respectively, of the finger portion  1620 . 
     The electrical terminal  434  has the terminal portion  437  disposed directly on the voltage sense wall  1762  of the voltage sense member  1640 , and the terminal portion  438  disposed directly on and coupled to the voltage sense wall  1760  of the voltage sense member  1640 . 
     The electrical terminal  444  has the terminal portion  447  disposed directly on the voltage sense wall  1764  of the voltage sense member  1640 , and the terminal portion  448  disposed directly on and coupled to the terminal portion  438  of the electrical terminal  434 . The terminal portion  438  is sandwiched between the voltage sense wall  1760  and the terminal portion  448 . 
     The voltage sense member  1642  is coupled to the finger portion  1622 . The voltage sense member  1642  has voltage sense walls  1770 ,  1772 ,  1774 . The voltage sense walls  1772 ,  1774  are coupled to and extend from first and second ends, respectively, of the voltage sense wall  1770 . The voltage sense walls  1772 ,  1774  extend substantially perpendicular to the voltage sense wall  1770 . The voltage sense wall  1770  is disposed directly on the flat outer surface  1710  of the finger portion  1622 . The voltage sense walls  1772 ,  1774  are disposed directly on the side surfaces  1712 ,  1714 , respectively, of the finger portion  1622 . 
     The electrical terminal  454  has the terminal portion  457  disposed directly on the voltage sense wall  1772  of the voltage sense member  1622 , and the terminal portion  458  disposed directly on and coupled to the voltage sense wall  1770  of the voltage sense member  1642 . 
     The electrical terminal  464  has the terminal portion  467  disposed directly on the voltage sense wall  1774  of the voltage sense member  1642 , and the terminal portion  468  disposed directly on and coupled to the terminal portion  458  of the electrical terminal  454 . The terminal portion  458  is sandwiched between the voltage sense wall  1770  and the terminal portion  468 . 
     The voltage sense member  1644  is coupled to the finger portion  1624 . The voltage sense member  1644  has voltage sense walls  1790 ,  1792 ,  1794 . The voltage sense walls  1792 ,  1794  are coupled to and extend from first and second ends, respectively, of the voltage sense wall  1790 . The voltage sense walls  1792 ,  1794  extend substantially perpendicular to the voltage sense wall  1790 . The voltage sense wall  1790  is disposed directly on the flat outer surface  1720  of the finger portion  1624 . The voltage sense walls  1792 ,  1794  are disposed directly on the side surfaces  1722 ,  1724 , respectively, of the finger portion  1624 . 
     The electrical terminal  474  has the terminal portion  477  disposed directly on the voltage sense wall  1792  of the voltage sense member  1644 , and the terminal portion  478  disposed directly on and coupled to the voltage sense wall  1790  of the voltage sense member  1644 . 
     The electrical terminal  484  has the terminal portion  487  disposed directly on the voltage sense wall  1794  of the voltage sense member  1644 , and the terminal portion  488  disposed directly on and coupled to the terminal portion  478  of the electrical terminal  474 . The terminal portion  478  is sandwiched between the voltage sense wall  1790  and the terminal portion  488 . 
     The voltage sense member  1646  is coupled to the finger portion  1626 . The voltage sense member  1646  has voltage sense walls  1810 ,  1812 ,  1814 . The voltage sense walls  1812 ,  1814  are coupled to and extend from first and second ends, respectively, of the voltage sense wall  1810 . The voltage sense walls  1812 ,  1814  extend substantially perpendicular to the voltage sense wall  1810 . The voltage sense wall  1810  is disposed directly on the flat outer surface  1730  of the finger portion  1626 . The voltage sense walls  1812 ,  1814  are disposed directly on the side surfaces  1732 ,  1734 , respectively, of the finger portion  1626 . 
     The electrical terminal  494  has the terminal portion  497  disposed directly on the voltage sense wall  1812  of the voltage sense member  1626 , and the terminal portion  498  disposed directly on and coupled to the voltage sense wall  1810  of the voltage sense member  1646 . 
