US 11515528

US Patent 11515528 (literally interpreted as 11515528, not 11515528B2 as per Google Patents) is titled "Electrodes, lithium-ion batteries, and methods of making and using same."

Summary of US Patent 11515528:

• Title: Electrodes, lithium-ion batteries, and methods of making and using same
• Assignee: Georgia Tech Research Corp, Sila Nanotechnologies Inc
• Inventors: Gleb Yushin, Oleksandr Magazynskyy, Patrick Dixon, Benjamin Hertzberg
• Filing Date: March 10, 2022
• Issue Date: November 29, 2022
• Abstract: The patent describes improved composite anodes and lithium-ion batteries, along with methods for their manufacture and use. The anodes generally consist of a porous composite containing multiple agglomerated nanocomposites. Each nanocomposite features a dendritic particle, which is a three-dimensional, randomly-ordered assembly of nanoparticles made from an electrically conducting material. On the surface of this dendritic particle are discrete, non-porous nanoparticles of a non-carbon Group 4A element or a mixture thereof. A key aspect is that at least a portion of the dendritic particle of one nanocomposite is in electrical communication with a dendritic particle of an adjacent nanocomposite within the agglomerated structure.

Plain-Language Overview of Independent Claims:

Please note: The full text of the patent claims was not provided in the authoritative document. The following overview is derived from the "Summary of the Invention" section, which typically outlines the scope of the independent claims. Therefore, the exact numbering and precise legal wording of the claims are not available, and this represents an interpretation of the core inventive concepts.

1. Anode Composition Claim: This claim likely describes an anode for a lithium-ion battery. The anode is a porous composite made of several clustered (agglomerated) nanocomposites. Each nanocomposite contains a core dendritic particle, which is essentially a tangled, three-dimensional network of very small particles (nanoparticles) of an electrically conductive material (such as carbon, silicon, or lithium-silicon alloys). Attached to the surface of this dendritic particle are distinct, solid (non-porous) nanoparticles of a non-carbon Group 4A element (like silicon, germanium, tin, lead, or their alloys). A crucial feature is that the dendritic particles within different nanocomposites are electrically connected to each other, ensuring good conductivity throughout the anode.

2. Granular Anode Composition Claim: This claim likely focuses on a specific type of anode where the porous composite is structured as a matrix of multiple spherical or nearly-spherical granules. Each of these granules, in turn, is made up of agglomerated nanocomposites. In this specific embodiment, the dendritic particles are formed from annealed carbon black nanoparticles, and the discrete non-porous nanoparticles disposed on their surface are silicon nanoparticles. Similar to the first claim, the dendritic particles of adjacent nanocomposites within and between the granules are in electrical communication.

3. Lithium-Ion Battery Claim: This claim broadly covers a lithium-ion battery that incorporates any of the anode structures described in the previous claims.

4. Method of Making an Anode Claim: This claim outlines a process for manufacturing the anode. The method involves several steps:

   • First, forming the three-dimensional, randomly-ordered dendritic particle from discrete nanoparticles of an electrically conducting material.
   • Second, placing (disposing) discrete, non-porous nanoparticles of a non-carbon Group 4A element (or mixture) onto the surface of the dendritic particle to create a nanocomposite particle.
   • Third, assembling many of these nanocomposite particles together to form either a single, solid anode body or a spherical granule.
   • A key aspect of this assembly is ensuring that the dendritic particles of individual nanocomposites are in electrical contact with the dendritic particles of neighboring nanocomposites.

CAFC 2026 Dockets:
A general search of the CAFC 2026 dockets did not immediately return any cases specifically listing patent number 11515528. A full review of all scheduled cases for May, June, and July 2026 was not performed, so it is possible there could be related litigation not appearing in top-level search results.

As of April 26, 2026, a specific search for patent number 11515528 in litigation dockets, including those from the CAFC and Unified Patents, did not reveal any known litigation involving this patent. The previously conducted general search of CAFC 2026 dockets also did not return any cases for patent 11515528.

Proceedings overview

There are no AIA trial proceedings on file for US Patent 11515528.

Strategic summary

As of the current date, US Patent 11515528 has no history of AIA trial proceedings at the PTAB. This means all claims of the patent remain untested in an IPR, PGR, or CBM setting, and there are no canceled or sustained claims to report from such proceedings. Consequently, there is no estoppel landscape established by PTAB decisions.

The absence of PTAB activity could imply several things. It might suggest that the patent has not yet been asserted aggressively in a way that would provoke an AIA challenge, or that potential challengers have not identified strong prior art grounds for an IPR, PGR, or CBM.

Recommended next steps

There are no active or concluded PTAB proceedings to monitor. If facing an assertion of US Patent 11515528, a potential defendant would have a full range of prior art grounds available for an AIA trial petition, should they choose to pursue that route. The absence of prior PTAB challenges means there's no established record of claim construction or patentability arguments from the PTAB to consider, which could be both an opportunity and a challenge for a new petitioner.

Inventors

• Gleb Yushin: Co-founder and CTO of Sila Nanotechnologies Inc. At the time of the priority application (September 29, 2009), he was a professor at Georgia Tech. At the filing date of this specific continuation (March 10, 2022), his interest was assigned to Sila Nanotechnologies, Inc.
• Oleksandr Magazynskyy: Associated with Georgia Tech Research Corp at the time of the filing of this continuation (March 10, 2022), with his interest assigned to Georgia Tech Research Corp.
• Patrick Dixon: Associated with Georgia Tech Research Corp at the time of the filing of this continuation (March 10, 2022), with his interest assigned to Georgia Tech Research Corp.
• Benjamin Hertzberg: Associated with Georgia Tech Research Corp at the time of the filing of this continuation (March 10, 2022), with his interest assigned to Georgia Tech Research Corp.

No unusual patterns (e.g., all inventors departing within 12 months) are immediately apparent, given the co-assignment to both an academic institution's research arm and a spin-off company founded by one of the inventors.

Original assignee

The entities named on the issued patent are Georgia Tech Research Corp and Sila Nanotechnologies Inc.

• Georgia Tech Research Corp: The patent management arm of the Georgia Institute of Technology. Its primary line of business is facilitating research and transferring technology developed at Georgia Tech. It does not typically ship products. Current status: Operating.
• Sila Nanotechnologies Inc: An operating company focused on developing and manufacturing advanced silicon anode materials for lithium-ion batteries. This company actively ships products embodying claims related to battery anode technology. Current status: Operating.

Assignment timeline

A search of the USPTO Patent Assignment Search database (https://assignmentcenter.uspto.gov/) for patent number US11515528 revealed no recorded assignments. The ownership information reflected on Google Patents, indicating Georgia Tech Research Corp and Sila Nanotechnologies Inc as assignees, likely stems from declarations made at the time of the patent application's filing rather than separate, recorded post-issuance assignments.

Timeline diagram

timeline
    title Ownership of US 11515528
    2009 : Priority Date
    2022 : Application filed by Georgia Tech Res Corp, Sila Nano Inc
         : Issued to Georgia Tech Res Corp, Sila Nano Inc

NPE / troll-pattern signals

1. Shell-entity transfer — Not present. There are no recorded transfers to any entity, shell or otherwise.
2. Known asserter in the chain — Not present. There are no recorded transfers to any known asserter.
3. Repeat correspondent across the chain — Not present. With no recorded assignments, there is no correspondent chain to analyze.
4. Cascading transfers — Not present. No transfers are recorded.
5. Pre-litigation transfer — Not present. No litigation has been found for this patent, and no transfers are recorded.
6. Bankruptcy fire-sale — Not present. Both original assignees, Georgia Tech Research Corp and Sila Nanotechnologies Inc, appear to be currently operating.
7. Privateering — Unclear. Without transfers to an NPE, this pattern cannot be confirmed.
8. Defensive aggregator (anti-NPE) — Not present. The patent is not currently assigned to any known defensive aggregator.

Verdict

Operating-company assertion.
The USPTO Assignment Search shows no recorded assignments for US Patent 11515528. This means the patent remains under the ownership of its original co-assignees, Georgia Tech Research Corp and Sila Nanotechnologies Inc. Sila Nanotechnologies Inc is an active operating company that develops and manufactures products directly related to the patent's claims (silicon anode materials for lithium-ion batteries), indicating a likely operating-company assertion model if the patent were to be litigated.
(Verification: https://assignmentcenter.uspto.gov/patent/index.html?cn=11515528)

To identify the most relevant prior art for US patent 11515528, I will search the USPTO database for the patent and examine its cited references.

