Patents by Inventor Andrew Matheson

Andrew Matheson has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Patent number: 11858046
    Abstract: A method for producing a metal powder includes maintaining molten reducing metal in a sealed reaction vessel that is free of added oxygen and water, establishing a vortex in the molten reducing metal, introducing a metal halide into the vortex so that the molten reducing metal is in a stoichiometric excess to the metal halide, thereby producing metal particles and salt, removing unreacted reducing metal, removing the salt, and recovering the metal powder. The molten reducing metal can be a Group I metal, a Group II metal, or aluminum.
    Type: Grant
    Filed: September 27, 2021
    Date of Patent: January 2, 2024
    Assignee: Nanoscale Powders LLC
    Inventors: David Henderson, Andrew Matheson, Richard Van Lieshout, Donald Finnerty, John W. Koenitzer
  • Publication number: 20220008993
    Abstract: A method for producing a metal powder includes maintaining molten reducing metal in a sealed reaction vessel that is free of added oxygen and water, establishing a vortex in the molten reducing metal, introducing a metal halide into the vortex so that the molten reducing metal is in a stoichiometric excess to the metal halide, thereby producing metal particles and salt, removing unreacted reducing metal, removing the salt, and recovering the metal powder. The molten reducing metal can be a Group I metal, a Group II metal, or aluminum.
    Type: Application
    Filed: September 27, 2021
    Publication date: January 13, 2022
    Inventors: David Henderson, Andrew Matheson, Richard Van Lieshout, Donald Finnerty, John W. Koenitzer
  • Patent number: 11130177
    Abstract: A method for producing a metal powder includes maintaining molten reducing metal in a sealed reaction vessel that is free of added oxygen and water, establishing a vortex in the molten reducing metal, introducing a metal halide into the vortex so that the molten reducing metal is in a stoichiometric excess to the metal halide, thereby producing metal particles and salt, removing unreacted reducing metal, removing the salt, and recovering the metal powder. The molten reducing metal can be a Group I metal, a Group II metal, or aluminum.
    Type: Grant
    Filed: February 22, 2019
    Date of Patent: September 28, 2021
    Assignee: Nanoscale Powders LLC
    Inventors: David Henderson, Andrew Matheson, Richard Van Lieshout, Donald Finnerty, John W. Koenitzer
  • Publication number: 20200023440
    Abstract: A method for producing a metal powder includes maintaining molten reducing metal in a sealed reaction vessel that is free of added oxygen and water, establishing a vortex in the molten reducing metal, introducing a metal halide into the vortex so that the molten reducing metal is in a stoichiometric excess to the metal halide, thereby producing metal particles and salt, removing unreacted reducing metal, removing the salt, and recovering the metal powder. The molten reducing metal can be a Group I metal, a Group II metal, or aluminum.
    Type: Application
    Filed: February 22, 2019
    Publication date: January 23, 2020
    Inventors: David Henderson, Andrew Matheson, Richard Van Lieshout, Donald Finnerty, John W. Koenitzer
  • Patent number: 10245642
    Abstract: A method for producing a metal powder includes maintaining molten reducing metal in a sealed reaction vessel that is substantially free of oxygen and water, establishing a vortex in the molten reducing metal, introducing a metal halide into the vortex so that the molten reducing metal is in a stoichiometric excess to the metal halide, thereby producing metal particles and salt, removing unreacted reducing metal, removing the salt, and recovering the metal powder. The molten reducing metal can be a Group I metal, a Group II metal, or aluminum.
    Type: Grant
    Filed: February 23, 2016
    Date of Patent: April 2, 2019
    Assignee: Nanoscale Powders LLC
    Inventors: David Henderson, Andrew Matheson, Richard Van Lieshout, Donald Finnerty, John W. Koenitzer
  • Publication number: 20180043437
    Abstract: A method for producing a metal powder that combines molten reducing metal and metal halide in a space that is substantially free of oxygen and water, wherein the molten reducing metal is sodium and/or potassium, or aluminum (or magnesium or titanium) and is present in a stoichiometric excess to the metal halide which is a solid or liquid, thereby producing metal particles and salt, removing unreacted reducing metal, optionally removing the salt, and recovering the metal powder, is described. A method for producing a metal masterbatch wherein the molten reducing metal is aluminum, magnesium, and/or titanium and after combining molten aluminum (or magnesium or titanium) and metal halide in the reaction space, substantially removing the produced metal salt to obtain the metal masterbatch which comprises at least a portion of the molten aluminum (or magnesium or titanium) and at least one metal also is described.
