TECHNOLOGY FOCUS - ELECTRICAL POWER AND ENERGY - Preferred Battery: In the battery, the sealant extends across all the side perimeter surfaces. The protective shell encloses the support and cover. The sealant comprises at least one of epoxy, polymerized ethylene acid copolymer, hydrocarbon grease, paraffin and wax. The sealant comprises a thickness of less than 60 microns. The protective shell comprises first and second layers that are each different materials. The first layer comprises a polymer layer and the second layer comprises a diamond-like carbon layer. The polymer layer comprises at least one of polyvinylidene difluoride and polyurethane. The diamond-like carbon layer comprises a sputtered layer. The protective shell comprises a thickness of less than 60 microns. It comprises a gap between the cover and a top surface of the battery cell, and where the gap distance is less than about 10 microns. It also comprises: (a) a battery stack comprising battery cells on one or more supports, each battery cell comprising electrodes about an electrolyte; (b) a cover covering the battery stack to form side perimeter surfaces that extend around the battery stack; (c) a sealant extending along a side perimeter surface and between the cover and support; (d) a protective shell covering the sealant; and (e) first and second terminals extending out of at least one of the protective shell, support or cover, the first and second terminals being connected to different electrodes of the battery cell. The sealant extends across all the side perimeter surfaces. The protective shell encloses the support and cover. The battery stack comprises a stack of supports that each has a battery cell, and where the battery cells are aligned to one another. The battery stack comprises spaced apart battery cells on a support. It also comprises: (a) a battery comprising a support having planar top and bottom surfaces, and further comprising a first battery cell on the bottom surface and a second battery cell on the top surface, each battery cell comprising electrodes about an electrolyte; (b) a pair of covers enclosing the battery stack to define side perimeter surfaces that extend around the battery stack; (c) a sealant at the side perimeter surfaces and between the cover and support; (d) a protective shell covering the sealant; and (e) first and second terminals extending out of at least one of the protective shell, support or cover, the first and second terminals being connected to different electrodes of the battery cell. The battery cells are aligned to one another. The battery comprises a stack of supports, each support having battery cells. Preferred Method: The battery manufacturing method comprises sealing the side perimeter surface with a sealant comprising at least one of epoxy, polymerized ethylene acid copolymer, hydrocarbon grease, paraffin and wax. It comprises sealing all the side perimeter surfaces. It comprises forming a protective shell around all of the side perimeter surfaces, cover and support. It comprises forming a protective shell comprising first and second layers of different materials. It comprises forming a protective shell that includes a first layer comprising a polymer layer and the second layer comprising a diamond-like carbon layer. The polymer layer comprises at least one of polyvinylidene difluoride and polyurethane. It comprises depositing the diamond-like carbon layer by magnetron sputtering.