Abstract: A battery pack includes a cover coupled to a housing, wherein the cover and the housing are hermetically sealed to enclose one or more batteries. A wire is integrally molded within a perimeter of the cover to allow for the removal of the cover from the housing upon application of current to the wire. The wire is molded within the cover so as to be co-located along an edge of the housing. First and second contacts are coupled to the wire and remain exposed on the cover. The cover can be separated from the housing in response to current being applied to the first and second contacts and pulling of the wire.

Abstract: This invention includes a hybrid housing for rechargeable battery packs. The housing utilizes thin metal sidewalls with overlaid plastic end walls by way of an insert molding process. In a single cell, lithium-ion application, the resultant battery pack is 4.9% smaller by volume. Each sidewall up to 75% thinner than prior art sidewalls made by way of an injection molding process. The resultant battery housing is thinner and stronger than prior art housings.

Abstract: This invention includes a hybrid housing for rechargeable battery packs. The housing utilizes thin metal sidewalls with overlaid plastic end walls by way of an insert molding process. In a single cell, lithium-ion application, the resultant battery pack is 4.9% smaller by volume. Each sidewall up to 75% thinner than prior art sidewalls made by way of an injection molding process. The resultant battery housing is thinner and stronger than prior art housings.