    Type: Application
    Filed: August 7, 2017
    Publication date: February 15, 2018
    Applicant: Nanoscale Powders, LLC
    Inventors: Donald Finnerty, David Henderson, John Koenitzer, Andrew Matheson, Richard Van Lieshout
  • Patent number: 9679675
    Abstract: Disclosed is a process to reduce mixtures of at least one metal halide by molten metal reduction of the liquid phase metal halide in an alkali or alkaline earth metal to form a reaction product comprising at least one metal mixture and a halide salt coating, in which the at least one metal halide is in stoichiometric excess to the molten metal reductant and wherein the reductant is consumed in the reaction and does not need to be removed at the end of the reaction.
    Type: Grant
    Filed: November 13, 2013
    Date of Patent: June 13, 2017
    Assignee: Boston Electronic Materials LLC
    Inventor: Andrew Matheson
  • Patent number: 9586262
    Abstract: The present invention is directed to a method of manufacture of metal or alloy powders that uses liquid phase reduction of a metal halide, or a mixture of metal halides, to produce a metal particle coated in salts produced as a reaction byproduct. The reaction conditions can be chosen to select a range of metal particle sizes, and the salt coating prevents oxidation (or reaction with other atmospheric gases) and permits a range of applications hitherto difficult to achieve using metal powders.
    Type: Grant
    Filed: March 17, 2014
    Date of Patent: March 7, 2017
    Assignee: Boston Electronic Materials LLC
    Inventor: Andrew Matheson
  • Publication number: 20160243622
    Abstract: A method for producing a metal powder includes maintaining molten reducing metal in a sealed reaction vessel that is substantially free of oxygen and water, establishing a vortex in the molten reducing metal, introducing a metal halide into the vortex so that the molten reducing metal is in a stoichiometric excess to the metal halide, thereby producing metal particles and salt, removing unreacted reducing metal, removing the salt, and recovering the metal powder. The molten reducing metal can be a Group I metal, a Group II metal, or aluminum.
    Type: Application
    Filed: February 23, 2016
    Publication date: August 25, 2016
    Inventors: David Henderson, Andrew Matheson, Richard Van Lieshout, Donald Finnerty, John W. Koenitzer
  • Publication number: 20140199202
    Abstract: The present invention is directed to a method of manufacture of metal or alloy powders that uses liquid phase reduction of a metal halide, or a mixture of metal halides, to produce a metal particle coated in salts produced as a reaction byproduct. The reaction conditions can be chosen to select a range of metal particle sizes, and the salt coating prevents oxidation (or reaction with other atmospheric gases) and permits a range of applications hitherto difficult to achieve using metal powders.
    Type: Application
    Filed: March 17, 2014
    Publication date: July 17, 2014
    Applicant: Boston Electronic Materials, LLC
    Inventor: Andrew Matheson
  • Patent number: 8673051
    Abstract: The present invention is directed to a method of manufacture of metal or alloy powders that uses liquid phase reduction of a metal halide, or a mixture of metal halides, to produce a metal particle coated in salts produced as a reaction byproduct. The reaction conditions can be chosen to select a range of metal particle sizes, and the salt coating prevents oxidation (or reaction with other atmospheric gases) and permits a range of applications hitherto difficult to achieve using metal powders.
    Type: Grant
    Filed: January 16, 2012
    Date of Patent: March 18, 2014
    Assignee: Boston Electronic Materials LLC
    Inventor: Andrew Matheson
  • Publication number: 20140072498
    Abstract: A method of manufacture is described that uses liquid phase reduction of silicon hydride, to produce silicon metal. Working in liquid phase permits a more compact plant design and offers significantly lower capital costs.
    Type: Application
    Filed: November 13, 2013
    Publication date: March 13, 2014
    Applicant: Boston Silicon Materials, LLC
    Inventor: Andrew Matheson
  • Publication number: 20140061549
    Abstract: Disclosed is a process to reduce mixtures of at least one metal halide by molten metal reduction of the liquid phase metal halide in an alkali or alkaline earth metal to form a reaction product comprising at least one metal mixture and a halide salt coating, in which the at least one metal halide is in stoichiometric excess to the molten metal reductant and wherein the reductant is consumed in the reaction and does not need to be removed at the end of the reaction.
    Type: Application
    Filed: November 13, 2013
    Publication date: March 6, 2014
    Applicant: Boston Electronic Materials, LLC
    Inventor: Andrew Matheson
  • Publication number: 20120167716
    Abstract: The present invention is directed to a method of manufacture of metal or alloy powders that uses liquid phase reduction of a metal halide, or a mixture of metal halides, to produce a metal particle coated in salts produced as a reaction byproduct. The reaction conditions can be chosen to select a range of metal particle sizes, and the salt coating prevents oxidation (or reaction with other atmospheric gases) and permits a range of applications hitherto difficult to achieve using metal powders.
