A method of manufacturing a secondary battery includes the following steps. An insertion portion of a negative-electrode terminal is inserted into a terminal connection hole that is formed in a first negative-electrode current collector and crimped on a tapered portion to form a crimped portion. A gap is formed between the crimped portion and the tapered portion. Energy rays are radiated toward at least one of the crimped portion and the tapered portion to melt the at least one of the crimped portion and the tapered portion such that a melted metal flows into the gap. The melted metal is solidified to form a solidified portion, and the negative-electrode terminal and the first negative-electrode current collector are joined to each other. The solidified portion has a recessed portion.

Disclosed is a pressing jig for welding an electrode lead located in a lead slit formed at the bus bar to the bus bar in a closely adhered state. The pressing jig includes a first frame having a first distance adjusting unit and a first pressing unit, and a second frame having a second distance adjusting unit facing the first distance adjusting unit and a second pressing unit facing the first pressing unit. The first frame and the second frame are coupled so that a distance between first pressing unit and the second pressing unit is increased when a distance between the first distance adjusting unit and the second distance adjusting unit is decreased, and the distance between first pressing unit and the second pressing unit is decreased when the distance between the first distance adjusting unit and the second distance adjusting unit is increased.

Disclosed is a pressing jig for welding an electrode lead located in a lead slit formed at the bus bar to the bus bar in a closely adhered state. The pressing jig includes a first frame having a first distance adjusting unit and a first pressing unit, and a second frame having a second distance adjusting unit facing the first distance adjusting unit and a second pressing unit facing the first pressing unit. The first frame and the second frame are coupled so that a distance between first pressing unit and the second pressing unit is increased when a distance between the first distance adjusting unit and the second distance adjusting unit is decreased, and the distance between first pressing unit and the second pressing unit is decreased when the distance between the first distance adjusting unit and the second distance adjusting unit is increased.

Disclosed are a tab, a battery core having the same, a battery module, and a battery pack. The tab includes a first tab sheet and a second tab sheet. The second tab sheet is arranged on a side of the first tab sheet in a thickness direction. At least one cooling cavity is defined between the second tab sheet and the first tab sheet. The cooling cavity is filled with a cooling medium.

An electrode roll connection automation apparatus is configured for uniformly maintaining the width of electrode tabs in a process of connecting electrode sheets to each other and for automatically connecting the electrode sheets to each other. The electrode roll connection automation apparatus includes first and second supply units, a connection unit, and an electrode tab sensing unit. The first and the second supply units are configured to supply first and second electrode sheets, respectively, on which electrode tabs are formed. The connection unit is configured to connect the first electrode sheet and the second electrode sheet to each other. The electrode tab sensing unit is disposed between the first supply unit and the connection unit. The electrode tab sensing unit is configured to measure the distance between the electrode tabs.

Provided is a battery module. The battery module includes: a plurality of battery packs; a bus bar electrically connecting neighboring battery packs to each other; and a bus bar cover covering an end portion of the bus bar for insulating the bus bar, the bus bar cover including a hollow portion through which a coupling hole of the bus bar is exposed, the hollow portion extending in a direction away from the bus bar. According to embodiments, in the battery module, the bus bar electrically connecting different battery packs is sufficiently insulated to prevent malfunctions and safety accidents caused by a short circuit of the bus bar through which charging and discharging high-voltage current flows.

Provided is a battery module. The battery module includes: a plurality of battery packs; a bus bar electrically connecting neighboring battery packs to each other; and a bus bar cover covering an end portion of the bus bar for insulating the bus bar, the bus bar cover including a hollow portion through which a coupling hole of the bus bar is exposed, the hollow portion extending in a direction away from the bus bar. According to embodiments, in the battery module, the bus bar electrically connecting different battery packs is sufficiently insulated to prevent malfunctions and safety accidents caused by a short circuit of the bus bar through which charging and discharging high-voltage current flows.

Busbar includes joining surface to which a voltage detection line is to be joined, and position restriction part provided on at least a part of a periphery of joining surface and configured to restrict spreading of a corrosion inhibitor that covers joining surface.

A shroud configured to connect a leadframe to a battery system for a hybrid motor vehicle is provided. The shroud is removably attachable to the leadframe. The shroud has at least one shroud alignment feature, the shroud being removably attached to the leadframe in a predetermined orientation wherein the shroud alignment feature is aligned with a complimentary leadframe alignment feature. The shroud may include a hollow cylindrical portion and at least one connecting feature configured to attach the shroud to the leadframe. The shroud may be provided as part of a connector system that includes the leadframe. In this case, the leadframe is configured to provide an electrical and mechanical connection between a power inverter and the battery system of the electric motor. The leadframe includes at least one leadframe alignment feature that is aligned with the shroud alignment feature.

A shroud configured to connect a leadframe to a battery system for a hybrid motor vehicle is provided. The shroud is removably attachable to the leadframe. The shroud has at least one shroud alignment feature, the shroud being removably attached to the leadframe in a predetermined orientation wherein the shroud alignment feature is aligned with a complimentary leadframe alignment feature. The shroud may include a hollow cylindrical portion and at least one connecting feature configured to attach the shroud to the leadframe. The shroud may be provided as part of a connector system that includes the leadframe. In this case, the leadframe is configured to provide an electrical and mechanical connection between a power inverter and the battery system of the electric motor. The leadframe includes at least one leadframe alignment feature that is aligned with the shroud alignment feature.