Secondary battery pack exhibiting enhanced coupling strength between a battery cell and mounting members

1. A secondary battery pack comprising:

a battery cell having an electrode assembly of a cathode/separator/anode structure mounted in a battery case together with an electrolyte in a sealed state;

an insulative mounting member having openings, through which electrode terminals of the battery cell are exposed to an outside, the insulative mounting member being in direct contact with the top of the battery cell;

a safety element mounted to a top of the insulative mounting member; and

an insulative cap coupled to the top of the battery cell such that the insulative cap surrounds the insulative mounting member while the safety element is mounted to the insulative mounting member,

wherein the battery case is provided at the top thereof with at least one coupling groove, and the insulative mounting member is provided at a bottom thereof with at least one coupling protrusion corresponding to the at least one coupling groove, whereby the coupling of the insulative mounting member to the battery cell is accomplished by insertion of the coupling protrusion into the coupling groove, and

wherein the insulative mounting member has a size approximately corresponding to that of the top of the battery cell, the insulative mounting member is provided at the middle thereof with a first opening, through which a first electrode terminal of the battery cell is exposed to the outside, and the insulative mounting member is provided at a position spaced a predetermined distance from the first opening with a second opening, through which a portion of the top of the battery case of the battery cell is exposed to the outside.

2. The secondary battery pack according to claim 1 , wherein the battery case is a metal container.

3. The secondary battery pack according to claim 1 , wherein the insulative mounting member is constructed in a structure in which opposite-side ends of the insulative mounting member protrude upward by a predetermined height.

4. The secondary battery pack according to claim 1 , wherein the safety element is one or more selected from a group consisting of a positive temperature coefficient (PTC) element, a fuse, and a protection circuit board.

5. The secondary battery pack according to claim 1 , wherein the safety element includes a PTC element and a protection circuit board, one end of the PTC element is connected to the first electrode terminal of the battery cell, an other end of the PTC element is connected to the protection circuit board, and the second electrode terminal of the battery cell is connected to the protection circuit board.

6. The secondary battery pack according to claim 5 , wherein a first connection between the PTC element and the protection circuit board and a second connection between the second electrode terminal and the protection circuit board are carried out by variable connecting members.

7. The secondary battery pack according to claim 6 , wherein the connecting member for the first connection and the connecting member for the second connection are coupled to the protection circuit board, and the connecting members are coupled to the respective electrode terminals of the battery cell.

8. The secondary battery pack according to claim 7 , wherein the connecting members are coupled to the electrode terminals of the battery cell, while the protection circuit board is placed on the top of the battery cell such that an angle between the protection circuit board and the top of the battery cell exceeds approximately 90 ; degrees, the variable connecting members are bent such that the protection circuit board is placed on the insulative mounting member while the protection circuit board is parallel with the top of the battery cell, and the connecting members are coupled to the protection circuit board such that a bent portions of the connecting members are directed to the same side.

9. The secondary battery pack according to claim 6 , wherein the connecting members are nickel plates.

10. The secondary battery pack according to claim 1 , wherein an adhesive is injected into the coupling grooves before the coupling protrusions are inserted into the corresponding coupling grooves.

11. The secondary battery pack according to claim 1 , wherein the insulative cap extends downward by a predetermined length sufficient for at least some of the insulative cap to surround the outside of the top of the battery cell while the insulative cap is mounted on the battery cell.

12. The secondary battery pack according to claim 11 , wherein a downward extending portion of the insulative cap is fixed to the outside of the top of the battery cell by a bonding fashion or a mechanical coupling fashion.

13. The secondary battery pack according to claim 1 , further comprising:

another insulative cap coupled to the bottom of the battery cell.

14. The secondary battery pack according to claim 1 , further comprising:

a sheathing film attached to an outer surface of the battery case of the battery cell.

15. The secondary battery pack according to claim 14 , wherein the sheathing film is attached to the outer surface of the battery case of the battery cell such that the sheathing film surrounds the downward extending portion of the insulative cap.

16. The secondary battery pack according to claim 1 , wherein the battery cell is a prismatic lithium secondary battery cell.

17. The secondary battery pack according to claim 4 , wherein the safety element includes a PTC element and a protection circuit board, one end of the PTC element is connected to the first electrode terminal of the battery cell, the other end of the PTC element is connected to the protection circuit board, and the second electrode terminal of the battery cell is connected to the protection circuit board.

18. The secondary battery pack according to claim 12 , further comprising:

a sheathing film attached to the outer surface of the battery case of the battery cell.