     The electrical terminal  504  has the terminal portion  507  disposed directly on the voltage sense wall  1814  of the voltage sense member  1646 , and the terminal portion  508  disposed directly on and coupled to the terminal portion  498  of the electrical terminal  494 . The terminal portion  498  is sandwiched between the voltage sense wall  1810  and the terminal portion  508 . 
     The voltage sense member  1648  is coupled to the finger portion  1628 . The voltage sense member  1648  has voltage sense walls  1830 ,  1832 ,  1834 . The voltage sense walls  1832 ,  1834  are coupled to and extend from first and second ends, respectively, of the voltage sense wall  1830 . The voltage sense walls  1832 ,  1834  extend substantially perpendicular to the voltage sense wall  1830 . The voltage sense wall  1830  is disposed directly on the flat outer surface  1740  of the finger portion  1628 . The voltage sense walls  1832 ,  1834  are disposed directly on the side surfaces  1742 ,  1744 , respectively, of the finger portion  1628 . 
     The electrical terminal  514  has the terminal portion  517  disposed directly on the voltage sense wall  1832  of the voltage sense member  1648 , and the terminal portion  518  disposed directly on and coupled to the voltage sense wall  1830  of the voltage sense member  1648 . 
     The electrical terminal  524  has the terminal portion  527  disposed directly on the voltage sense wall  1834  of the voltage sense member  1648 , and the terminal portion  528  disposed directly on and coupled to the terminal portion  518  of the electrical terminal  514 . The terminal portion  518  is sandwiched between the voltage sense wall  1830  and the terminal portion  528 . 
     The voltage sense member  1650  is coupled to the finger portion  1630 . The voltage sense member  1650  has voltage sense walls  1850 ,  1852 ,  1854 . The voltage sense walls  1852 ,  1854  are coupled to and extend from first and second ends, respectively, of the voltage sense wall  1850 . The voltage sense walls  1852 ,  1854  extend substantially perpendicular to the voltage sense wall  1850 . The voltage sense wall  1850  is disposed directly on the flat outer surface  1750  of the finger portion  1630 . The voltage sense walls  1852 ,  1854  are disposed directly on the side surfaces  1852 ,  1854 , respectively, of the finger portion  1630 . 
     The electrical terminal  534  has the terminal portion  537  disposed directly on the voltage sense wall  1852  of the voltage sense member  1650 , and the terminal portion  538  disposed directly on and coupled to the voltage sense wall  1850  of the voltage sense member  1650 . 
     The electrical terminal  544  has the terminal portion  547  disposed directly on the voltage sense wall  1854  of the voltage sense member  1650 , and the terminal portion  558  disposed directly on and coupled to the terminal portion  538  of the electrical terminal  534 . The terminal portion  538  is sandwiched between the voltage sense wall  1850  and the terminal portion  558 . 
     Referring to  FIGS. 1 and 20 , the removable wire harness assembly  96  is provided to route voltages from the voltage sense members  1640 - 1650  to a battery management system. The removable wire harness assembly  96  includes spade clips  1940 ,  1942 ,  1944 ,  1946 ,  1948 ,  1950 ,  1952 , electrical cables  1960 ,  1962 ,  1964 ,  1966 ,  1968 ,  1970 , and an electrical connector  1980 . 
     The spade clip  1940  is coupled to the electrical cable  1960  and is further removably physically and electrically coupled to the electrical tab member of the voltage sense member  1640 . The electrical cable  1960  is further coupled to the electrical connector  1980 . 
     The spade clip  1942  is coupled to the electrical cable  1962  and is further removably physically and electrically coupled to an electrical tab member of the voltage sense member  1642 . The electrical cable  1962  is further coupled to the electrical connector  1980 . 
     The spade clip  1944  is coupled to the electrical cable  1964  and is further removably physically and electrically coupled to an electrical tab member of the voltage sense member  1644 . The electrical cable  1964  is further coupled to the electrical connector  1980 . 
