Rechargeable battery and method

Abstract

A method of assembling a rechargeable battery is disclosed. The method includes inserting rechargeable energy storage cells into a battery housing, the battery housing having a base portion, a side portion extending from the base portion, and an aperture defined by the side portion, wherein the rechargeable energy storage cells are inserted into the battery housing through the aperture; installing an insulator on the rechargeable energy storage cells; and securing a housing cover to the battery housing such that the insulator and the rechargeable energy storage cells are maintained in compression between the housing cover and the housing base portion. Also disclosed is a rechargeable battery including a battery housing, a housing cover, a plurality of rechargeable energy storage cells disposed within the battery housing, and an insulator disposed between the rechargeable energy storage cells and the housing cover and maintained in compression.

1 . A method of assembling a rechargeable battery comprising:
 inserting rechargeable energy storage cells into a battery housing, the battery housing having a base portion, a side portion extending from the base portion, and an aperture defined by the side portion, wherein the rechargeable energy storage cells are inserted into the battery housing through the aperture;   installing an insulator on the rechargeable energy storage cells; and   securing a housing cover to the battery housing such that the insulator and the rechargeable energy storage cells are maintained in compression between the housing cover and the housing base portion.   
     
     
         2 . The method of assembling a rechargeable battery as claimed in  claim 1 , wherein the insulator comprises a plurality of mica sheets. 
     
     
         3 . The method of assembling a rechargeable battery as claimed in  claim 2 , wherein installing the insulator on the rechargeable energy storage cells further comprises installing the plurality of mica sheets such that the mica sheets extend through a plane defined by the perimeter of the aperture of the battery housing. 
     
     
         4 . The method of assembling a rechargeable battery as claimed in  claim 1 , wherein the insulator is compressed at least 5% in the direction between the base portion and the housing cover when the housing cover is secured to the battery housing. 
     
     
         5 . The method of assembling a rechargeable battery as claimed in  claim 1 , wherein securing the housing cover to the battery housing comprises applying at least 1.7 kpa of force to the housing cover to compress the insulator. 
     
     
         6 . The method of assembling a rechargeable battery as claimed in  claim 1 , wherein the compression of the insulator inhibits movement of the energy storage cells in a direction between the housing cover and the housing base portion. 
     
     
         7 . The method of assembling a rechargeable battery as claimed in  claim 1 , wherein the side portion of the battery housing comprises four sides forming a substantially rectangular cross-section of the battery housing. 
     
     
         8 . The method of assembling a rechargeable battery as claimed in  claim 1 , wherein the battery housing comprises a deep drawn enclosure. 
     
     
         9 . The method of assembling a rechargeable battery as claimed in  claim 1 , wherein the side portion of the battery housing is welded to the base portion to form the battery housing. 
     
     
         10 . The method of assembling a rechargeable battery as claimed in  claim 1 , wherein the housing cover is secured to the battery housing by welding. 
     
     
         11 . The method of assembling a rechargeable battery as claimed in  claim 1 , wherein the housing cover is secured to the battery housing by mechanical fasteners. 
     
     
         12 . The method of assembling a rechargeable battery as claimed in  claim 1 , further comprising the step of evacuating the rechargeable battery after securing the housing cover to the battery housing. 
     
     
         13 . The method of assembling a rechargeable battery as claimed in  claim 1 , wherein the rechargeable energy storage cells are sodium-halide cells. 
     
     
         14 . A rechargeable battery comprising:
 a battery housing having a base portion, a side portion extending from the base portion, and an aperture defined by the side portions;   a housing cover secured to the battery housing;   a plurality of rechargeable energy storage cells disposed within the battery housing with at least a portion of the energy storage cells electrically connected to one another; and   an insulator disposed between the rechargeable energy storage cells and the housing cover;   wherein the insulator and the energy storage cells are maintained in compression between the housing cover and the housing base portion.   
     
     
         15 . The rechargeable battery as claimed in  claim 14 , wherein the insulator comprises a plurality of mica sheets. 
     
     
         16 . The rechargeable battery as claimed in  claim 14 , wherein the insulator is maintained in compression with at least 1.7 kpa of compressive force. 
     
     
         17 . The rechargeable battery as claimed in  claim 14 , wherein the compression of the insulator inhibits movement of the energy storage cells between the housing cover and the housing base portion. 
     
     
         18 . The rechargeable battery as claimed in  claim 14 , wherein said at least the portion of the energy storage cells are electrically connected by welded connections. 
     
     
         19 . A rechargeable battery comprising:
 a battery housing having a base portion, a side portion extending from the base portion, and an aperture defined by the side portions;   a housing cover secured to the side portion of the battery housing and covering the aperture;   a plurality of electrically interconnected, rechargeable energy storage cells disposed within the battery housing; and   a plurality of mica sheets disposed between the rechargeable energy storage cells and the housing cover;   wherein the plurality of mica sheets and the energy storage cells are maintained in compression between the housing cover and the housing base portion, for inhibiting movement of the energy storage cells between the housing cover and the housing base portion, and wherein said compression comprises at least one of 1.7 kpa or more of compressive force or a compressive force suitable to compress the plurality of mica sheets by at least 5% in the vertical dimension from its uncompressed state.   
     
     
         20 . The rechargeable battery as claimed in  claim 19 , wherein the energy storage cells are sodium-halide cells having an operating temperature of at least 100 degrees C.