Battery pack housing and battery pack and power supply device incorporating the same

A battery pack comprising:

• a) a housing including:
• 1) a first shell portion including a first base wall and a plurality of upstanding first side walls extending from said first base wall, said first base wall and said first side walls defining a first cavity;
• 2) a second shell portion foldably connected to said first shell portion, said second shell portion including a second base wall and a plurality of upstanding second side walls extending from said second base wall, said second base wall and said second side walls defining a second cavity;
• and
• 3) wherein said first shell portion and said second shell portion are formed of a polymeric material;
• b) at least one battery disposed in said first and second cavities;
• and
• c) at least one wire operatively connected to said battery
• d) wherein:
• 1) said battery is partly surrounded by said first and second shell portions;
• and
• 2) said first and second shell portions define a gap therebetween, said gap extending fully about said housing between said first and second shell portions except where said second shell portion is foldably connected to said first shell portion.

A battery pack comprising:

• a) a housing including:
• 1) a first shell portion including a first base wall and a plurality of upstanding first side walls extending from said first base wall, said first base wall and said first side walls defining a first cavity;
• 2) a second shell portion foldably connected to said first shell portion, said second shell portion including a second base wall and a plurality of upstanding second side walls extending from said second base wall, said second base wall and said second side walls defining a second cavity;
• and
• 3) wherein said first shell portion and said second shell portion are formed of a polymeric material;
• b) at least one battery disposed in said first and second cavities;
• and
• c) at least one wire operatively connected to said battery;
• d) wherein:
• 1) said battery is partly surrounded by said first and second shell portions;
• and
• 2) said first and second shell portions define a gap therebetween;
• and
• 3) said battery pack further includes a self-adhesive warning label adhered to each of said first and second shell portions and extending across said gap.

A battery pack comprising:

• a) a unitary, transparent housing formed of a polymeric material, said housing including:
• 1) a first shell portion including a first base wall and a plurality of upstanding first side walls extending from said first base wall, said first base wall and said first side walls defining a first cavity;
• 2) a second shell portion including a second base wall and a plurality of upstanding second side walls extending from said second base wall, said second base wall and said second side walls defining a second cavity;
• 3) a hinge wall having first and second opposed edges adjoining said first and second shell portions, respectively;
• 4) a plurality of perforations formed in said hinge wall adjacent at least one of said first and second shell portions to facilitate folding of said first and second shell portions about said hinge wall;
• 5) a handle integral with said housing and extending from at least one of said first and second side walls;
• 6) a vent hole defined in at least one of said first and second base walls;
• and
• 7) a wire channel formed in at least one of said first and second shell portions;
• and
• b) a plurality of batteries disposed in said first and second cavities such that said batteries are partly surrounded by said first and second shell portions and said first and second shell portions define a gap therebetween;
• c) a self-adhesive warning label adhered to each of said first and second shell portions and extending across said gap;
• and
• d) a plurality of wires operatively connected to each of said batteries and extending through said wire channel.

A housing for a battery pack, said housing comprising:

• a) a first shell portion including a first base wall and a plurality of upstanding first side walls extending from said first base wall, said first base wall and said first side walls defining a first cavity;
• b) a second shell portion foldably connected to said first shell portion, said second shell portion including a second base wall and a plurality of upstanding second side walls extending from said second base wall, said second base wall and said second side walls defining a second cavity;
• and
• c) a handle integral with said housing and extending from at least one of said first and second side walls;
• d) wherein said first shell portion, said second shell portion and said hinge wall are formed of a polymeric material.

A method for forming a battery pack, said method comprising the steps of:

• a) providing a continuous sheet of polymeric material;
• b) thermoforming a unitary housing in the sheet, the housing including:
• 1) a first shell portion including a first base wall and a plurality of upstanding first side walls extending from the first base wall, the first base wall and the first side walls defining a first cavity;
• 2) a second shell portion foldably connected to the first shell portion, the second shell portion including a second base wall and a plurality of upstanding second side walls extending from the second base wall, the second base wall and the second side walls defining a second cavity;
• c) removing the housing from a remaining portion of the sheet;
• d) placing a plurality of batteries in the first cavity;
• e) electrically connecting the plurality of batteries with at least one wire;
• and
• f) folding the second shell portion about the first shell portion such that the battery is received in the second cavity.

A power supply device comprising:

• a) a device case;
• b) a power supply circuit mounted in said device case;
• and
• c) a battery pack mounted in said device case, said battery pack comprising:
• 1) a housing including.
• a first shell portion including a first base wall and a plurality of upstanding first side walls extending from said first base wall, said first base wall and said first side walls defining a first cavity;
• and
• a second shell portion foldably connected to said first shell portion, said second shell portion including a second base wall and a plurality of upstanding second side walls extending from said second base wall, said second base wall and said second side walls defining a second cavity;
• 2) at least one battery disposed in said first and second cavities;
• and
• 3) at least one wire operatively connecting said battery to said power supply circuit;
• 4) wherein said wire extends through and out of said housing.