Electrochemical device and method for assembling an electrochemical device

1. An electrochemical device, comprising:

an electrochemical module; and

an enclosure configured to enclose said electrochemical module, comprising:

a first housing portion forming a first rim;

a second housing portion forming a second rim, said first housing portion and said second housing portion at least partially forming, when said first rim substantially abuts said second rim, a volume configured to enclose said electrochemical device;

at least one of said first housing portion and said second housing portion being comprised of an insulative material;

a crimp ring engaging said first rim and said second rim, said crimp ring being configured to secure said first housing portion with respect to said second housing portion; and

a grommet positioned between and contacting said first rim and said second rim;

wherein said enclosure is substantially sealed.

2. The electrochemical device of claim 1 , further comprising a first feedthrough in said first housing portion and a second feedthrough in second housing portion configured to contact and provide electrical connection to said electrochemical cell at first and second locations, respectively.

3. The electrochemical device of claim 2 wherein said first feedthrough and said second feedthough are co-molded with said first housing portion and said second housing portion, respectively.

4. The electrochemical device of claim 1 wherein said first housing portion and said second housing portion are irregularly shaped.

5. The electrochemical device of claim 4 wherein said first housing portion and said second housing portion each have a major surface having an edge, wherein said edge comprises at least one linear portion.

6. The electrochemical device of claim 5 wherein said edge further comprises at least one non-linear portion.

7. The electrochemical device of claim 1 wherein said insulative material is a polymer.

8. The electrochemical device of claim 1 wherein said insulative material has a breakdown voltage of at least approximately 18.9 kiloVolts per millimeter.

9. The electrochemical device of claim 1 wherein said crimp ring is metallic.

10. The electrochemical device of claim 9 wherein said crimp ring is metal.

11. The electrochemical device of claim 1 wherein said crimp ring comprises a plurality of discontinuous segments.

12. The electrochemical device of claim 1 :

wherein said crimp ring comprises opposing longitudinal edges;

wherein said first rim of said first housing portion and said second rim of said second housing portion each form a lip having a contact surface, said contact surface being configured to contact, at least in part, said grommet portion; and

wherein each of said lip of said first rim of said first housing portion and said lip of said second rim of said second housing portion is configured to admit a respective one of said longitudinal edges of said crimp ring.

13. The electrochemical device of claim 1 wherein said crimp ring engages around a periphery of said first rim of said first housing portion and said second rim of said second housing portion.

14. The electrochemical device of claim 1 wherein at least one of said grommet and said first rim and said second rim have texture configured to secure, at least in part, said grommet to said first rim and said second rim.

15. The electrochemical device of claim 1 wherein said enclosure is substantially sealed with a leak rate of not greater than approximately 1×10 −8 standard cubic centimeters of helium per second.

16. A method of assembling an electrochemical device, comprising the steps of:

placing an electrochemical module into a first housing portion having a first rim and a first feedthrough so that a first electrical terminal of said electrochemical module is in electrical contact with said first feedthrough;

placing a second rim of a second housing portion in juxtaposition with said first rim of said housing portion, said second housing having a second feedthrough forming a volume enclosing said electrochemical module so that a second electrical terminal of said electrochemical module is in electrical contact with said second feedthrough, at least one of said first housing portion and said second housing portion being formed of an insulative material;

positioning a grommet between and in contact with said first rim of said first housing portion and said second rim of said second housing portion;

positioning a crimp ring proximate said first rim of said first housing portion and said second rim of said second housing portion; and

crimping said crimp ring to engage with said first rim of said first housing portion and said second rim of said second housing portion and to secure, at least in part, said first housing portion with respect to said second housing portion and substantially seal said volume enclosing said electrochemical module.

17. The method of claim 16 wherein said first feedthrough and said second feedthough are co-molded with said first housing portion and said second housing portion, respectively.

18. The method of claim 16 wherein said first housing portion and said second housing portion are irregularly shaped.

19. The electrochemical device of claim 18 wherein said first housing portion and said second housing portion each have a major surface having an edge, wherein said edge comprises at least one linear portion.

20. The method of claim 19 wherein said edge further comprises at least one non-linear portion.

21. The method of claim 16 wherein said insulative material is a polymer.

22. The method of claim 16 wherein said crimp ring is metal.

23. The method of claim 16 wherein said crimp ring comprises a plurality of discontinuous segments.

24. The method of claim 16 :

wherein said crimp ring comprises substantially opposing longitudinal edges;

wherein said first rim of said first housing portion and said second rim of said second housing portion each form a lip having a contact surface, said contact surface being configured to contact, at least in part, said grommet portion; and

wherein said crimping step admits a respective one of said longitudinal edges of said crimp ring into each of said lip of said first rim of said first housing portion and said lip of said second rim of said second housing portion.

25. The method of claim 16 wherein crimping step engages said crimp ring around a periphery of said first rim of said first housing portion and said second rim of said second housing portion.

26. The method of claim 16 wherein at least one of said grommet and said first rim and said second rim have texture configured to secure, at least in part, said grommet to said first rim and said second rim.

27. The method of claim 16 wherein crimping step substantially seals said enclosure with a leak rate of not greater than approximately 1×10 −8 standard cubic centimeters of helium per second.

28. The method of claim 16 wherein said insulative material has a breakdown voltage of at least approximately 18.9 kiloVolts per millimeter.