Dimensional constraints for three-dimensional batteries

A method of manufacturing a secondary battery comprising a battery enclosure, an electrode assembly, carrier ions, and a constraint system, the method comprising

• forming the electrode assembly, the electrode assembly having mutually perpendicular longitudinal, transverse, and vertical axes, a first longitudinal end surface and a second longitudinal end surface separated from each other in the longitudinal direction, and a lateral surface surrounding an electrode assembly longitudinal axis AEA and connecting the first and second longitudinal end surfaces, the lateral surface having opposing first and second regions on opposite sides of the longitudinal axis and separated in a first direction that is orthogonal to the longitudinal axis, the electrode assembly having a maximum width WEA measured in the longitudinal direction, a maximum length LEA bounded by the lateral surface and measured in the transverse direction, and a maximum height HEA bounded by the lateral surface and measured in the vertical direction, the ratio of each of LEA and WEA to HEA being at least 2:1, respectively,
• the electrode assembly comprising a population of electrode structures, a population of counter-electrode structures, and an electrically insulating separator material electrically separating members of the electrode and counter-electrode populations, with members of the electrode and counter-electrode structure populations being arranged in an alternating sequence in the longitudinal direction, and
• constraining the electrode assembly with the constraint system, the constraint system comprising first and second primary growth constraints separated from each other in the longitudinal direction, the first and second primary growth constraints being placed in tension with one another via connection through first and second primary connecting members, the first and second primary connecting members being separated from each other in the vertical direction, and
• connecting one or more of (i) member(s) of the population of electrode structures, or (ii) member(s) of population of counter-electrode structures to the first and second primary connecting members.