USPTO Search for US Patent 115155528

As per the USPTO website, "Patent Public Search" is the tool to search the database of patents and patent application publications. I will use this tool to search for US Patent 11515528.

Most Relevant Prior Art for US Patent 11515528

The full text of US11515528 provides a "Prior art keywords" section listing "composite particle", "dendritic", "carbon", "particles", and "ion permeable". While these keywords provide a general idea of the prior art landscape, to find the most relevant prior art in the context of 35 U.S.C. § 102 (anticipation), it's necessary to examine the specific patent references cited within US11515528 itself.

Since the complete list of cited patents is not available in the provided text, I will identify the most relevant types of prior art discussed and their potential implications for anticipation based on the patent's own background and summary.

The patent explicitly discusses the shortcomings of existing technologies in its "Background of the Invention" section, which often points to the closest prior art the inventors aimed to improve upon.

1. Carbon-based anode materials (e.g., graphite):

   • Description: The patent states that carbon (C) in the form of graphite has a theoretical specific capacity of about 372 mAh/g but suffers from significant capacity losses during cycling.
   • Potential Anticipation (35 U.S.C. § 102): While basic carbon electrodes are fundamental prior art, US11515528 aims to overcome the capacity limitations and cycling losses by incorporating silicon and a specific porous, dendritic structure. Therefore, a generic graphite anode would not anticipate the novel features of US11515528's claims related to silicon nanocomposites and porous structures. However, prior art disclosing specific carbon electrode designs aimed at improving cycle life or capacity might be relevant to specific aspects of the claims related to the carbon dendritic particle's role or structure.
   • Relevant Claims: Potentially relevant to any claim that broadly mentions an "electrically conducting material" (e.g., carbon) as part of the dendritic particle, but the combination of features in US11515528's claims would likely differentiate it.

2. Silicon-based anode materials (pure Si):

   • Description: The patent highlights that silicon (Si) has a high theoretical specific capacity (about 4200 mAh/g) but suffers from significant volume expansion and contraction (up to 400%) during charge cycling, leading to irreversible mechanical damage and loss of contact with the current collector. It also notes their low electrical conductivity relative to carbon.
   • Potential Anticipation (35 U.S.C. § 102): Pure silicon anodes would not anticipate the claims of US11515528 because the claimed invention specifically addresses the drawbacks of pure Si by combining it with an electrically conducting material in a porous, dendritic nanocomposite structure designed to accommodate volume changes.
   • Relevant Claims: Potentially relevant to claims broadly covering "non-carbon Group 4A element" (e.g., silicon) nanoparticles, but again, the specific structural and compositional combination in US11515528's claims would be key to differentiating.

3. Silicon-carbon composites (prior art):

   • Description: The patent mentions that prior art silicon-carbon composites, prepared by pyrolysis, mechanical mixing, or milling, generally include Si particles embedded in or on a dense carbon matrix. However, it states that these composites offer "only limited stability and capacity enhancements relative to pure Si-based anodes" because the carbon can only accommodate large volume changes in Si particles to a limited degree.
   • Potential Anticipation (35 U.S.C. § 102): This category represents the most direct prior art. Any prior patent disclosing a Si-C composite anode would be highly relevant. To anticipate US11515528's claims, a prior art reference would need to disclose a porous composite with agglomerated nanocomposites, where each nanocomposite features a dendritic particle of an electrically conducting material, and discrete, non-porous nanoparticles of a non-carbon Group 4A element (like silicon) are disposed on its surface, with the dendritic particles being in electrical communication. The porous, dendritic structure designed to accommodate volume changes, and the discrete, non-porous nature of the Si nanoparticles are distinguishing features emphasized by US11515528.
   • Relevant Claims: All independent claims (Anode Composition Claim, Granular Anode Composition Claim, and Method of Making an Anode Claim) would need to be carefully compared against such prior art Si-C composites. Specifically, claims related to the specific morphology (dendritic, agglomerated, porous, discrete non-porous nanoparticles) and electrical communication between dendritic particles would be critical.

Without the specific list of "Prior Art Documents" cited in US11515528, a definitive analysis of anticipation for each claim is not possible. However, the patent's own description of the relevant art strongly indicates that prior Si-C composite technologies would be the most critical area for anticipation analysis.

I'll ground this analysis by searching for the actual prior art record of US11515528 and the closest known references in the Si–C composite anode space.

Key leads found — including an actual PTAB petition involving this patent family (IPR2020-01589, US 9,979,017) and a search report citing specific references. Let me pin those down.

Obviousness Analysis of US 11515528 under 35 U.S.C. § 103

Date of analysis: April 26, 2026 · Patent: US 11515528 / US11515528B2, "Electrodes, lithium-ion batteries, and methods of making and using same" (Appl. No. 17/692,030, filed Mar. 10, 2022; granted Nov. 29, 2022; listed prior-art date 2009-09-29).

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0. Verification status up front (read this before relying on any reference below)

I ran targeted searches to move from the previous section's generic prior-art discussion to specific references. Results:

Flagged tension with earlier sections: the Litigation/PTAB sections state there is no AIA proceeding for US 11515528 — that remains true. However, I located an AIA trial artifact (IPR2020-01589) concerning US 9,979,017 whose exhibit bundle contains this family's claim language and search-report citations. US 9,979,017 as listed on Golden is Rojeski's "Energy storage devices" (filed Apr. 25, 2014), i.e., a different patent and different owner. The attribution discrepancy is unresolved and is exactly the kind of thing to verify on the PTAB docket before relying on it.

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1. The § 103 framework that matters most here: the effective filing date

Before any combination is assembled, the single highest-leverage § 103 question is what date the claims are entitled to.

The chain is: 61/246,741 (Sep. 29, 2009) → PCT/US2010/050794 (Sep. 29, 2010) → 13/431,591 (Mar. 27, 2012, a continuation-in-part of the PCT) → 14/513,920 → 15/612,890 → 16/853,301 → 17/692,030 (this patent).

A CIP is a new application containing new matter. Under § 120/§ 365(c), each claim is entitled only to the date of the first application in the chain that provides § 112(a) written-description support for that claim as a whole. Consequently:

• Claims directed to matter first disclosed in the Mar. 27, 2012 CIP get an effective date no earlier than Mar. 27, 2012, and the entire 2009-09-29 → 2012-03-27 window becomes § 102/§ 103 art.
• Direct evidence that subject matter shifted after 2009: the earlier family publication US 2012/0321959 A1 recites the pore-volume floor as "at least about three times the volume occupied by all of the nanoparticles," whereas this patent's text states "at least about 1.5 times." A downward bracket expansion of a numerical claim limitation is the classic footprint of amendment-driven broadening during prosecution (or of a later-added embodiment). That change alone suggests the applicant was reaching for scope that the art had pushed back on — i.e., art taught pore volumes in the 1.5×–3× region.
• Practically: a challenger should build the § 103 case on 2012-dated art in the alternative, so the petition does not rise or fall on the 2009 priority claim. Anything filed/published before Mar. 27, 2012 but after Sep. 29, 2009 — including, for example, PCT publications entering the US national phase from 2010–2011 filings — must be run down as § 102(a)(2) art for the CIP-only claims.

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2. Limitation-by-limitation decomposition (the target)

Claim 1 (as verified from the family publication) requires:

Dependent/embodied features a challenger must also address: 5–500 nm particles; 15–90 wt% Group 4A content; total pore volume 1.5×–20× the volume of the nanoparticles; spherical/substantially-spherical granule; matrix of granules; carbon coating; carbon conducting additive; CVD of silane/chlorosilane; wet granulation with a carbonizable polymeric binder.

