Patent ID: 7648797

Claim:
A method of preparing a single integrated cap assembly used for a secondary battery comprising a battery can and the cap assembly, comprising: (i) mounting a cap subassembly comprising a protective circuit module on one side of a top cap comprising two electrode terminals such that the protective circuit module is electrically connected to the two electrode terminals of the top cap; and (ii) injecting a resin material in the cap subassembly to couple the top cap and the cap subassembly to form the single integrated cap assembly, wherein at least one of the protective circuit module and the top can have at least one guide groove formed thereon and configured to prevent the protective circuit module and the top cap from being misaligned within a mold during an injection molding process, and at least one connecting member is coupled to the at least one guide groove to connect the protective circuit module and the top cap; and wherein the at least one guide groove comprises first and second guide grooves, said first guide groove having a perforation shape and said second guide groove having an indentation shape.