Patent ID: 8216502

Claim:
A method of manufacturing a battery pack, the method comprising the steps of: inserting a first end of each of a plurality of battery cells into a corresponding cell constraint of a first plurality of cell constraints located on an interior surface of a first housing member; inserting a second end of each of said plurality of battery cells into a corresponding cell constraint of a second plurality of cell constraints located on an interior surface of a second housing member, wherein said first housing member, said second housing member and said plurality of battery cells comprise a battery pack assembly; injecting a first quantity of encapsulation material through a first plurality of raised encapsulant injection ports within said interior surface of said second housing member, wherein said first quantity of encapsulation material surrounds said first end of each of said plurality of battery cells, wherein said first quantity of encapsulation material surrounds a first section of a second plurality of raised encapsulant injection ports within said interior surface of said first housing member, and wherein said first quantity of encapsulation materials does not contact a second section of said second plurality of raised encapsulant injection ports within said interior surface of said first housing member, wherein said second section of said second plurality of raised encapsulant injection ports extends further from said interior surface of said first housing member than does said first section of said second plurality of raised encapsulant injection ports; rotating said battery pack assembly; and injecting a second quantity of encapsulation material through said second plurality of raised encapsulant injection ports within said interior surface of said first housing member, wherein said second quantity of encapsulation material surrounds said second end of each of said plurality of battery cells, wherein said second quantity of encapsulation material surrounds a first section of said first plurality of raised encapsulant injection ports within said interior surface of said second housing member, and wherein said second quantity of encapsulation materials does not contact a second section of said first plurality of raised encapsulant injection ports within said interior surface of said second housing member, wherein said second section of said first plurality of raised encapsulant injection ports extends further from said interior surface of said second housing member than does said first section of said first plurality of raised encapsulant injection ports.