Two claim-drafting features make the obviousness case materially easier:

1. "at least one" / "as many as all" — limitation D is satisfied by a single inter-particle contact. In any consolidated or simply packed powder of conductive particles, such contacts are inherent. The patent's own specification concedes this: electrical communication "is generally accomplished by having at least a portion of a surface of the dendritic particle … in contact with at least a portion of a surface of a dendritic particle … of another nanocomposite." That is the physical consequence of agglomerating conductive particles, not a design choice.
2. "dendritic" is a term of degree and the specification defines it purely functionally ("three-dimensional, randomly-ordered assembly or agglomerate of nanoparticles"). Carbon black is by definition a branched/aggregated (fractal, "dendritic") assembly of primary nanoparticles by fusion. Under the broadest reasonable interpretation, most aggregated-carbon-black composites with deposited Si read on B.

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3. Combination #1 — Primary § 103 attack on the anode claim: Graetz + Debe + Umeno (with Kim 2008)

The references (as categorized in the family's search report; content to be verified):

• US 2004/0126659 A1 (Graetz et al.) — cited as "Y," i.e., obviousness-type art, over claims 1–26, with the search report pointing to the abstract, Figs. 4A–4D, and paras. [0012], [0017], [0050]–[0053]. Graetz is in the nanostructured-Si anode space (Si films/nanoparticles deposited by CVD on conductive substrates to manage lithiation strain).
• US 2008/0020923 A1 (Debe et al.) — cited as "Y"; the search report points to paras. [0004], [0034], [0039]. Debe is the 3M nanostructured-thin-film (NSTF) line: a non-porous, three-dimensionally disordered ("randomly ordered") whisker/nanostructured support coated with a thin active layer. That is structurally the dendritic particle + coating architecture.
• US 2002/0086211 A1 (Umeno et al.) — cited as "Y" for the narrower claim set (mapped in the excerpt to claims 5, 6, 10, 12, 13, 18, 19, 24), with abstract, Fig. 7, and paras. [0054], [0063], [0074], [0075], [0097], [0105], [0108]. The paragraph density and claim mapping indicate this reference teaches deposition conditions and conductive-coating features — i.e., the dependent limitations (CVD Si, electrically conducting coating).
• Kim et al. 2008 — carbon-coated Si/graphite composite anode; verified as cited by the applicant themselves in the family.

The proposed combination and the KSR motivation:

The problem was not obscure; the specification itself frames it: Si offers ~4200 mAh/g but undergoes up to ~400% volume change, producing "irreversible mechanical damage" and loss of contact with the current collector, and has "low electrical conductivity relative to carbon-based anode materials." By 2009 the field's collective answer had three prongs, each independently documented:

1. Nanostructure the Si so individual particles are below the fracture-critical size (Graetz; Chan & Cui, Nature Nanotech. 2008 — verified as published Jan. 2008 for the nanowire work, and the meeting abstract "Silicon Nanowire/Carbon Composite Electrodes for Lithium-ion Battery Anodes," Chan & Cui, 2009 Meet. Abstr. MA2009-02 529, was located by search).
2. Embed/dispose the Si on a conductive, high-surface-area carbon support (Umeno; Kim 2008; Guo 2005).
3. Provide the support as a 3D, non-planar, high-aspect, randomly-oriented scaffold — supporting a coating on all its faces rather than a planar film (Debe).

Why a POSA would combine: the references are all in the same field (Li-ion anodes) and address the same deficiency. KSR Int'l Co. v. Teleflex Inc., 550 U.S. 398 (2007), makes the combination straightforward: (a) combining two known elements (nanostructured Si; a 3D randomly-oriented conductive support/coating architecture) to solve a known problem is a design choice, "not innovation"; (b) the solution is "obvious to try" where the field presents only a finite number of identified, predictable solutions; (c) the market pressure toward higher-capacity anodes (the specification's own recitation of HEV/grid needs) supplies an explicit design incentive.

Why the expectation of success is reasonable: aggregation of carbon black into a fused, branched assembly is inherent to the material; Si CVD on carbon supports from silane was a routine, commercially exercised technique; and contact between conductive agglomerates is a physical consequence of consolidation (limitation D). In re O'Farrell, 853 F.2d 894 (Fed. Cir. 1988), requires only reasonable, not absolute, predictability.

Anticipation overlay: for at least the broadest claim, an inherency argument exists under § 102(b): a compacted powder of carbon-black-based dendritic aggregates with CVD Si nanoparticles necessarily is a "porous composite comprising a plurality of agglomerated nanocomposites" with dendritic-to-dendritic contact. Anticipating disclosures "need not be provided for the purpose of showing what is inherent" (In re Schreiber; PAR Pharm. v. TWI Pharms.). Obviousness is the safer theory, but the inherency point removes any "unexpected arrangement" defense to limitation D.

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4. Combination #2 — Solution-based / carbon-matrix art: Guo 2005 + Lee 2008 + Kasavajjula review + Yoshio/Dimov carbon-coating

References (Guo verified from the search-report excerpt as "A"-category art; others verified only as family-cited or as search hits):

• Guo et al., "Silicon/Disordered Carbon Nanocomposites for Lithium-Ion Battery Anodes," J. Electrochem. Soc. 152(11):A2211–A2216 (2005) — verified citation. Si nanoparticles dispersed in a disordered-carbon matrix.
• Kim et al. 2008 (carbon-coated Si/graphite).
• Lee et al., J. Power Sources 176:353–358 (2008), "Spherical silicon/graphite/carbon composites as anode material for lithium-ion batteries" — verified via a reference list I retrieved. This is the most on-point reference for the granular/matrix claims: spherical Si/graphite/carbon composite granules.
• Kasavajjula, Wang & Appleby, J. Power Sources 163:1003 (2007) reference-list and Datta & Kumta, J. Power Sources 194:1043–1052 (2009) — verified via retrieved reference lists; both address Si–C anodes with void space.
• Liu et al., J. Power Sources 189:733 (2009) and Luo et al., J. Power Sources 189:16 (2009) — verified via reference list (Si/C composites).

The combination: Guo/Kim/Yoshio teach dispersing Si in a conductive carbon host and carbon-coating Si to address conductivity; Lee 2008 teaches spray-dried spherical granules of Si/graphite/carbon for handling and tap density; Kasavajjula's 2007 review collects the motivation — nanostructuring plus void/buffer space to accommodate expansion. A POSA combining these arrives at: porous spherical granules, each a composite of nanoscale Si on/in a conductive carbon skeleton, with inter-particle electrical contact.

The obviousness clincher is the numerical ranges. The claims recite 5–500 nm particles, 15–90 wt% Si, and 1.5×–20× pore volume. Under In re Peterson, 315 F.3d 1325 (Fed. Cir. 2003), In re Woodruff, 919 F.2d 1575 (Fed. Cir. 1990), and In re Aller, 220 F.2d 454 (CCPA 1955), a claimed range that overlaps or is adjacent an art-recognized range is prima facie obvious absent criticality evidenced in the specification. The specification here supplies a rationale only for the upper bound ("when the pore volume is greater than about 20 times … the volumetric capacitance … begins to suffer"). For the 1.5× floor it supplies nothing — and the 2009-era family text actually required 3×, which means the 1.5× floor is not only unsupported by criticality evidence, it is inconsistent with the applicant's own prior characterization. That is a § 103 problem, not merely a § 112 one.

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5. Combination #3 — The granular/matrix claim: Lee 2008 + carbon-black-aggregate knowledge + Umeno

The "granular anode" claim narrows to (i) annealed carbon black, (ii) Si nanoparticles, (iii) spherical granules in a matrix.

• Lee 2008 supplies the matrix-of-spherical-granules architecture outright.
• Umeno supplies the carbon-black/conductive-carbon + Si morphology.
• Annealing carbon black is not a point of novelty: the specification admits it as conventional and states its purpose ("increase the purity of the carbon, which in turn serves to increase the cycle life"; graphitization above ~2000 °C). Purpose-stated, routine parameter optimization is obvious (In re Aller; KSR, "a court must ask whether the improvement is more than the predictable use of prior art elements according to their established functions").
• Inherency of "dendritic": carbon black's primary particles are fused into branched aggregates; that is the material's definition, not an inventor's morphology choice. So limitation B is met by selecting an off-the-shelf material — the weakest possible position to be in.

Additionally, the application itself is an admission of the closest art: it recites that Si–C composites "prepared by pyrolysis, mechanical mixing and milling … generally include Si particles embedded in or on a dense carbon matrix." Applicant-admitted prior art may be used in an obviousness challenge without further corroboration (see Riverwood Int'l Corp. v. R.A. Jones & Co., 324 F.3d 1346 (Fed. Cir. 2003) on admissions as art).

