Abstract: In a battery pack (1),a current loop between the positive and negative electrode plates of an electrode assembly passes points P1, P2, P3, P4, P5, P6, P7, P8, P9, P10, P11, P12, P13 and P14 in this order. A line that connects P2 to P3 intersects a line that connects P11 to P12 in the part where the loop passes a sealing plate (12), which is arranged on the top of a battery unit (10). The loop can be divided into loop parts B1 and B2. The part B1 is formed on the exterior side of the battery unit, and extends from the intersection A through a circuit board (20) back to the intersection A. The part B2 is formed on the interior side of the battery unit relative to the intersection A. The current flows counterclockwise and clockwise in the parts B1 and B2, respectively.

Abstract: In a battery pack (1), a current loop between the positive and negative electrode plates of an electrode assembly passes points P1, P2, P3, P4, P5, P6, P7, P8, P9, P10, P11, P12, P13 and P14 in this order. A line that connects P2 to P3 intersects a line that connects P11 to P12 in the part where the loop passes a sealing plate (12), which is arranged on the top of a battery unit (10). The loop can be divided into loop parts B1 and B2. The part B1 is formed on the exterior side of the battery unit, and extends from the intersection A through a circuit board (20) back to the intersection A. The part B2 is formed on the interior side of the battery unit relative to the intersection A. The current flows counterclockwise and clockwise in the parts B1 and B2, respectively.

Abstract: A method including the steps of assembling a battery pack core; holding the core in a mold that forms a molded resin region; closing a cavity of the mold; injecting synthetic resin into the closed cavity; and ejecting the battery pack from the cavity to configure the battery pack with the battery pack core insert-molded in the molded resin region. A projection that protrudes towards an inner surface of the mold cavity is provided on the surface of the insulating cover fixed on the battery. In the resin injection step, the projection on the insulating cover is pressed directly or indirectly by the mold in a direction to put the insulating cover tightly in contact with the surface of the battery; and synthetic resin is injected into the cavity of the mold in this pressed configuration.

Abstract: A battery pack including a molded resin portion, which holds a part of or the entire battery, and an externally exposed output terminal. The battery pack further includes an insulating block, which is provided with a breaker mechanism for cutting-off current flow when an over-current flows. The insulating block is held by being inserted in the molded resin portion. The insulating block holds the output terminal on its surface. The output terminal held by the insulating block is held at a prescribed position so as to be externally exposed from the molded resin portion.

Abstract: In a battery pack, a battery core pack having a connector is inserted into a resin molded portion which is formed of a plastic material. The battery core pack includes a rechargeable unit cell, a circuit board electrically connected to the unit cell, and a connector fixed to the circuit board. The connector incorporates a contact point in a connector casing which is formed of an insulation material, and the connector casing is inserted into the resin molded portion so as to partially appear to a surface of the resin molded portion. Further, the battery pack is provided with a sealing groove at a boundary between the connector casing and the resin molded portion, along a peripheral edge of an exposed portion of the connector, appearing outside the resin molded portion.

Abstract: A method comprising: assembling a battery pack core; holding the core in a mold that forms a molded resin region; closing a cavity of the mold; injecting synthetic resin into the closed cavity; and ejecting the battery pack from the cavity to configure the battery pack with the battery pack core insert-molded in the molded resin region. A projection that protrudes towards an inner surface of the mold cavity is provided on the surface of the insulating cover fixed on the battery. In the resin injection step, the projection on the insulating cover is pressed directly or indirectly by the mold in a direction putting the insulating cover tightly in contact with the surface of the battery; and synthetic resin is injected into the cavity of the mold in this pressed configuration.

Abstract: The battery 2 of the battery pack is temporarily held in a mold 30 to form a molded resin region 1, synthetic resin injected into the mold cavity 31 to form the molded resin region 1 attaches to the battery 2, and the molded resin region 1 attaches to a safety valve opening surface 20 established at the battery safety valve opening region 9. Further, insulating material 15 is attached at the interface between the battery safety valve opening surface 20 and the molded resin region 1 in a position which closes off the safety valve opening region 9.

Abstract: The battery pack is provided with a rechargeable battery that can be charged, and a protection device to protect the rechargeable battery when an abnormality occurs. The protection device is provided with an externally exposed first output terminal connected to the first electrode of the rechargeable battery, an externally exposed second output terminal connected to the second electrode of the rechargeable battery, and an externally exposed third output terminal for signal detection as output terminals, and a contact switching section that can switch contact when a rechargeable battery abnormality is detected. The protection device is formed as a single piece with the output terminals and contact switching section. The contact switching section has one end connected to the second electrode of the rechargeable battery, the other end is connected to allow switching between a contact connected to the second output terminal and a contact connected to the third output terminal.

Abstract: A battery pack comprises a molded resin portion which holds a part of or the whole of battery inserted thereto, and an externally exposed output terminal. The battery pack further comprises an insulating block which is provided with a breaker mechanism for cutting-off current flow when an over-current flows. The insulating block is held by being inserted in the molded resin portion. The insulating block holds the output terminal on its surface. The output terminal held by the insulating block is held at a prescribed position so as to be externally exposed from the molded resin portion.

Abstract: The battery pack is provided with a rechargeable battery that can be charged, and a protection device to protect the rechargeable battery when an abnormality occurs. The protection device is provided with an externally exposed first output terminal connected to the first electrode of the rechargeable battery, an externally exposed second output terminal connected to the second electrode of the rechargeable battery, and an externally exposed third output terminal for signal detection as output terminals, and a contact switching section that can switch contact when a rechargeable battery abnormality is detected. The protection device is formed as a single piece with the output terminals and contact switching section. The contact switching section has one end connected to the second electrode of the rechargeable battery, the other end is connected to allow switching between a contact connected to the second output terminal and a contact connected to the third output terminal.

Abstract: The battery of the battery pack is temporarily held in a mold to form a molded resin region, synthetic resin injected into the mold cavity to form the molded resin region attaches to the battery, and the molded resin region attaches to a safety valve opening surface established at the battery safety valve opening region. Further, insulating material is attached at the interface between the battery safety valve opening surface and the molded resin region in a position which closes off the safety valve opening region.