NOVELTY - A battery pack assembly (100) comprises a housing (102) presenting an enclosure; cells (112) disposed in the enclosure; fins from a heat absorbing material sandwiched between the cell and extending beyond the housing for receiving heat from the cells and sinking heat away from the housing; and a foam (18) injected between the housing and the cells and surrounding the cells and the fins with the foam fusibly interconnecting the cells with the housing and compressing the cell relative to one another.    USE - Battery pack assembly for a vehicle (claimed) i.e. electric/hybrid vehicles, and useful in various configurations including an overlapping battery cell packaging configuration and a vertical stack battery cell packaging configuration used in an automotive vehicle applications.    ADVANTAGE - The assembly has efficient packaging characteristics, which provides excellent retention that surrounds and secures cells, and secures the internal electrode stack within the cell; provides a cost effective, low mass design of a battery pack, which includes polyurethane foam as a retention device versus that of traditional methods of retention, such as silicone adhesives; provides a battery pack having a chemical resistant design where internal components of the battery pack are encapsulated by the polyurethane foam which greatly reduces the potential permeation of liquids into the battery pack, or leakage from inside the battery pack to the outside of the battery pack, preventing reduced product life or premature failures of the battery pack; provides a battery pack design with improved heat absorption characteristics where insulating air gaps are eliminated which promotes the absorption of heat generated inside the pack to be transferred to the outside of the pack; provides a battery pack having a balanced air management cooling system where each cell of the battery pack receives a similar temperature and flow of inlet air to assist removing the undesired heat; provides a cooling system, which allows the battery pack to deliver and receive high and fast rates of current, i.e. the C-rate, without producing heat during the rapid charge or discharge pulse that may negatively impact the performance and life span of the battery pack; and provides a pack that is simple in design.    DETAILED DESCRIPTION - INDEPENDENT CLAIMS are included for:    (1) a method of forming a battery pack;    (2) a vehicle; and    (3) a method of forming a battery pack assembly.    DESCRIPTION OF DRAWING(S) - The figure is a perspective view of a pack having a housing (only one half is shown) having cells disposed in the housing and the foam injected to fill voids defined between the cells and the housing, the cells being partially encapsulated, where cells are connected to the electrical bus assembly.    Foam (18)    Battery pack assembly (100)    Housing (102)    Cells (112)    Electrical components (116)