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6. Combination #4 — The method claim

Method steps and their obviousness posture:

The combination of (i) agglomerating conductive composite particles by wet granulation and (ii) converting the binder to carbon is a classic "known technique applied to a known material, with predictable results" — the KSR formulation of obviousness. Note also that the method as claimed requires no particular morphology control, no particular pore-size distribution, and no performance outcome; it is a sequence of individually conventional unit operations.

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7. Additional single-reference / near-single-reference art worth running down

• US 10,366,802 B2 (Univ. of Pittsburgh; prov. Jun. 5, 2009 and Jul. 29, 2009) — verified to exist and to claim "compositions including nano-particles and a nano-structured support matrix … as reversible high capacity anodes," where the matrix "can include nanotubes, nanowires, nanorods, and mixtures thereof," the nanoparticles store/release Li, and the matrix "structurally supports the active material, electrically interconnects the active material, and accommodates the changes in volume." Its provisional filings predate the 2009-09-29 priority date and its 2019 issuance/2010s publications make it available as § 102(e)/§ 102(a)(2) art depending on the priority date the claims ultimately receive. This is the closest thing in my search results to a single-reference § 103 (or even § 102-type) killer for the "scaffolding matrix + volume accommodation" concept, and it should be the first document a challenger pulls.
• Debe-type NSTF art (US 2008/0020923 A1) read alone may disclose (3D randomly-oriented support + conformal active coating), leaving only "non-porous Group 4A nanoparticles … discrete" as the gap — a gap easily closed by Umeno/Graetz's CVD-Si-particle-on-carbon teaching, or by the inherent particulate (non-continuous-film) character of low-temperature Si CVD, which the specification itself describes ("High-purity 5% SiH₄ … at .about.1 torr … 500 C"), i.e., conditions a POSA would expect to give discrete islands rather than a film.
• Metal-oxide/fluoride/polymer Li-ion-permeable coatings (Al₂O₃, TiO₂, Ta₂O₅, Nb₂O₅, the recited metal fluorides; polyphenylene sulfide, PEEK, PEG, PEO; ALD/PE-CVD/sputtering/wet chemistry) map to the specification's own list of known coating options. Atomic-layer-deposited Al₂O₃ and other nm-scale coatings on battery electrodes were well established before 2012, so the "additional Li-ion permeable layer" embodiments are § 103-weak if ever asserted.
• Sn/Ge/SnCo-side art: Group 4A alternatives were commercially and technically established (e.g., amorphous tin-composite-oxide anodes), which matters because the claim covers Ge, Sn, Pb, and their alloys and solid solutions — a broad genus the specification does not exemplify. Obviousness over art in any of those species is available (In re Susi line of reasoning: recitation of a genus does not confer patentability when the art discloses a species).

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8. Where the obviousness case is weakest (for a defense-side view)

1. The pore-volume relationship. If the applicant can show that the 1.5×–20× window relative to nanoparticle volume (as opposed to total electrode porosity) is critical and that art taught only bulk porosity, the numerical limitation survives Peterson/Woodruff. But the specification's own evidence cuts the other way — the data disclosed is BET SSA (~24 m²/g) and 30–100 nm pores, not the claimed ratio.
2. In-situ self-assembly of granules during carbon CVD. The specification's most distinctive teaching is that spherical granules self-assemble during propylene decomposition at ~700 °C, with hydrocarbon intermediates (toluene, ethylbenzene, styrene, naphthalene, biphenyl) acting "as a liquid agglomeration binder before their final transformation into carbon." If that unified deposition-and-granulation step is in the asserted claims (it appears to be a dependent/embodied feature, not independent-claim language), art teaching sequential Si deposition → separate granulation would not literally read on it, and the applicant would argue the art's separate steps taught away from simultaneous operation. This is the strongest non-obviousness redoubt and should drive claim-charting.
3. Secondary considerations. The measured results — ~1950 mAh/g at C/20 with ~50 wt% Si, 1590/870 mAh/g at 1C/8C, ~15% first-cycle irreversibility, no 0.3 V delithiation peak, granule integrity after calendaring and cycling (FIG. 5(d)) — are genuinely strong. But they attach to the commercial embodiment, and under In re Kao and In re Huai-Hung Kao the applicant must establish a nexus between those results and the claimed scope. Because claim 1 permits "at least one" contact, a 5–500 nm particle range, 15–90 wt% Si, and 1.5×–20× pore volume, the nexus between the measured 50 wt% Si / 3×-class embodiment and the claim as a whole is attackable — and the disclosed data do not cover the full claimed ranges.
4. Teaching away. Pre-2010 literature cautioned against high-Si-content composites (cracking) and recommended thin films or low Si loadings; a defense would frame the stable 50 wt% Si composite as contrary to the art's expectation. Counter: KSR's own logic — the field's entire direction of travel (nanostructuring, void space, conductive matrix, granulation) pointed here, which is why "obvious to try" applies.

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9. Practical posture

• For a challenger: lead with the priority-date attack, then a three-reference § 103 combination (3D-randomly-ordered conductive support + deposited nanostructured Group 4A + agglomerated/spherical porous composite with inter-particle contact), supported by ranges-are-obvious law and the applicant's own admissions and reference-report citations. Build the record on US 10,366,802 first.
• For the patentee: the exposure is concentrated in claim breadth (open "at least one" language; the 1.5× floor; the unexemplified Ge/Sn/Pb genus) rather than in the disclosed embodiment. A reissue/continuation with narrower, data-supported claims (e.g., ≥3× pore volume; 30–60 wt% Si; specific granule-size and pore-size distributions with the in-situ granulation limitation; asserted experimental data) would be substantially more defensible.
• Estoppel: the earlier section's finding stands — no IPR/PGR/CBM against US 11515528, so no § 315(e) estoppel and no adverse PTAB claim-construction record binds the parties. If the IPR2020-01589 artifact is in fact family-relevant, its record is informative but non-binding as to this patent.

Remaining verification tasks (flagged, not asserted): pull the full texts of US 2004/0126659, US 2008/0020923, US 2002/0086211, and the exact ISR that produced the citation table; confirm the IPR2020-01589 exhibit attribution; and retrieve the file wrapper of 17/692,030 (and 13/431,591) to establish which claim limitations rest on post-2009 new matter — that record will determine whether the 2010–2012 art window is open, which is the pivotal issue in this § 103 analysis.

To determine the patent term adjustments (PTA), patent term extensions (PTE), continuation applications, divisional applications, related family members, and the projected expiration date for US Patent 11515528, I will rely on information typically found in the USPTO's Patent Center or Public Search databases.

A U.S. utility patent generally has a term of 20 years from its earliest non-provisional filing date. This term can be adjusted (PTA) for USPTO delays during prosecution or extended (PTE) for delays related to regulatory review, typically for drugs or medical devices. Continuation and divisional applications are part of the patent family and share the same priority date as their parent application.

Patent Term Adjustments (PTA)

PTA compensates patentees for certain delays incurred by the USPTO during patent prosecution. These delays fall into categories such as:

• A delay: Failure to issue a first Office Action or notice of allowance within 14 months of filing, or failure to act within 4 months of an applicant's response.
• B delay: Failure to issue a patent within three years of the actual filing date.
• C delay: Delays due to interference proceedings, secrecy orders, or successful appeals.

Any PTA granted can be reduced by applicant-caused delays, such as taking more than three months to respond to an Office action. The USPTO automatically calculates and provides notice of PTA upon patent issuance.

Without direct access to the specific Issue Notification for US11515528 or its full prosecution history from Patent Center, the exact PTA cannot be definitively stated. However, the Google Patents entry for US11515528 (which is often updated with PTA information) indicates an "Adjusted expiration" date of September 29, 2030. This suggests that some PTA was granted, as the patent's original 20-year term from its earliest priority date (September 29, 2009) would have been September 29, 2029.

Patent Term Extensions (PTE)

PTE is distinct from PTA and is available only for patents claiming a product, a method of using a product, or a method of manufacturing a product that has undergone a regulatory review period before its commercial marketing or use (e.g., by the FDA for drugs or medical devices). PTE is applied to restore some of the patent term lost during this regulatory review process.

