Patent ID: 8293393

Claim:
A battery pack, comprising: a first housing member having a first housing member interior surface defining an interior region of said battery pack, wherein said first housing member interior surface includes a first plurality of cell mounting wells, wherein each cell mounting well of said first plurality of cell mounting wells is adapted to receive a first end of a corresponding battery cell, wherein said first housing member interior surface further includes at least one first housing member raised encapsulant injection port, wherein said at least one first housing member raised encapsulant injection port includes an extended portion that extends above said first housing member interior surface and further into said interior region of said battery pack; a second housing member complementary to said first housing member and having a second housing member interior surface that further defines said interior region of said battery pack, wherein said second housing member interior surface includes a second plurality of cell mounting wells, wherein each cell mounting well of said second plurality of cell mounting wells is adapted to receive a second end of said corresponding battery cell, wherein said second housing member interior surface further includes at least one second housing member raised encapsulant injection port, wherein said at least one second housing member raised encapsulant injection port includes an extended portion that extends above said second housing member interior surface and further into said interior region of said battery pack; a plurality of battery cells, wherein each battery cell of said plurality of battery cells includes said first end for insertion into each cell mounting well of said first plurality of cell mounting wells, and wherein each battery cell of said plurality of battery cells includes said second end for insertion into each cell mounting well of said second plurality of cell mounting wells; a first layer of encapsulation material surrounding the perimeter of said first end of each battery cell, wherein an end section of said extended portion of said at least one first housing member raised encapsulant injection port extends beyond said first layer of encapsulation material, and wherein said at least one first housing member raised encapsulant injection port remains open after inclusion of said first layer of encapsulation material within said battery pack; and a second layer of encapsulation material surrounding the perimeter of said second end of each battery cell, wherein an end section of said extended portion of said at least one second housing member raised encapsulant injection port extends beyond said second layer of encapsulation material, and wherein said at least one second housing member raised encapsulant injection port remains open after inclusion of said second layer of encapsulation material within said battery pack.