Method and apparatus for the external application of battery pack encapsulant

A battery pack, comprising:

• a first housing member having a first housing member interior surface defining an interior region of said battery pack, said first housing member interior surface comprising a first plurality of cell constraints, wherein each cell constraint of said first plurality of cell constraints is adapted to receive a first end of at least one corresponding battery cell, said first housing member interior surface further comprising a plurality of first housing member raised encapsulant injection ports, wherein each of said plurality of first housing member raised encapsulant injection ports 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, said second housing member interior surface comprising a second plurality of cell constraints, wherein each cell constraint of said second plurality of cell constraints is adapted to receive a second end of said at least one corresponding battery cell;
• a plurality of battery cells constrained by said first plurality of cell constraints and by said second plurality of cell constraints;
• 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 each of said plurality of first housing member raised encapsulant injection ports extends beyond said first layer of encapsulation material, and wherein each of said plurality of first housing member raised encapsulant injection ports remains open after inclusion of said first layer of encapsulation material;
• and
• a second layer of encapsulation material surrounding the perimeter of said second end of each battery cell.

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.

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 first plurality of cell constraints located on an interior surface of a first housing member;
• adding a first quantity of encapsulation material into said first housing member, wherein said first quantity of encapsulation material covers said interior surface of said first housing member and 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 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 plurality of raised encapsulant injection ports within said interior surface of said first housing member, wherein said second section of said plurality of raised encapsulant injection ports extends further from said interior surface of said first housing member than does said first section of said plurality of raised encapsulant injection ports;
• inserting a second end of each of said plurality of battery cells into 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;
• rotating said battery pack assembly;
• and
• injecting a second quantity of encapsulation material through said 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.