Given that US11515528 is related to "Electrodes, lithium-ion batteries, and methods of making and using same," it is highly unlikely to be eligible for PTE, as battery components do not typically undergo the type of regulatory review by agencies like the FDA that qualifies for PTE. Therefore, it is projected that no PTE was granted for this patent.

Continuation and Divisional Applications

• A continuation application is a new application filed during the pendency of an earlier application, claiming the same invention as the earlier application but with different claims.
• A divisional application is filed when an examiner determines that the original application claims two or more independent and distinct inventions and requires restriction. The divisional application claims an invention disclosed in the parent but not claimed or elected for examination in the parent. Both continuation and divisional applications retain the benefit of the parent application's filing date.

The Google Patents information for US11515528 indicates the following priority claim: "The present application is a Continuation of U.S. patent application Ser. No. 16/853,301, filed Apr. 20, 2020, which is a Continuation of U.S. patent application Ser. No. 15/612,890, filed Jun. 2, 2017, which is a Continuation of U.S. patent application Ser. No. 14/513,920, filed Oct. 14, 2014, which is a Continuation of U.S. patent application Ser. No. 13/431,591, filed Mar. 27, 2012, which is a Continuation-in-part of International Application No. PCT/US2010/050794, filed Sep. 29, 2010, which claims the benefit of U.S. Provisional Application No. 61/246,741, filed on Sep. 29, 2009."

From this, we can identify the following related family members:

• Provisional Application: U.S. Provisional Application No. 61/246,741 (Filed: September 29, 2009)
• PCT Application: International Application No. PCT/US2010/050794 (Filed: September 29, 2010) - This is a Continuation-in-part of the provisional.
• Continuation Chain:
  • U.S. patent application Ser. No. 13/431,591 (Filed: March 27, 2012)
  • U.S. patent application Ser. No. 14/513,920 (Filed: October 14, 2014)
  • U.S. patent application Ser. No. 15/612,890 (Filed: June 2, 2017)
  • U.S. patent application Ser. No. 16/853,301 (Filed: April 20, 2020)
  • US11515528B2 (Filed: March 10, 2022) - The present patent, which is a continuation of 16/853,301.

This shows a continuous chain of continuation applications, all deriving priority from the initial provisional application. There is no explicit mention of divisional applications in this priority chain provided by Google Patents, which would typically be filed in response to a restriction requirement.

Projected Expiration Date

The patent term for utility patents is generally 20 years from the earliest non-provisional filing date, plus any applicable PTA.

• Earliest Priority Date (Provisional): September 29, 2009
• Earliest Non-Provisional Filing Date (PCT): September 29, 2010
• Base Expiration Date (20 years from PCT filing): September 29, 2030 (assuming no PTA or PTE).

However, Google Patents lists an "Adjusted expiration" date of September 29, 2030. This date is precisely 20 years from the International Application No. PCT/US2010/050794 filing date (September 29, 2010). The patent term is calculated from the earliest non-provisional filing date. Since the provisional application does not count as a non-provisional filing date for term calculation, the PCT filing date of September 29, 2010, serves as the effective start of the 20-year term. The fact that the "Adjusted expiration" is also September 29, 2030, suggests that any PTA calculation resulted in either zero adjustment or an adjustment that still aligned with this date, possibly due to applicant delays offsetting USPTO delays.

Therefore, the projected expiration date for US11515528 is September 29, 2030.

Defensive Disclosure: US Patent 11515528

This document serves as a defensive disclosure aimed at broadening the prior art landscape surrounding US Patent 11515528, titled "Electrodes, lithium-ion batteries, and methods of making and using same." The objective is to describe various derivative works and technical variations of the patented invention, thereby rendering future incremental improvements by competitors "obvious" or "non-novel" under 35 U.S.C. § 103 and § 102, respectively. The disclosures focus on material and component substitution, operational parameter expansion, cross-domain application, integration with emerging technologies, and inverse/failure mode designs, providing enabling descriptions and visual illustrations.

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Derivatives of Core Claim 1: Anode Composition

Core Claim 1 (Anode Composition Overview): An anode comprising a porous composite including agglomerated nanocomposites, each having a dendritic particle (3D, randomly-ordered assembly of electrically conducting nanoparticles) and discrete non-porous nanoparticles of a non-carbon Group 4A element disposed on its surface, with electrical communication between dendritic particles.

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Derivative 1.1: Material & Component Substitution - Metallic Dendritic Core with Germanium Nanoparticles

Enabling Description:
A porous composite anode is disclosed wherein the electrically conducting dendritic particle is formed from a three-dimensional, randomly-ordered assembly of annealed nickel (Ni) nanowires, each having an average diameter of 10-50 nm and a length of 500 nm to 5 µm. These Ni nanowires are sintered together at 800°C under a reducing atmosphere (e.g., 5% H₂ in Ar) to form the dendritic structure. Disposed on the surface of these Ni dendritic particles are a plurality of discrete, non-porous germanium (Ge) nanoparticles, with an average longest dimension of 20-150 nm. The Ge nanoparticles are deposited via atomic layer deposition (ALD) using germane (GeH₄) as a precursor, cycling at 150°C to ensure discrete, non-porous growth. The Ni dendritic particles are in direct electrical communication. The nanocomposites are agglomerated into a porous composite using a polyimide binder, subsequently carbonized at 900°C under argon, to further enhance electrical conductivity and mechanical stability. The total pore volume within the porous composite is maintained at approximately 2.5 times the volume occupied by all Ge nanoparticles.

graph TD
    A[Ni Nanowires] -- Sintering (800C, H2/Ar) --> B(Ni Dendritic Particle)
    B -- ALD (GeH4, 150C) --> C{Nanocomposite: Ni Dendrite + Discrete Ge NPs}
    C -- Agglomeration (Polyimide Binder) --> D[Agglomerated Nanocomposites]
    D -- Carbonization (900C, Ar) --> E(Porous Composite Anode)
    E -- Electrical Communication --> E

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Derivative 1.2: Operational Parameter Expansion - Ultra-Thin Film Anode for Micro-Batteries

Enabling Description:
An anode designed for ultra-thin film micro-batteries is disclosed, comprising a porous composite formed as a film with a thickness of 5-20 µm. The agglomerated nanocomposites are formed wherein the electrically conducting dendritic particles are derived from pyrolyzed polyacrylonitrile (PAN) nanofibers (100-300 nm diameter) forming a carbonaceous dendritic network. Discrete non-porous silicon-tin (Si₀.₈Sn₀.₂) alloy nanoparticles, with an average longest dimension of 5-20 nm, are deposited on the carbon nanofiber dendritic particles using co-sputtering of Si and Sn targets. The entire composite film is fabricated with a controlled porosity ranging from 60-85% to accommodate extreme volume changes during rapid charge/discharge cycles (up to 50C rate). The film operates reliably at temperatures down to -40°C, achieved by optimizing the electrolyte-interface and ensuring robust electrical pathways within the dense, yet porous, carbon network. The electrical communication between dendritic particles is enhanced by post-deposition calendering.

graph TD
    A[PAN Nanofibers] -- Pyrolysis --> B(Carbon Dendritic Particle)
    B -- Co-Sputtering (Si/Sn) --> C{Nanocomposite: C Dendrite + Discrete SiSn NPs}
    C -- Film Formation & Agglomeration --> D[Ultra-Thin Porous Composite Film Anode]
    D -- Operates at -40C / 50C rate --> E(Micro-Battery Application)

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Derivative 1.3: Cross-Domain Application - Bio-Integrated Catalyst Support

Enabling Description:
A porous composite is disclosed for use as a bio-integrated catalyst support in biochemical reactors. The nanocomposites feature dendritic particles formed from a three-dimensional, randomly-ordered assembly of electrically conductive polyaniline (PANI) nanofibers, synthesized via oxidative polymerization and having diameters of 50-200 nm. Disposed on the surface of these PANI dendritic particles are a plurality of discrete, non-porous gold (Au) nanoparticles, with an average longest dimension of 10-40 nm, applied via electroless deposition using HAuCl₄. The PANI dendritic particles facilitate electron transfer within the composite, and the discrete Au nanoparticles serve as catalytic sites for enzymatic reactions (e.g., glucose oxidation). The agglomerated nanocomposites form a porous matrix, allowing for efficient substrate diffusion and product removal in aqueous biological environments. Electrical communication between PANI dendritic particles provides an electron collection network for bio-electrocatalysis.

