Blade terminal bus bar with finger-proofing

A battery module comprising:

• a battery cell having an electrically conductive terminal;
• a nonconductive terminal cap configured to at least partially surround the terminal, the terminal cap has a perimeter wall configured to circumscribe at least a portion of the terminal to provide a gap exposing the terminal, the terminal cap includes a first attachment feature;
• a bus bar having an end mechanically and electrically engaging the terminal in an assembled condition;
• a nonconductive shroud enclosing the bus bar, the shroud includes a second attachment feature removably engaging the first attachment feature in the assembled condition to secure the shroud to the terminal cap.

A method of electrically connecting cells of a battery, comprising the steps of:

• a) providing a nonconductive terminal cap over a conductive battery cell terminal, wherein the terminal cap at least partially surrounds the terminal, the terminal is a male terminal, the terminal cap has a perimeter wall configured to circumscribe at least a portion of the terminal, the terminal arranged in a post that shields the terminal, the perimeter wall and the post cooperate to provide a gap that exposes the terminal;
• b) providing a bus bar assembly with a bus bar having an end providing a female terminal, a nonconductive shroud enclosing the bus bar with the end exposed through the shroud;
• c) pushing the end into the gap and into engagement with the terminal;
• and
• d) mating the shroud to the terminal cap to enclose the end, wherein the mating step is performed simultaneously with the pushing step c).