Battery pack and its manufacturing method

A battery pack for an electrical device, the battery pack comprising:

• a housing including
• a first housing portion,
• a second housing portion coupled to the first housing portion,
• a cavity, and
• at least one terminal configured to electrically connect the battery pack to the electrical device;
• a battery cell assembly including
• a plurality of battery cells disposed within the cavity and configured to supply power to the electrical device,
• a support structure that receives and support the plurality of battery cells within the cavity of the housing, and
• a battery cell potting that encases the plurality of battery cells and the support structure;
• and
• a circuit board disposed within the housing atop the plurality of battery cells and including a plurality of electrical components, the circuit board is configured to selectively power the plurality of battery cells,
• wherein the circuit board is coupled to the battery cell assembly.

A method of manufacturing a battery pack for a power tool, the battery pack including a housing having a first housing portion and a second housing portion that has a plurality of ribs that extend inward toward a cavity of the housing, a battery cell assembly disposed within the cavity of the housing having a plurality of battery cells and a support structure supporting the plurality of battery cells, and a circuit board positioned atop the battery cell assembly within the housing, the method comprising:

• injecting battery cell potting around the plurality of battery cells and the support structure, such that the plurality of battery cells and the support structure are coupled together via the battery cell potting;
• and
• forming a plurality of grooves within the battery cell potting that are configured to receive the plurality of the ribs of the housing;
• sliding the plurality of grooves along the plurality of ribs to secure the battery cell assembly within the cavity and inhibiting movement of the plurality of battery cells relative to the housing.