graph TD
    A[Aniline Monomers] -- Oxidative Polymerization --> B(PANI Nanofibers)
    B -- Self-Assembly --> C(PANI Dendritic Particle)
    C -- Electroless Deposition (HAuCl4) --> D{Nanocomposite: PANI Dendrite + Discrete Au NPs}
    D -- Agglomeration --> E[Porous Bio-Catalyst Support]
    E -- Substrate Diffusion & Electron Flow --> F(Biochemical Reactor)

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Derivative 1.4: Integration with Emerging Tech - AI-Optimized Smart Anode

Enabling Description:
A smart anode system for lithium-ion batteries is disclosed, integrating AI-driven optimization, IoT sensors, and blockchain technology. The anode consists of a porous composite with agglomerated nanocomposites. The dendritic particles are a 3D network of carbon nanotubes (CNTs), self-assembled and inter-grown via chemical vapor deposition. Discrete, non-porous silicon nanoparticles are disposed on the CNT surfaces. Integrated IoT sensors (e.g., thin-film thermocouples, strain gauges) are embedded within the porous composite during agglomeration to monitor internal temperature and volume expansion in real-time. Data from these sensors is fed into an AI-driven Battery Management System (BMS) that dynamically adjusts charge/discharge protocols to optimize cycle life and safety based on predicted degradation, specific to the anode's real-time state. Furthermore, the entire manufacturing process and material provenance (from raw material suppliers to final anode assembly) are recorded and verified using a blockchain ledger, ensuring transparency and quality control. The AI optimizes the initial morphological parameters (e.g., CNT density, Si nanoparticle size distribution) during synthesis via feedback loops.

graph LR
    A[Raw Materials] -- Provenance (Blockchain) --> B(CNT Synthesis)
    B -- AI-Optimized Growth --> C(CNT Dendritic Particle)
    C -- Si Nanoparticle Deposition --> D{Nanocomposite: CNT Dendrite + Discrete Si NPs}
    D -- Agglomeration + IoT Sensors --> E[Smart Porous Composite Anode]
    E -- Real-time Data (IoT) --> F(AI-driven BMS)
    F -- Dynamic Control --> E

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Derivative 1.5: The "Inverse" or Failure Mode - Self-Healing, Low-Capacity Anode

Enabling Description:
A low-capacity, self-healing anode is disclosed, designed for extended shelf-life and safe failure modes in long-duration, low-power applications (e.g., remote IoT sensors). The anode comprises a porous composite of agglomerated nanocomposites. The dendritic particles are formed from a conductive polymer matrix (e.g., polypyrrole, PPy) with lower electrical conductivity than carbon, structured as a 3D randomly-ordered network. Discrete, non-porous silicon-oxycarbide (SiOC) nanoparticles, exhibiting lower theoretical capacity and reduced volume expansion compared to pure Si, are disposed on the PPy dendritic particle surfaces. These SiOC nanoparticles are designed with a thin, self-healing polymer shell (e.g., microencapsulated with reversible Diels-Alder adducts) that can repair minor cracks or electrolyte decomposition layers upon thermal cycling, extending capacity retention in limited-functionality mode. Upon reaching a critical overcharge voltage, embedded micro-resistors within the composite trigger a localized exothermic reaction in specific, sacrificial regions of the PPy dendritic network, inducing a controlled increase in internal resistance and safe, gradual capacity fade, rather than catastrophic thermal runaway or short circuit.

stateDiagram
    [*] --> Idle
    Idle --> Charging: Li-ion Insertion
    Charging --> Discharging: Li-ion Extraction
    Charging --> Overcharge[Overcharge Detected]: Voltage Exceeds Threshold
    Overcharge --> FailSafe[Trigger Fail-Safe]: Activate Micro-Resistors
    FailSafe --> IncResistance[Increase Internal Resistance]: Localized Exothermic Reaction
    IncResistance --> CapacityFade[Gradual Capacity Fade]: Reduced Functionality
    CapacityFade --> Off[*]
    Idle --> Degradation: Micro-cracks
    Degradation --> SelfHeal: Thermal Cycling / Reversible Polymer
    SelfHeal --> Idle

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Derivatives of Core Claim 2: Granular Anode Composition

Core Claim 2 (Granular Anode Composition Overview): An anode comprising a matrix of spherical or substantially-spherical porous composite granules. Each granule includes agglomerated nanocomposites, where dendritic particles are formed from annealed carbon black nanoparticles, and discrete non-porous silicon nanoparticles are disposed on their surface, with electrical communication.

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Derivative 2.1: Material & Component Substitution - Graphitic Nanofiber Dendrites in Granules with Tin Nanoparticles

Enabling Description:
An anode comprises a matrix of spherical porous composite granules, where each granule (average diameter 20-40 µm) is formed from agglomerated nanocomposites. Within these nanocomposites, the dendritic particles are formed from a three-dimensional, randomly-ordered assembly of vapor-grown carbon nanofibers (VGCNFs) with diameters of 50-150 nm, annealed at 2500°C for graphitization and interconnection. Discrete, non-porous tin (Sn) nanoparticles, with an average longest dimension of 50-250 nm, are deposited on the surface of the graphitic VGCNF dendritic particles via thermal evaporation in a low-pressure environment. The VGCNF dendritic particles within each nanocomposite, and between adjacent nanocomposites, are in electrical communication due to their highly graphitized and interconnected nature. The granules are formed by spray drying a suspension of the nanocomposites with a lignosulfonate binder, followed by pyrolysis at 800°C to carbonize the binder and further stabilize the granular structure.

graph TD
    A[Vapor Grown Carbon Nanofibers] -- Annealing (2500C) --> B(Graphitic VGCNF Dendritic Particle)
    B -- Thermal Evaporation (Sn) --> C{Nanocomposite: VGCNF Dendrite + Discrete Sn NPs}
    C -- Spray Drying (Lignosulfonate Binder) --> D[Spherical Granule Precursor]
    D -- Pyrolysis (800C) --> E(Porous Composite Granule)
    E -- Matrix Formation --> F(Anode Matrix)

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Derivative 2.2: Operational Parameter Expansion - High-Temperature Granules for Solid-State Batteries

Enabling Description:
A granular anode composition for solid-state lithium-ion batteries is disclosed, specifically engineered for operational temperatures ranging from 80°C to 150°C. The spherical porous composite granules (average diameter 10-30 µm) are composed of agglomerated nanocomposites. The dendritic particles are formed from highly crystalline boron-doped graphitic carbon black nanoparticles, annealed at 2200°C to ensure enhanced thermal stability and conductivity. Discrete, non-porous lithium-silicon (LiₓSi) alloy nanoparticles (Li₂Si₅, average longest dimension 10-50 nm) are pre-lithiated and then directly disposed on the surface of the boron-doped carbon dendritic particles via a reactive deposition process using silane and lithium vapor at 400°C. The granules are then coated with a thin, thermally stable solid-state electrolyte interface (SEI) layer (e.g., LiPON or Li₂S-P₂S₅) via ALD to ensure stable operation at elevated temperatures and interface compatibility with solid electrolytes. The agglomeration process involves hot pressing the nanocomposites, followed by sintering at 700°C in an inert atmosphere, yielding high-density, thermally robust granules.

graph TD
    A[Boron-Doped Carbon Black] -- Annealing (2200C) --> B(Crystalline B-C Dendritic Particle)
    B -- Reactive Deposition (SiH4/Li vapor, 400C) --> C{Nanocomposite: B-C Dendrite + Discrete LiSi NPs}
    C -- Hot Pressing & Sintering (700C) --> D[High-Temp Porous Granule]
    D -- ALD (LiPON/LiSPS) --> E(SEI-Coated Granule for Solid-State)
    E -- Matrix Formation --> F(Solid-State Anode)

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Derivative 2.3: Cross-Domain Application - Granular Hydrogen Storage Media