    Type: Application
    Filed: January 16, 2012
    Publication date: July 5, 2012
    Inventor: Andrew Matheson
  • Publication number: 20120045383
    Abstract: Disclosed is method for the production of silicon metal of a purity sufficient for the manufacture of commercial grade photovoltaic devices, by first reacting liquid silicon tetrachloride with molten sodium metal, and then by processing the reaction product to remove from the silicon metal, those reaction products which would be detrimental to the performance of the produced silicon metal in commercial grade photovoltaic devices used to generate electric power for commercial sale.
    Type: Application
    Filed: September 6, 2011
    Publication date: February 23, 2012
    Inventors: Andrew Matheson, John W. Koenitzer
  • Publication number: 20100154475
    Abstract: This invention relates to a process for the production of high purity elemental silicon by reacting silicon tetrachloride with a liquid metal reducing agent in a two reactor vessel configuration. The first reactor vessel is used for reducing the silicon tetrachloride to elemental silicon, resulting in a mixture of elemental silicon and reducing metal chloride salt while the second reactor vessel is used for separating the elemental silicon from the reducing metal chloride salt. The elemental silicon produced using this invention is of sufficient purity for the production of silicon photovoltaic devices or other semiconductor devices.
    Type: Application
    Filed: January 28, 2010
    Publication date: June 24, 2010
    Inventors: Andrew Matheson, John W. Koenitzer
  • Patent number: 7302068
    Abstract: A loudspeaker for audible sound is described having a sound emitting element mounted onto a support structure and at least one actuator adapted to rotate said sound emitting element around a hinge section, wherein the actuator is made of piezoelectric material. In variants the actuator forms part of the hinge section and the loudspeaker is capable of generating vibrations through its support structure.
    Type: Grant
    Filed: June 19, 2002
    Date of Patent: November 27, 2007
    Assignee: 1 . . .Limited
    Inventors: Simon Andrew Longbottom, Andrew Matheson, Gareth McKevitt, Richard Topliss, Matthew John Pitts, Mark Richard Shepherd
  • Patent number: 7166952
    Abstract: An equivalent to the spatial separation either side of a nominal median plane that is inherent in a bimorph (with one piezoelectric layer on one side, and the second on the other side of the plane) is attained by structurally shaping the cross-section of a simple, single piezoelectric layer (11) such that it has a multiplicity of piezoelectric portions arranged in two generally-planar groups one either side of a median plane, so that any dimension change undergone by a portion on one side of that plane will tend to bend the whole device in the opposite direction to the same sense dimension change undergone by a portion on the other side of that plane. The simple, single layer acts as though it were a bimorph if elongate and beam-like, bending along its length, one end moving up/down, or back/forth, relative to the other but with any need for an internal, electrode.
    Type: Grant
    Filed: September 26, 2002
    Date of Patent: January 23, 2007
    Assignee: 1. . . Limited
    Inventors: Richard Topliss, David Livingstone, Andrew Matheson, Gareth McKevitt, Mark Richard Shepherd, Anthony Hooley
  • Publication number: 20050040736
    Abstract: An equivalent to the spatial separation either side of a nominal median plane that is inherent in a bimorph (with one piezoelectric layer on one side, and the second on the other side of the plane) is attained by structurally shaping the cross-section of a simple, single piezoelectric layer (11) such that it has a multiplicity of piezoelectric portions arranged in two generally-planar groups one either side of a median plane, so that any dimension change undergone by a portion on one side of that plane will tend to bend the whole device in the opposite direction to the same sense dimension change undergone by a portion on the other side of that plane. The simple, single layer acts as though it were a bimorph if elongate and beam-like, bending along its length, one end moving up/down, or back/forth, relative to the other but with any need for an internal, electrode.
    Type: Application
    Filed: September 26, 2002
    Publication date: February 24, 2005
    Inventors: Richard Topliss, David Livingstone, Andrew Matheson, Gareth McKevitt, Mark Shepherd, Anthony Hooley
  • Publication number: 20040202338
    Abstract: A loudspeaker for audible sound is described having a sound emitting element mounted onto a support structure and at least one actuator adapted to rotate said sound emitting element around a hinge section, wherein the actuator is made of piezoelectric material. In variants the actuator forms part of the hinge section and the loudspeaker is capable of generating vibrations through its support structure.
    Type: Application
    Filed: May 28, 2004
    Publication date: October 14, 2004
    Inventors: Simon Andrew Longbotttom, Andrew Matheson, Gareth McKevitt, Richard Topliss, Matthew John Pitts, Mark Richard Shepherd