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.

tool_code
print(google_search.search(queries=["US11515528 cited prior art references", "US11515528 prosecution history", "prior art for silicon anode volume expansion lithium ion battery", "dendritic carbon nanoparticles silicon anode prior art"]))
thought
The user is asking for an obviousness analysis of US Patent 11515528 under 35 U.S.C. § 103, building on the previously generated "Prior Art" section. I need to identify combinations of prior art references that would render the claims obvious and explain the motivation to combine them for a Person Having Ordinary Skill in the Art (PHOSITA).

To do this effectively, I first need to get the specific prior art cited within US11515528, as this is typically the most relevant starting point for obviousness arguments. The previous section noted that the complete list of cited patents was not available. Therefore, my first step will be to search for the cited prior art references of US11515528.

Once I have the cited prior art, I will:

1. Review the independent claims of US11515528 (as summarized in the "Patent Summary" section).
2. Examine the cited prior art documents (or at least their abstracts/summaries if I can't access full text directly) to understand their teachings.
3. Look for combinations of these prior art references that, together, disclose all the elements of the independent claims.
4. Articulate a motivation for a PHOSITA to combine these references, considering the problems discussed in the "Background of the Invention" (volume expansion of Si, low conductivity of Si, limited stability of prior Si-C composites).

If I cannot find the specific cited prior art references, I will have to rely on the types of prior art discussed in the patent itself (carbon electrodes, pure silicon electrodes, and prior Si-C composites) and try to construct hypothetical obviousness arguments based on common knowledge in the field, while explicitly stating the limitation of not having the specific cited art.

Let's start by searching for the cited prior art references.## Obviousness Analysis of US Patent 11515528 under 35 U.S.C. § 103

To perform an obviousness analysis under 35 U.S.C. § 103, it is crucial to identify combinations of prior art references that would have rendered the claimed invention obvious to a person having ordinary skill in the art (PHOSITA) at the time of the invention (priority date: September 29, 2009). This analysis requires considering the scope and content of the prior art, the differences between the prior art and the claims at issue, the level of ordinary skill in the art, and any secondary considerations of non-obviousness.

Given that the complete list of "Prior Art Documents" cited in US11515528 was not provided in the authoritative text, a direct analysis of specific cited references cannot be performed. However, based on the patent's "Background of the Invention" and "Summary of the Invention," which explicitly discuss the state of the art and the problems the invention aims to solve, we can identify categories of relevant prior art and construct hypothetical obviousness arguments.

The patent itself outlines the primary challenges in lithium-ion battery anodes as:

• Limited capacity and cycling losses of carbon (graphite) anodes (372 mAh/g).
• Significant volume expansion (up to 400%), mechanical damage, and low electrical conductivity of pure silicon anodes (4200 mAh/g).
• Limited ability of prior silicon-carbon composites (Si particles embedded in or on a dense carbon matrix) to accommodate Si volume changes, leading to limited stability and capacity enhancements.

The invention of US11515528 addresses these issues by proposing anodes comprising a porous composite with agglomerated nanocomposites. Each nanocomposite features a dendritic particle of an electrically conducting material (e.g., carbon) with discrete, non-porous nanoparticles of a non-carbon Group 4A element (e.g., silicon) disposed on its surface. A key feature is the electrical communication between dendritic particles and the overall porous structure to accommodate volume changes and facilitate ion transport.

Level of Ordinary Skill in the Art (PHOSITA)

A PHOSITA in this field at the priority date (2009) would likely possess a graduate degree (M.S. or Ph.D.) in materials science, chemistry, chemical engineering, or a related discipline, with several years of experience in electrochemical energy storage, particularly lithium-ion battery materials development. Such a person would be familiar with:

• The electrochemical principles of lithium-ion batteries.
• Various anode materials, including graphite and silicon, and their respective advantages and disadvantages.
• Nanomaterial synthesis and characterization techniques (e.g., CVD, PVD, electron microscopy).
• The concepts of porosity, electrical conductivity, and mechanical stability in electrode design.
• Strategies for mitigating volume expansion in high-capacity anode materials.

Hypothetical Obviousness Combinations

Given the patent's own description of the prior art, the most relevant area for obviousness lies in the combination of known carbon electrode structures with silicon, specifically in a way that addresses the volume expansion issue.

Combination 1: Carbon Black Particles (Dendritic/Agglomerated) + Discrete Silicon Nanoparticles + Porous Structure (General Teaching)

• Prior Art Reference A (Hypothetical): A reference disclosing the use of carbon black (CB) nanoparticles as an electrically conductive matrix or support material for electrodes in lithium-ion batteries. This reference might describe CB's inherent agglomerated or somewhat "dendritic" nature, its high surface area, and its role in improving conductivity. For example, the patent itself mentions annealing carbon black particles at elevated temperatures to form fused/sintered dendritic carbon particles. Prior art would likely include methods for forming such carbon structures.
• Prior Art Reference B (Hypothetical): A reference disclosing the use of silicon nanoparticles as an active material in lithium-ion battery anodes to achieve high capacity. This reference would acknowledge the severe volume expansion of silicon and might propose strategies for managing it, such as reducing particle size to the nanoscale, coating silicon, or embedding it in a matrix.
• Prior Art Reference C (Hypothetical): A general teaching in the art regarding the benefits of porous electrode structures for accommodating volume changes in active materials and facilitating electrolyte infiltration and ion transport in high-capacity electrodes. This could come from a review article or another patent discussing electrode architecture.

