Low-profile battery construct with engineered interfaces

A battery structure, comprising:

• an active battery region including:
• a textured anode metal formed on first textured packaging material;
• a hydrogel separator formed on the textured anode metal;
• a textured cathode metal formed on second textured packaging material;
• a MnO2 paste formed on the textured cathode metal;
• and
• a first battery seal region configured to contain the hydrogel separator outside the active battery region on an anode side;
• a second battery seal region configured to contain the MnO2 paste outside the active battery region on a cathode side;
• and
• an electrolyte disposed in any gap between the hydrogel separator and the MnO2 paste, the gap being filled with electrolyte.

A method for forming a battery structure, comprising:

• texturing an anode packaging material to form a first textured surface;
• depositing one or more metal layers including an anode metal on the first textured surface;
• forming a separator on the anode metal;
• texturing a cathode packaging material to form a second textured surface;
• depositing a cathode metal on the second textured surface;
• and
• forming an electrolyte binder paste on the cathode metal, which contacts the separator with any gap being filled with electrolyte.