Lead tap, battery pack having the lead tap and method of manufacturing the lead tap

A battery pack comprising:

• a plurality of battery cells comprising terminals;
• and
• a plurality of lead taps coupled with the terminals of the battery cells,
• wherein a lead tap of the lead taps comprises:
• an insulation cover comprising an electrical insulating material and a boss unit which protrudes from an upper surface of the insulation cover, the insulation cover having an opening;
• and
• a thermal cut-off device assembly comprising:
• a thermal cut-off device exposed at a lower surface of the insulation cover by the opening, the thermal cut-off device having a thickness that is less than a height of the insulation cover such that a peripheral surface of the thermal cut-off device is entirely contained within the insulation cover;
• and
• a first lead and a second lead that are coupled to the thermal cut-off device, the thermal cut-off device assembly having a hole through which a portion of the boss unit of the insulation cover protrudes,
• wherein the boss unit of the insulation cover comprises an edge unit that is larger than an opening of the hole of the thermal cut-off device assembly to secure the insulation cover to the thermal cut-off device assembly.

A method of manufacturing a lead tap, the method comprising:

• preparing an insulation cover comprising an electrical insulating material and a boss unit which protrudes from an upper surface of the insulation cover, the insulation cover having a second opening;
• preparing a thermal cut-off device assembly comprising:
• a thermal cut-off device;
• and
• a first lead and a second lead that are coupled to the thermal cut-off device, the thermal cut-off device assembly having a hole configured to receive the boss unit of the insulation cover;
• arranging the thermal cut-off device assembly on the insulation cover so that the boss unit of the insulation cover is inserted into the hole of the thermal cut-off device assembly and the thermal cut-off device is at the second opening, the thermal cut-off device having a thickness that is less than a height of the insulation cover such that a peripheral surface of the thermal cut-off device is entirely contained within the insulation cover;
• and
• thermal-pressing a portion of the boss unit that protrudes through the hole of the thermal cut-off device assembly to form an edge unit of the boss unit.