     The spade clip  1946  is coupled to the electrical cable  1966  and is further removably physically and electrically coupled to an electrical tab member of the voltage sense member  1646 . The electrical cable  1966  is further coupled to the electrical connector  1980 . 
     The spade clip  1948  is coupled to the electrical cable  1968  and is further removably physically and electrically coupled to an electrical tab member of the voltage sense member  1648 . The electrical cable  1968  is further coupled to the electrical connector  1980 . 
     The spade clip  1950  is coupled to the electrical cable  1970  and is further removably physically and electrically coupled to an electrical tab member of the voltage sense member  1650 . The electrical cable  1970  is further coupled to the electrical connector  1980 . 
     Referring to  FIGS. 6 and 23-25 and 29 , a flowchart of a method for coupling electrical terminals of battery cells  42 ,  44 ,  46 ,  48  to the interconnect assembly  90  in accordance with an exemplary embodiment will now be described. 
     At step  2100 , a user provides battery cells  42 ,  44 ,  46 ,  48  having electrical terminals  442 ,  452 ,  462 ,  472  respectively. The battery cells  42 ,  44  are disposed adjacent to one another. The battery cells  46 ,  48  are disposed adjacent to one another. 
     At step  2102 , the user provides the interconnect assembly  90  having the plate portion  600 , finger portions  622 ,  624 , and voltage sense members  642 ,  644 . The finger portions  622 ,  624  are coupled to and extend from the first end  684  of the plate portion  600 . The finger portions  622 ,  624  extend substantially parallel to one another and are spaced apart from one another. A first gap is defined below the finger portion  622 , a second gap is defined between the finger portions  622 ,  624 , and a third gap is defined above the finger portion  624 . The finger portion  622  has side surfaces  712 ,  714  and a flat outer surface  710 . The flat outer surface  710  of the finger portion  622  is disposed between the side surfaces  712 ,  714  of the finger portion  622 . The voltage sense member  642  is coupled to the finger portion  622 . The voltage sense member  642  has voltage sense walls  770 ,  772 ,  774 . The voltage sense walls  772 ,  774  of the voltage sense member  642  are coupled to first and second ends, respectively, of the voltage sense wall  770  of the voltage sense member  642 . The voltage sense walls  772 ,  774  of the voltage sense member  642  extend perpendicular to the voltage sense wall  770  of the voltage sense member  642 . The voltage sense wall  770  of the voltage sense member  642  is disposed directly on the flat outer surface  710  of the finger portion  622 . The finger portion  624  has side surfaces  712 ,  714  and a flat outer surface  710 . The flat outer surface  710  of the finger portion  624  is disposed between the side surfaces  712 ,  714  of the finger portion  624 . The voltage sense member  644  is coupled to the finger portion  624 . The voltage sense member  644  has voltage sense walls  790 ,  792 ,  794 . The voltage sense walls  792 ,  794  of the voltage sense member  644  are coupled from first and second ends, respectively, of the voltage sense wall  790  of the voltage sense member  644 . The voltage sense walls  792 ,  794  of the voltage sense member  644  extend perpendicular to the voltage sense wall  790  of the voltage sense member  644 . The voltage sense wall  790  of the voltage sense member  644  is disposed directly on the flat outer surface  720  of the finger portion  624 . 
     At step  2104 , the user provides a frame member  22  having a first plastic frame  330  and a frame extension portion  332  extending outwardly from the first plastic frame  330 . 
     At step  2106 , the user disposes the frame member  22  between the battery cells  44 ,  46  such that the battery cell  44  is disposed against a first side of the first plastic frame  330 , and the battery cell  46  is disposed against a second side of the first plastic frame  330 . The frame extension portion  332  extends through the second gap substantially parallel to the finger portions  622 ,  624 . 
