Method for Producing Silicon-Based Anodes for Secondary Batteries

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This patent discloses a method for manufacturing silicon-based anodes for secondary batteries, such as lithium-ion batteries. The process involves depositing a silicon layer on a metal substrate (like nickel or copper), then subjecting it to controlled heating and high-intensity flash lamp irradiation. This treatment creates multi-phase regions within the silicon and metal (including amorphous/crystalline silicon, silicide, and crystalline metal), which improves the electrochemical stability and performance of the anode. The process is compatible with roll-to-roll manufacturing, enabling efficient large-scale production.

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• Manufacture of high-capacity anodes for lithium-ion batteries used in electric vehicles (EVs)
• Production of advanced rechargeable batteries for consumer electronics (e.g., smartphones, laptops)
• Development of cost-effective and scalable energy storage solutions for renewable power grid systems
• Creation of rechargeable batteries for hearing aids, medical devices, and other portable electronics
• Battery manufacturing processes that demand fast, scalable, and integrated production lines, such as roll-to-roll assembly

BenefitsContent extracted from patent full text and abstract with AI.

• Significantly higher storage capacity compared to traditional carbon-based anodes (e.g., graphite)
• Enhanced durability and longer lifecycle of the battery due to reduced mechanical stress and better accommodation of volume changes in silicon
• Lower manufacturing costs and energy consumption thanks to scalable, fast, and integrated roll-to-roll processes
• Use of abundant and non-toxic materials like silicon, supporting better resource sustainability
• Improved safety and stability of the anode material, which helps prevent battery failure and degradation
• Enables the production of large-format batteries required for grid-scale and electromobility applications

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Patent Abstract

The invention relates to a method for producing silicon-based anodes for secondary batteries, wherein the following steps for producing an anode (20) are carried out: - depositing a silicon layer (3) on a metal substrate (1) having grain boundaries (2), wherein the silicon layer (3) has a first boundary surface (14) directed towards the metal substrate (1), - heating the metal substrate (1) by means of a heating unit (22) to a temperature between 200°C and 1000°C, - conditioning the region of the second boundary surface (15) of the silicon layer (3) that is facing away from the metal substrate (1) by means of an energy-intensive irradiation during the heating, - generating polyphases in the region of the silicon layer (3) and the metal substrate (1), consisting of amorphous silicon and/or crystalline silicon of the silicon of the silicon layer (3) and of crystalline metal of the metal substrate (1) and of silicide and - generating crystalline metal of the metal substrate (1).