Patents by Inventor Charles A. Mason

Charles A. Mason 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).

  • Publication number: 20250174636
    Abstract: The invention relates to a particulate material comprising a plurality of composite particles, wherein the composite particles comprise: (a) a porous carbon framework comprising micropores and mesopores having a total pore volume of at least 0.6 cm3/g, where the volume fraction of micropores is in the range from 0.1 to 0.9 and the volume fraction of pores having a pore diameter no more than 20 nm is at least 0.75, and the porous carbon framework has a D50 particle size of less than 20 ?m; (b) silicon located within the micropores and/or mesopores of the porous carbon framework in a defined amount relative to the volume of the micropores and/or mesopores.
    Type: Application
    Filed: June 24, 2024
    Publication date: May 29, 2025
    Inventors: Charles A. Mason, Richard Gregory Taylor, Christopher Michael Friend
  • Patent number: 12218341
    Abstract: This invention relates to particulate electroactive materials consisting of a plurality of composite particles, wherein the composite particles comprise: (a) a porous carbon framework including micropores and/or mesopores having a total volume of at least 0.6 cm 3/g, wherein at least half of the micropore/mesopore volume is in the form of pores having a diameter of no more than 2 nm; and (b) an electroactive material located within the micropores and/or mesopores of the porous carbon framework. The D 90 particle diameter of the composite particles is no more than 10 nm.
    Type: Grant
    Filed: November 8, 2019
    Date of Patent: February 4, 2025
    Assignee: Nexeon Limited
    Inventors: Charles A. Mason, Richard Gregory Taylor, James Farrell, William James Macklin, Christopher Michael Friend
  • Patent number: 12203165
    Abstract: The disclosure relates to a process for preparing particulate materials having high electrochemical capacities that are suitable for use as anode active materials in rechargeable metal-ion batteries. In one aspect, the disclosure provides a process for preparing a particulate material comprising a plurality of composite particles. The process includes providing particulate porous carbon frameworks comprising micropores and/or mesopores, wherein the porous carbon frameworks have a D50 particle diameter of at least 20 ?m; depositing an electroactive material selected from silicon and alloys thereof into the micropores and/or mesopores of the porous carbon frameworks using a chemical vapour infiltration process in a fluidised bed reactor, to provide intermediate particles; and comminuting the intermediate particles to provide said composite particles.
    Type: Grant
    Filed: February 19, 2024
    Date of Patent: January 21, 2025
    Assignee: Nexeon Limited
    Inventors: Sefa Yilmaz, Charles A. Mason, Richard Gregory Taylor, David Bent
  • Patent number: 12176521
    Abstract: This invention relates to particulate electroactive materials comprising a plurality of composite particles, wherein the composite particles comprise: (a) a porous carbon framework including micropores and/or mesopores having a total volume of at least 0.7 cm3/g, wherein at least half of the micropore/mesopore volume is in the form of pores having a diameter of no more than 5 nm; and (b) silicon located within the micropores and/or mesopores of the porous carbon framework in a defined amount relative to the volume of the micropores and/or mesopores.
    Type: Grant
    Filed: November 8, 2019
    Date of Patent: December 24, 2024
    Assignee: Nexeon Limited
    Inventors: Charles A. Mason, Richard Gregory Taylor, James Farrell, William James Macklin
  • Publication number: 20240384398
    Abstract: The disclosure relates to a process for preparing particulate materials having high electrochemical capacities that are suitable for use as anode active materials in rechargeable metal-ion batteries. In one aspect, the disclosure provides a process for preparing a particulate material comprising a plurality of composite particles. The process includes providing particulate porous carbon frameworks comprising micropores and/or mesopores, wherein the porous carbon frameworks have a D50 particle diameter of at least 20 ?m; depositing an electroactive material selected from silicon and alloys thereof into the micropores and/or mesopores of the porous carbon frameworks using a chemical vapour infiltration process in a fluidised bed reactor, to provide intermediate particles; and comminuting the intermediate particles to provide said composite particles.
    Type: Application
    Filed: February 19, 2024
    Publication date: November 21, 2024
    Inventors: Sefa Yilmaz, Charles A. Mason, Richard Gregory Taylor, David Bent
  • Patent number: 12021227
    Abstract: The invention relates to a particulate material comprising a plurality of composite particles, wherein the composite particles comprise: (a) a porous carbon framework comprising micropores and mesopores having a total pore volume of at least 0.6 cm3/g, where the volume fraction of micropores is in the range from 0.1 to 0.9 and the volume fraction of pores having a pore diameter no more than 20 nm is at least 0.75, and the porous carbon framework has a D50 particle size of less than 20 ?m; (b) silicon located within the micropores and/or mesopores of the porous carbon framework in a defined amount relative to the volume of the micropores and/or mesopores.
    Type: Grant
    Filed: December 21, 2019
    Date of Patent: June 25, 2024
    Assignee: Nexeon Limited
    Inventors: Charles A. Mason, Richard Gregory Taylor, Christopher Michael Friend
  • Patent number: 11905593
    Abstract: The disclosure relates to a process for preparing particulate materials having high electrochemical capacities that are suitable for use as anode active materials in rechargeable metal-ion batteries. In one aspect, the disclosure provides a process for preparing a particulate material comprising a plurality of composite particles. The process includes providing particulate porous carbon frameworks comprising micro pores and/or mesopores, wherein the porous carbon frameworks have a D50 particle diameter of at least 20 ?m; depositing an electroactive material selected from silicon and alloys thereof into the micropores and/or mesopores of the porous carbon frameworks using a chemical vapour infiltration process in a fluidised bed reactor, to provide intermediate particles; and comminuting the intermediate particles to provide said composite particles.