Enabling Description:
Porous composite granules are disclosed for use as reversible hydrogen storage media. The spherical granules (average diameter 50-100 µm) comprise agglomerated nanocomposites where the dendritic particles are formed from an interconnected network of porous graphene nanosheets, synthesized by chemical vapor deposition on a templating agent that is later removed. Discrete, non-porous magnesium hydride (MgH₂) nanoparticles, with an average longest dimension of 5-30 nm, are infiltrated and deposited onto the surface of the graphene dendritic particles using a solution-based synthesis route followed by thermal desorption. The graphene network acts as a highly conductive scaffold to facilitate heat transfer during hydrogen adsorption/desorption cycles, overcoming the slow kinetics of bulk MgH₂. Electrical communication throughout the graphene dendritic particles aids in electrochemical promotion of catalysis for hydrogen uptake/release. The porous nature of the granules provides ample surface area and interstitial volume for high hydrogen storage capacity.

graph TD
    A[Graphene Nanosheets] -- Interconnection --> B(Porous Graphene Dendritic Particle)
    B -- Infiltration & Deposition (MgH2) --> C{Nanocomposite: Graphene Dendrite + Discrete MgH2 NPs}
    C -- Agglomeration --> D[Porous Composite Granule]
    D -- Heat Transfer & Hydrogen Flow --> E(Hydrogen Storage Reactor)

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Derivative 2.4: Integration with Emerging Tech - Granule-Based Self-Assembling Anode

Enabling Description:
A self-assembling anode system is disclosed, utilizing spherical porous composite granules (average diameter 15-30 µm) designed for robotic placement and in-situ characterization. Each granule contains agglomerated nanocomposites with dendritic particles of annealed carbon black and discrete non-porous silicon nanoparticles, as per the original patent. However, these granules are surface-functionalized with specific ligands or magnetic tags (e.g., iron oxide nanoparticles encapsulated in a polymer) that enable automated, spatially-controlled self-assembly into a defined electrode matrix using robotic manipulators or magnetic fields. Each granule incorporates a passive RFID tag containing a unique identifier and batch manufacturing data, allowing for individual granule tracking via IoT readers during assembly and throughout the battery's lifecycle. Post-assembly, real-time impedance spectroscopy data collected from the electrode is processed by a machine learning algorithm to verify optimal electrical communication between granules and identify any assembly defects, ensuring homogeneous performance.

sequenceDiagram
    Robotic Arm -> Granule 1: Pick & Place (Ligand/Magnetic)
    Granule 1 -> Granule 2: Self-Assembly Trigger
    Granule 2 -> Granule 3: Self-Assembly Trigger
    Granule 3 -> IoT Reader: RFID Scan (Batch Data)
    IoT Reader -> ML Algorithm: Impedance Data
    ML Algorithm -> Robotic Arm: Feedback (Assembly Correction)
    Note over ML Algorithm: Verify Electrical Communication

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Derivative 2.5: The "Inverse" or Failure Mode - Environmentally Responsive Degradation Granules

Enabling Description:
Porous composite granules are disclosed, engineered for controlled, environmentally responsive degradation post-lifecycle, minimizing hazardous waste. Each spherical granule (average diameter 25-50 µm) is built upon annealed carbon black dendritic particles decorated with discrete, non-porous silicon nanoparticles. The binding matrix for agglomeration is a bio-degradable polymer (e.g., polylactic acid, PLA) that is carbonized only superficially to provide initial mechanical integrity and electrical pathways, leaving the core PLA intact. Upon exposure to specific environmental conditions (e.g., high humidity, microbial activity, or a specific pH solution) post-disposal, the internal PLA binder fully degrades, causing the granules to disintegrate into their constituent, less harmful, nano-components. This controlled disintegration prevents large-scale mechanical integrity issues associated with spent batteries while facilitating easier separation and recycling of silicon and carbon, operating as a "degradation-on-demand" system rather than a long-lasting, robust structure.

stateDiagram
    [*] --> ActiveUse
    ActiveUse --> Disposal
    Disposal --> EnvironmentalExposure[Environmental Exposure (Humidity/Microbes/pH)]
    EnvironmentalExposure --> PLADegradation[PLA Binder Degradation]
    PLADegradation --> GranuleDisintegration[Granule Disintegration]
    GranuleDisintegration --> MaterialSeparation[Facilitated Material Separation]
    MaterialSeparation --> Recycling[*]

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Derivatives of Core Claim 4: Method of Making an Anode

Core Claim 4 (Method of Making Overview): A method including forming a 3D, randomly-ordered dendritic particle from discrete nanoparticles of an electrically conducting material; disposing discrete non-porous nanoparticles of a non-carbon Group 4A element on its surface to form a nanocomposite particle; and assembling these nanocomposite particles to form a bulk unitary body or granule, ensuring electrical communication.

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Derivative 4.1: Material & Component Substitution - Template-Assisted Formation of Metal Oxide Dendrites

Enabling Description:
A method of making an anode involves:

1. Forming Dendritic Particle: Utilizing a template-assisted hydrothermal synthesis to grow three-dimensional, randomly-ordered dendritic particles from discrete titanium dioxide (TiO₂) nanoparticles. This involves a sol-gel process within a porous alumina template, followed by template removal, yielding a mesoporous TiO₂ dendritic network.
2. Disposing Non-Carbon Group 4A Nanoparticles: Introducing discrete, non-porous lead (Pb) nanoparticles, with an average longest dimension of 30-100 nm, onto the surface of the TiO₂ dendritic particles via galvanic displacement using lead acetate solution. The TiO₂ acts as a scaffold, and the Pb nanoparticles are selectively grown.
3. Assembling Nanocomposite Particles: The resulting TiO₂-Pb nanocomposite particles are then assembled into a bulk unitary body via electrophoretic deposition (EPD) onto a current collector. The EPD parameters (voltage, time, solvent) are controlled to ensure sufficient packing and electrical communication between the TiO₂ dendritic frameworks of adjacent nanocomposites, followed by annealing at 400°C under vacuum to enhance inter-particle connectivity and partially reduce TiO₂ for improved electronic conductivity.

graph TD
    A[Porous Alumina Template + TiO2 Precursors] -- Hydrothermal Synthesis & Template Removal --> B(TiO2 Dendritic Particle)
    B -- Galvanic Displacement (Lead Acetate) --> C{Nanocomposite: TiO2 Dendrite + Discrete Pb NPs}
    C -- Electrophoretic Deposition (EPD) --> D[Bulk Unitary Anode Body]
    D -- Annealing (400C, Vacuum) --> E(Enhanced Electrical Communication)

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Derivative 4.2: Operational Parameter Expansion - Continuous In-Situ Plasma Synthesis

Enabling Description:
A method for high-throughput continuous manufacturing of an anode involves:

1. Forming Dendritic Particle: Utilizing a continuous flow atmospheric-pressure plasma reactor to form three-dimensional, randomly-ordered dendritic particles. Carbon precursors (e.g., methane/argon mixture) are injected into a plasma jet, causing rapid nucleation and growth of carbon nanoparticles (10-50 nm), which immediately fuse into dendritic structures due to high collision frequency and temperature gradients within the plasma plume.
2. Disposing Non-Carbon Group 4A Nanoparticles: In-situ introduction of silane gas downstream in the same plasma reactor. The silane undergoes rapid decomposition and deposition, forming discrete, non-porous silicon nanoparticles (15-80 nm) directly on the still-forming carbon dendritic particles. The short residence time and precise control of gas mixing prevent continuous film formation.
3. Assembling Nanocomposite Particles: The nascent nanocomposite particles, still entrained in the gas flow, are immediately directed into a turbulent flow agglomeration chamber. A solvent spray (e.g., ethanol) with a polymeric binder (e.g., polyimide precursor) induces wet agglomeration into spherical granules (20-50 µm). These granules are then collected, dried, and heat-treated in a continuous furnace at 900°C under inert gas to pyrolyze the binder to carbon, ensuring robust electrical communication within and between the granules.

flowchart TD
    A[Methane/Argon Plasma Precursors] -- Plasma Jet --> B(Carbon Dendritic Particle Growth)
    B -- Silane Injection (In-Situ) --> C(Si Nanoparticle Deposition)
    C -- Turbulent Flow Agglomeration (Solvent + Binder) --> D(Wet Granule Formation)
    D -- Continuous Furnace (Drying & Pyrolysis) --> E(Porous Composite Granules)
    E -- Collection --> F(Anode Material)

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Derivative 4.3: Cross-Domain Application - Fabricating Biosensor Scaffolds with Quantum Dots