Motivation for Combination:
A PHOSITA would be motivated to combine elements from these hypothetical references to address the well-known problems of silicon volume expansion and poor conductivity, while simultaneously leveraging silicon's high capacity and carbon's conductivity and structural integrity.

1. Why use carbon black (Reference A) with silicon (Reference B)? Carbon black is a known electrically conductive material, often used in battery electrodes to improve conductivity. A PHOSITA, aware of silicon's low electrical conductivity and the need for an efficient electron pathway, would naturally consider combining silicon with carbon black. The "dendritic" or agglomerated nature of carbon black (as acknowledged by the patent) provides an inherent, randomly-ordered, three-dimensional network that could serve as a conductive backbone.
2. Why use discrete silicon nanoparticles on the carbon black surface? The problem of silicon's massive volume expansion was well-known. A PHOSITA would understand that forming silicon as discrete nanoparticles, rather than a continuous film, would allow individual particles to expand and contract without causing catastrophic damage to the overall electrode structure. Placing these discrete nanoparticles on the surface of a conductive carbon backbone (like annealed carbon black) would ensure good electrical contact while potentially allowing space for expansion within the interstitial voids of the carbon network.
3. Why aim for a porous composite (Reference C)? The patent explicitly states that prior Si-C composites suffered because the carbon could only accommodate volume changes to a limited degree, often having Si embedded in a dense carbon matrix. A PHOSITA, understanding the need for space for silicon expansion, would naturally consider designing a porous composite structure. The inherent porosity of an agglomerated carbon black network, combined with discretely placed silicon nanoparticles, could naturally lead to a porous composite. The motivation would be to provide sufficient void volume for silicon expansion and improve lithium-ion diffusion kinetics.

Therefore, the idea of using a porous, conductive carbon network (like annealed carbon black) to support discrete, high-capacity silicon nanoparticles, thereby accommodating volume changes and maintaining electrical contact, would likely have been an obvious design choice for a PHOSITA in 2009. The challenge would be in how to achieve such a structure reliably and effectively.

Combination 2: Prior Si-C Composites (Dense Matrix) + Teaching of Dendritic/Porous Structures for Expansion Accommodation

• Prior Art Reference D (Hypothetical): A reference disclosing prior art silicon-carbon composites where silicon particles are embedded in or on a dense carbon matrix, as described in the background of US11515528. This reference would highlight the attempts to combine Si and C but also implicitly or explicitly show the limitations regarding volume expansion management.
• Prior Art Reference E (Hypothetical): A reference or general knowledge in the art emphasizing the benefits of dendritic, porous, or interconnected network structures in battery electrodes, particularly for active materials that undergo significant volume changes or require fast ion/electron transport. This could be a teaching about using carbon nanofibers, carbon nanotubes, or other high-surface-area carbon forms to create conductive and flexible frameworks.

Motivation for Combination:
A PHOSITA, starting from the known limitations of prior dense Si-C composites (Reference D), would be motivated to improve their performance by incorporating principles from advanced electrode architectures (Reference E). The problem with dense matrices was clearly the limited accommodation of silicon's volume changes. If a PHOSITA knew about dendritic or highly porous carbon structures that could provide both conductivity and void space, it would be an obvious step to apply such structural concepts to Si-C composites. The motivation would be to create a composite that more effectively manages silicon's volume expansion while maintaining electrical connectivity. The specific "three-dimensional, randomly-ordered assembly of nanoparticles of an electrically conducting material" forming a "dendritic particle" as a backbone for silicon nanoparticles, and then agglomerating these into a "porous composite," could be seen as an optimized implementation of this general concept.

Conclusion on Obviousness

Without the specific cited prior art documents, it is challenging to definitively conclude on obviousness. However, based on the patent's own self-characterization of the prior art and the problems it solves, a strong argument for obviousness could likely be constructed. The inventive step appears to lie in the specific hierarchical structure—the dendritic conducting particle, discrete non-porous silicon nanoparticles disposed on its surface, and the agglomeration into a porous composite with electrical communication—rather than the general idea of combining silicon and carbon or making a porous electrode.

A PHOSITA in 2009, faced with the known problems of silicon volume expansion and poor conductivity, and aware of various carbon forms (like carbon black with its inherent agglomerated structure) and the benefits of porosity, would likely have been motivated to develop a composite structure that:

1. Provides a continuous electrical pathway (carbon).
2. Incorporates high-capacity silicon.
3. Offers sufficient void space to accommodate silicon's volume changes without sacrificing structural integrity or electrical contact.

The combination of existing knowledge about carbon black's morphology, silicon's electrochemical properties, and the need for porous architectures in high-volume-change materials would provide a strong motivation for a PHOSITA to arrive at structures conceptually similar to those claimed in US11515528. The specific methods of forming these structures (e.g., CVD of silane for Si nanoparticles, wet granulation for agglomeration, carbon CVD for binding) were also generally known techniques in materials science and electrochemistry at the time.

To make a more conclusive determination, an in-depth review of the actual cited prior art in US11515528's prosecution history would be essential.

Disclaimer: This analysis is based on the provided text of US11515528 and general knowledge of the prior art landscape in 2009. A complete obviousness analysis would require examining the full patent prosecution history, including all cited references by the examiner and applicant, as well as potentially other relevant non-cited prior art.

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.