Secondary battery and the fabrication method thereof

A secondary battery, comprising:

• an electrode assembly comprising a first electrode, a second electrode, and a separator interposed between the first electrode and the second electrode;
• a container receiving the electrode assembly, the container having an opening;
• a cap coupled with the opening of the container, the cap comprising a terminal plate, an insulating plate, a cap plate, a gasket and an electrode terminal electrically connected to one of the first and second electrodes, the terminal plate comprising a first through-hole which is aligned with the electrode terminal;
• a first electrode tab electrically connected to the first electrode and a second electrode tab electrically connected to the second electrode, the first and second electrode tabs protruding from the electrode assembly towards the cap;
• and
• an injection-molded insulating member mounted between the electrode assembly and the cap and the injection-molded insulating member being in contact with the terminal plate, the insulating member comprising a plate and a sidewall protruding from the plate in a direction toward the cap, the plate making an obtuse angle with an outer surface of the sidewall, a spot for injecting raw material being disposed in a first side of the insulating member opposite to a second side of the insulating member facing to the electrode assembly, the spot being exposed by the first through-hole and facing directly to the electrode terminal through the first through-hole, the injection-molded insulating member comprising a second through-hole through which the first electrode tab passes and a third through-hole through which the second electrode tab passes,
• wherein the opening of the container has an inversely stepped cross-sectional profile along an inner wall of the container, and the inversely stepped cross-sectional profile comprises an upper side including an upper inner wall of the opening and a lower side including a lower inner wall of the opening, the upper inner wall of the opening having a cross-sectional dimension that is smaller than a corresponding cross-sectional dimension of the lower inner wall of the opening, and
• wherein an uppermost part of the sidewall of the insulating member is positioned in a lower side of the inversely stepped profile to keep the insulating member from escaping from the container, an entirety of the insulating member is positioned within the lower side of the inversely stepped profile.

A fabrication method of a secondary battery, comprising:

• preparing an electrode assembly, the electrode assembly comprising a first electrode, a second electrode, and a separator interposed between the first electrode and the second electrode;
• preparing a first electrode tab electrically connected to the first electrode and a second electrode tab electrically connected to the second electrode, the first and second electrode tabs protruding away from the electrode assembly;
• inserting the electrode assembly into a container;
• preparing an insulating member by injecting a raw material into a mold from a first side of the insulating member opposite to a second side of the insulating member to be faced with the electrode assembly, solidifying the inserted raw material, and removing the solidified material from the mold, the insulating member comprising a first through-hole through which the first electrode tab passes and a second through-hole through which the second electrode tab passes;
• positioning the insulating member over the electrode assembly;
• and
• coupling a cap to an opening of the container with the insulating member positioned over the electrode assembly, the cap comprising a terminal plate, an insulating plate, a cap plate, a gasket and an electrode terminal electrically connected to one of the first and second electrodes, the terminal plate comprising a third through-hole which is aligned with the electrode terminal, the terminal plate being in contact with the insulating member,
• wherein the injection of the raw material forms a spot on the first side of the insulating member, and the spot is exposed by the third through-hole and faces directly to the electrode terminal through the third through-hole,
• wherein the insulating member comprises a plate and a sidewall protruding from the plate, and the raw material is injected from the side of the insulating member opposite to the side of the insulating member on which the sidewall of the insulating member is to be formed, and the plate makes an obtuse angle with the outer surface of the sidewall,
• wherein the opening of the container has an inversely stepped cross-sectional profile along an inner wall of the container, and the inversely stepped cross-sectional profile comprises an upper side including an upper inner wall of the opening and a lower side including a lower inner wall of the opening, the upper inner wall of the opening having a cross-sectional dimension that is smaller than a corresponding cross-sectional dimension of the lower inner wall of the opening, and
• wherein an uppermost part of the sidewall of the insulating member is positioned in a lower side of the inversely stepped profile to keep the insulating member from escaping from the container, an entirety of the insulating member is positioned within the lower side of the inversely stepped profile.