Enabling Description:
A method is disclosed for fabricating biosensor scaffolds:

1. Forming Dendritic Particle: Forming a three-dimensional, randomly-ordered dendritic particle from discrete nanoparticles of a biocompatible, electrically conducting polymer, such as poly(3,4-ethylenedioxythiophene) (PEDOT) nanoparticles (average diameter 20-80 nm). This is achieved via electrospinning of a PEDOT solution followed by solvent evaporation to form the entangled network.
2. Disposing Non-Carbon Group 4A Nanoparticles: Disposing a plurality of discrete, non-porous cadmium selenide (CdSe) quantum dots (average longest dimension 2-8 nm, acting as "non-carbon Group 4A element" analogs for quantum sensing) on the surface of the PEDOT dendritic particle. This is performed via a directed self-assembly technique, where the CdSe QDs are functionalized with thiol groups to selectively bind to the PEDOT surface.
3. Assembling Nanocomposite Particles: The resulting PEDOT-CdSe nanocomposite particles are assembled to form a porous bulk unitary body or micro-patterned scaffold using 3D bioprinting techniques, where a bio-ink containing the nanocomposites is extruded layer-by-layer. The printing parameters ensure adequate electrical communication pathways between the PEDOT dendritic particles, creating a scaffold for specific analyte detection through changes in quantum dot fluorescence or electrical impedance.

graph TD
    A[PEDOT Solution] -- Electrospinning & Solvent Evaporation --> B(PEDOT Dendritic Particle)
    B -- Functionalized CdSe QD Self-Assembly --> C{Nanocomposite: PEDOT Dendrite + Discrete CdSe QDs}
    C -- 3D Bioprinting --> D[Porous Biosensor Scaffold]
    D -- Analyte Detection --> E(Biosensor Application)

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Derivative 4.4: Integration with Emerging Tech - Digital Twin Guided Manufacturing

Enabling Description:
A method of making an anode employing a digital twin for real-time process optimization is disclosed:

1. Forming Dendritic Particle: A three-dimensional, randomly-ordered dendritic particle is formed from a plurality of discrete nanoparticles of an electrically conducting material (e.g., graphitized multi-walled carbon nanotubes). The growth parameters (temperature, gas flow rates, catalyst concentration) in a fluidized bed CVD reactor are continuously monitored by IoT sensors and input into a digital twin simulation. The digital twin, an AI model, predicts the dendritic morphology and electrical conductivity based on these parameters.
2. Disposing Non-Carbon Group 4A Nanoparticles: Discrete, non-porous silicon nanoparticles are disposed on the surface of the dendritic particle via chemical vapor deposition. The silane precursor flow rate, temperature, and reaction time are adjusted in real-time by the AI-driven digital twin to achieve a target nanoparticle size distribution and coverage, minimizing aggregation and ensuring non-porosity, based on predictive modeling.
3. Assembling Nanocomposite Particles: The resulting nanocomposite particles are assembled into spherical granules using a wet granulation process. The AI-driven digital twin monitors granule size distribution and moisture content using in-line vision systems and adjusts binder spray rates and agitator speed to maintain optimal granule characteristics. Electrical communication between dendritic particles within the agglomerated granules is verified in-situ via electrical impedance tomography, with feedback provided to the digital twin for closed-loop control of the granulation process.

graph TD
    A[MWCNT Precursors + CVD] -- IoT Sensors --> B(Digital Twin)
    B -- AI Optimization --> C(Dendritic Particle Formation)
    C -- Silane CVD + AI Optimization --> D(Si Nanoparticle Disposition)
    D -- Wet Granulation + IoT/Vision --> E(Nanocomposite Particle Assembly into Granules)
    E -- EIT Feedback --> B
    F(Anode Material)
    E --> F

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Derivative 4.5: The "Inverse" or Failure Mode - Reversible De-Aggregation for End-of-Life Recycling

Enabling Description:
A method for making an anode with integrated end-of-life de-aggregation functionality for enhanced recycling is disclosed:

1. Forming Dendritic Particle: Three-dimensional, randomly-ordered dendritic particles are formed from discrete nanoparticles of highly purified graphitic carbon black, annealed at 2000°C.
2. Disposing Non-Carbon Group 4A Nanoparticles: Discrete, non-porous silicon nanoparticles are disposed on the carbon black dendritic particles via plasma-enhanced chemical vapor deposition (PECVD).
3. Assembling Nanocomposite Particles: A crucial step involves assembling the nanocomposite particles using a sacrificial, pH-sensitive, polymeric binder (e.g., poly(lactic-co-glycolic acid) PLGA or chitosan) that maintains electrical communication but is designed to rapidly degrade and release its binding capacity under specific acidic or basic conditions. The assembly forms spherical granules via wet granulation. The electrical communication between dendritic particles is achieved through initial compaction and a thin, secondary carbon coating applied via low-temperature CVD, which coats the granules externally but leaves the core binder intact. At the end of the battery's life, immersion of the anode in a dilute acid (e.g., 0.1M acetic acid) or base (e.g., 0.1M NaOH) causes the PLGA/chitosan binder to dissolve, allowing the granules to de-aggregate into individual nanocomposites, thereby facilitating the separation and recycling of silicon and carbon components with reduced energy input.

graph TD
    A[Graphitic Carbon Black NPs] -- Annealing --> B(Carbon Dendritic Particle)
    B -- PECVD (Si) --> C{Nanocomposite: C Dendrite + Discrete Si NPs}
    C -- Wet Granulation (pH-Sensitive Binder) --> D[Granule with Sacrificial Binder]
    D -- Low-Temp C-CVD (External Coating) --> E(Anode Granules with Electrical Comm.)
    E -- End-of-Life Disposal --> F(pH-Controlled De-Aggregation)
    F --> G(Separated Si/C for Recycling)

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Combination Prior Art Scenarios

These scenarios combine elements of US Patent 11515528 (or its derivatives as disclosed above) with existing open-source standards, further broadening the defensive publication.

1. Anode Synthesis Process Control (Derivative 4.4) + OPC UA:
   A manufacturing method for US11515528-type anodes (specifically Derivative 4.4, Digital Twin Guided Manufacturing) where all process parameters (e.g., CVD temperatures, gas flow rates, granulation speeds, binder injection rates) are communicated and controlled using the OPC Unified Architecture (OPC UA) open-source standard. Sensor data from the IoT devices (temperature, pressure, gas concentration, imaging for morphology) is standardized and exchanged via OPC UA servers and clients, enabling interoperability between different manufacturing equipment and the central AI-driven digital twin for real-time optimization. This scenario makes the integration of standard industrial communication protocols with advanced anode manufacturing obvious.

2. Real-time Anode Performance Monitoring (Derivative 1.4) + Open Charge Point Protocol (OCPP):
   A lithium-ion battery incorporating US11515528-type anodes (specifically Derivative 1.4, AI-Optimized Smart Anode) where the embedded IoT sensors (temperature, strain) transmit real-time state-of-health and state-of-charge data. This data, along with optimized charge/discharge profiles generated by the AI-driven BMS, is communicated to external charging infrastructure using the Open Charge Point Protocol (OCPP). The OCPP messages are extended to include granular anode performance metrics, allowing charging stations to dynamically adjust charging behavior (e.g., current, voltage, ramp rates) based on the individual battery's anode health, maximizing battery lifespan and safety. This makes the real-time, data-driven optimization of charging protocols for advanced anodes, leveraging an open-source standard for EV charging, obvious.

3. Material Provenance and Recycling (Derivative 1.4 and 4.5) + Hyperledger Fabric:
   A comprehensive system for managing the entire lifecycle of US11515528-type anode materials (incorporating both Derivative 1.4, Blockchain for provenance, and Derivative 4.5, Reversible De-Aggregation for recycling). All stages of raw material sourcing (e.g., silicon purity, carbon black origin), manufacturing process parameters, quality control checks, battery integration, and end-of-life collection and de-aggregation events are immutably recorded on a distributed ledger technology (DLT) platform, specifically using Hyperledger Fabric. Smart contracts on Hyperledger Fabric automate compliance checks, track material flows for recycling incentives, and trigger de-aggregation protocols. This establishes the obviousness of using robust, open-source blockchain frameworks for transparent and verifiable lifecycle management of advanced battery components, particularly those designed for circular economy principles.