     At step  2108 , the placement machine  2400  disposes the interconnect assembly  90  proximate to the battery cells  42 ,  44 ,  46 ,  48  such that the electrical terminal  442  extends through the first gap, the electrical terminal  452  extends through the second gap between the frame extension portion  332  and the finger portion  622 , the electrical terminal  462  extends through the second gap between the frame extension portion  332  and the finger portion  624 , and the electrical terminal  472  extends through the third gap. 
     At step  2110 , the placement machine  2400  disposes the terminal portion  446  of the electrical terminal  442  directly on the voltage sense wall  770  of the voltage sense member  642 . 
     At step  2112 , the placement machine  2400  disposes the terminal portion  456  of the electrical terminal  452  directly on the terminal portion  446  of the electrical terminal  442  such that the terminal portion  446  of the electrical terminal  442  is sandwiched between the voltage sense wall  770  of the voltage sense member  642  and the terminal portion  456  of the electrical terminal  452 . 
     At step  2114 , the placement machine  2400  disposes a terminal portion  466  of the electrical terminal  462  directly on the voltage sense wall  790  of the voltage sense member  644 . 
     At step  2116 , the placement machine  2400  disposes of the terminal portion  476  of the electrical terminal  472  directly on the terminal portion  466  of the electrical terminal  462  such that the terminal portion  466  of the electrical terminal  462  is sandwiched between the voltage sense wall  790  of the voltage sense member  644  and the terminal portion  476  of the electrical terminal  472 . 
     At step  2118 , a laser  2404  emits a first laser beam to weld the terminal portion  446  of the electrical terminal  442  and the terminal portion  456  of the electrical terminal  452  to the voltage sense member  642 . 
     At step  2120 , the laser  2404  emits a second laser beam to weld a terminal portion  466  of the electrical terminal  462  and the terminal portion  476  of the electrical terminal  472  to the voltage sense member  644 . The frame extension portion  332  electrically isolates the electrical terminal  452  from the electrical terminal  462 . 
     Referring to  FIGS. 7, 22 and 26-29 , a flowchart of a method for coupling electrical terminals of battery cells  40 ,  42 ,  44 ,  46  to the interconnect assembly  94  in accordance with another exemplary embodiment will now be described. 
     At step  2300 , a user provides battery cells  40 ,  42 ,  44 ,  46  having electrical terminals  434 ,  444 ,  454 ,  464 , respectively. 
     At step  2302 , the user provides the interconnect assembly  94  having the plate portion  1600 , the finger portions  1620 ,  1622 , the blade portion  1633 , and the voltage sense members  1640 ,  1642 . The finger portion  1620  is coupled to and extends from the first end  1684  of the plate portion  1600 . The finger portion  1620  having side surfaces  1702 ,  1704  and a flat outer surface  1700 . The flat outer surface  1700  of the finger portion  1620  is disposed between the side surfaces  1702 ,  1704  of the finger portion  1620 . The voltage sense member  1640  is coupled to the finger portion  1620 . The voltage sense member  1640  has a voltage sense wall  1760  disposed directly on the flat outer surface  1700  of the finger portion  1620 . The finger portion  1622  is coupled to and extends from the first end  1684  of the plate portion  1600 . The finger portion  1622  extends substantially parallel to the finger portion  1620  and is spaced apart from the finger portion  1620 . The finger portion  1622  has side surfaces  1712 ,  1714  and a flat outer surface  1710 . The flat outer surface  1710  of the finger portion  1622  is disposed between the side surfaces  1712 ,  1714  of the finger portion  1622 . The voltage sense member  1622  is coupled to the finger portion  1622 . The voltage sense member  1622  has a voltage sense wall  1770  that is disposed directly on the flat outer surface  1710  of the finger portion  1622 . The blade portion  1633  is coupled to and extends from the first end  1684  of the plate portion  1600 . The blade portion  1633  extends substantially parallel to the finger portion  1620 ,  1622  and is disposed between the finger portions  1620 ,  1622 . A first gap is defined below the finger portion  1620 . A second gap is defined between the finger portion  1620  and the blade portion  1633 . A third gap is defined between the finger portion  1622  and the blade portion  1633 . Further, a fourth gap is defined above the finger portion  1622 . 
