Patent ID: 8764852

Claim:
A method of manufacturing a battery pack including a top housing, a bottom housing, a frame, a cell pad, a plurality of battery cells, a circuit board, and an electric coupler assembly being formed from a single sheet of metal and having a plurality of links, a plurality of cell couplings, and a plurality of circuit board couplings, the plurality of cell couplings electrically connecting the plurality of battery cells, the plurality of links electrically connecting the plurality of cell couplings, the method comprising: molding the frame around the electric coupler assembly into the frame; after molding, severing the plurality of links between the plurality of cell couplings to provide desired electrical connections between the plurality of battery cells; attaching the battery cells to the plurality of cell couplings after the links have been severed; and attaching the circuit board to the plurality of circuit board couplings; wherein the circuit board is electrically connected to each battery cell individually.