Battery pack assembly

A holding frame for use in manufacturing a battery pack assembly, the holding frame having a first major surface and a second major surface, on one or both of the first major surface and the second major surface the holding frame has one or more cell-locating structures which are shaped and/or sized and/or configured to accommodate at least a portion of one or more cells, the one or more cell-locating structures comprising a first wall upstanding from one of the first or second major surfaces, the first upstanding wall comprising a first portion extending from the first or second major surface and a free or terminal portion which is shaped to provide a lead-in portion terminating at a distal end, the free or terminal portion providing a minor portion of the upstanding wall and the holding frame extending from the first major surface to the distal end.

A battery pack assembly, the assembly comprising a first holding frame and a second holding frame, a plurality of cells having terminals, and an electrically conductive conductor plate for providing electrical contact to at least two of said plurality of cells, the first holding frame having a first major surface and a second major surface, the first major surface having first and second cell-locating structures extending therefrom each of which are shaped and/or sized and/or configured to accommodate at least a portion of one of said plurality of cells, the second holding frame having a first major surface and a second major surface, the first major surface having first and second cell-locating structures extending therefrom each of which are shaped and/or sized and/or configured to accommodate at least a portion of said one of said plurality of cells, the distance between the facing first major surfaces of the first holding frame and the second holding frame being different for the respective first cell locating structures and second cell location structures.

A method for assembling a battery pack assembly, the method comprising:

• i. providing a holding frame having a first major surface and a second major surface, on one or both of the first major surface and the second major surface the holding frame having one or more cell-locating structures which are shaped and/or sized and/or configured to accommodate at least a portion of one or more cells, the one or more cell-locating structures comprising a first wall upstanding from one of the first or second major surfaces, the first upstanding wall comprising a free or terminal portion which is shaped to provide a lead-in portion;
• ii. locating a conductor plate on the holding frame;
• iii. simultaneously locating a plurality of cells on the conductor plate by moving the cells past the lead-in portion of each cell-locating structure.