     At step  2304 , the user provides the frame member  20  and disposes the frame member  20  between the battery cells  40 ,  42  such that the battery cell  40  is disposed against a first side of the frame member  20 , and the battery cell  42  is disposed against a second side of frame member  20 . 
     At step  2306 , the user provides the frame member  22  and disposes the frame member  22  between the battery cells  44 ,  46  such that the battery cell  44  is disposed against a first side of the frame member  22 , and the battery cell  46  is disposed against a second side of the frame member  22 . 
     At step  2308 , the placement machine  2400  disposes the interconnect assembly  94  proximate to the battery cells  40 ,  42 ,  44 ,  46  such that the electrical terminal  434  extends through the first gap, the electrical terminal  444  extends through the second gap, the electrical terminal  454  extends through the third gap, and the electrical terminal  464  extends through the fourth gap. 
     At step  2310 , the placement machine  2400  disposes the terminal portion  438  of the electrical terminal  434  directly on the voltage sense wall  1760  of the voltage sense member  1640 . 
     At step  2312 , the placement machine  2400  disposes the terminal portion  448  of the electrical terminal  444  directly on the terminal portion  438  of the electrical terminal  434  such that the terminal portion  438  of the electrical terminal  434  is sandwiched between the voltage sense wall  1760  of the voltage sense member  1640  and the terminal portion  448  of the electrical terminal  444 . 
     At step  2314 , the placement machine  2400  disposes the terminal portion  458  of the electrical terminal  454  directly on the voltage sense wall  1770  of the voltage sense member  1622 . 
     At step  2316 , the placement machine  2400  disposes the terminal portion  468  of the electrical terminal  464  directly on the terminal portion  458  of the electrical terminal  454  such that the terminal portion  458  of the electrical terminal  454  is sandwiched between the voltage sense wall  1770  of the voltage sense member  1622  and the terminal portion  468  of the electrical terminal  464 . 
     At step  2318 , the laser  2404  emits a first laser beam to weld the terminal portion  438  of the electrical terminal  434  and the terminal portion  448  of the electrical terminal  444  to the voltage sense member  1640 . 
     At step  2320 , the laser  2404  emits a second laser beam to weld the terminal portion  458  of the electrical terminal  454  and the terminal portion  468  of the electrical terminal  464  to the voltage sense member  1622 , and the blade portion  1633  electrically isolating the electrical terminal  444  from the electrical terminal  454 . 
     Referring to  FIG. 29 , a system  2398  for performing at least a portion of the steps in the above described flowcharts is illustrated. The system  2398  includes the placement machine  2400  and the laser  2404  that are operably coupled to the computer  2406 . The computer  2406  includes a memory device that is programmed with software programs to implement at least a portion of the steps in the above described flowcharts. In particular, the computer  2406  to generate signals to induce the placement machine  2400  and the laser  2404  to perform the steps associated with the placement machine  2400  and the laser  2404  in the above described flowcharts. 
     The battery module and the method of coupling first and second electrical terminals of first and second battery cells, respectively, to first and second voltage sense members, respectively, of an interconnect assembly provide a substantial advantage over other battery modules and methods. In particular, the battery module utilizes an interconnect assembly having a plate portion, first and second finger portions extending from the plate portion, first and second voltage sense members disposed on the first and second finger portions, respectively, and a blade portion extending from the plate portion between the first and second finger portions. The first and second electrical terminals are coupled (e.g., welded) to the first and second voltage sense members, respectively, utilizing a laser beam from a laser. Further, the blade portion electrically isolates the first voltage sense member from the second voltage sense member. 
     While the claimed invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the invention is not limited to such disclosed embodiments. Rather, the claimed invention can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. Additionally, while various embodiments of the claimed invention have been described, it is to be understood that aspects of the invention may include only some of the described embodiments. Accordingly, the claimed invention is not to be seen as limited by the foregoing description.