    Type: Grant
    Filed: December 20, 2019
    Date of Patent: February 20, 2024
    Assignee: Nexeon Limited
    Inventors: Sefa Yilmaz, Charles A. Mason, Richard Gregory Taylor, David Bent
  • Publication number: 20230395774
    Abstract: Silicon-containing composite particles, the process comprising the steps of: (a) providing a plurality of porous particles comprising micropores and/or mesopores, wherein the D50 particle diameter of the porous particles from 0.5 to 200 ?m; the total pore volume of micropores and mesopores is from 0.4 to 2.2 cm3/g; and the PD50 pore diameter is no more than 30 nm; c (b) combining a charge of the porous particles with a charge of a silicon-containing precursor in a batch pressure reactor, wherein the charge of porous particles has a volume of at least 20 cm3 per litre of reactor volume (cm3/LRV), and wherein the charge of the silicon-containing precursor comprises at least 2 g of silicon per litre of reactor volume (g/LRV); and (c) heating the reactor to a temperature effective to cause deposition of silicon in the pores of the porous particles, thereby providing the silicon-containing composite particles.
    Type: Application
    Filed: October 22, 2021
    Publication date: December 7, 2023
    Applicants: WACKER CHEMIE AG, NEXEON LIMITED
    Inventors: Jan TILLMANN, Christoph DRÄGER, Alena KALYAKINA, Sebastian KNEISSL, Thomas RENNER, Markus ANDERSON, Charles A. MASON, José MEDRANO-CATALAN, Richard Gregory TAYLOR, Joshua WHITTAM
  • Publication number: 20220336791
    Abstract: The invention provides methods for providing composite particles with a carbon coating and the resulting core-shell particulate material. The process comprises subjecting a plurality of precursor composite particles to a heat treatment in contact with a pyrolytic carbon precursor such that an outer shell of a pyrolytic conductive carbon material is formed on the precursor composite particles, wherein the heat treatment is carried out at a temperature of no more than 700° C.
    Type: Application
    Filed: September 10, 2020
    Publication date: October 20, 2022
    Inventors: Charles A. Mason, Richard Gregory Taylor, Sefa Yilmaz, Kseniia Katok, Joshua Whittam, Limunga Silo Meoto, Mauro Chiacchia
  • Publication number: 20220336790
    Abstract: This invention relates to particulate electroactive materials consisting of a plurality of composite particles, wherein the composite particles comprise: (a) a porous conductive particle framework including micropores and/or mesopores having a total volume of at least 0.4 to 2.2 cm3/g; (b) an electroactive material disposed within the porous conductive particle framework; and (c) a lithium-ion permeable filler penetrating the pores of the porous conductive particle framework and disposed intermediate the nanoscale silicon domains and the exterior of the composite particles.
    Type: Application
    Filed: September 10, 2020
    Publication date: October 20, 2022
    Inventors: Charles A. Mason, Richard Gregory Taylor, Joshua Whittam, Limunga Silo Meoto, Mauro Chiacchia
  • Publication number: 20220149349
    Abstract: This invention relates to particulate electroactive materials comprising a plurality of composite particles, wherein the composite particles comprise: (a) a porous carbon framework including micropores and/or mesopores having a total volume of at least 0.7 cm3/g, wherein at least half of the micropore/mesopore volume is in the form of pores having a diameter of no more than 5 nm; and (b) silicon located within the micropores and/or mesopores of the porous carbon framework in a defined amount relative to the volume of the micropores and/or mesopores.
    Type: Application
    Filed: November 8, 2019
    Publication date: May 12, 2022
    Inventors: Charles A. Mason, Richard Gregory Taylor, James Farrell, William James Macklin
  • Publication number: 20220123282
    Abstract: This invention relates to particulate electroactive materials consisting of a plurality of composite particles, wherein the composite particles comprise: (a) a porous carbon framework including micropores and/or mesopores having a total volume of at least 0.6 cm 3/g, wherein at least half of the micropore/mesopore volume is in the form of pores having a diameter of no more than 2 nm; and (b) an electroactive material located within the micropores and/or mesopores of the porous carbon framework. The D 90 particle diameter of the composite particles is no more than 10 nm.
    Type: Application
    Filed: November 8, 2019
    Publication date: April 21, 2022
    Inventors: Charles A. Mason, Richard Gregory Taylor, James Farrell, William James Macklin, Christopher Michael Friend
  • Publication number: 20220077457
    Abstract: The invention relates to a particulate material comprising a plurality of composite particles, wherein the composite particles comprise: (a) a porous carbon framework comprising micropores and mesopores having a total pore volume of at least 0.6 cm3/g, where the volume fraction of micropores is in the range from 0.1 to 0.9 and the volume fraction of pores having a pore diameter no more than 20 nm is at least 0.75, and the porous carbon framework has a D50 particle size of less than 20 ?m; (b) silicon located within the micropores and/or mesopores of the porous carbon framework in a defined amount relative to the volume of the micropores and/or mesopores.
    Type: Application
    Filed: December 21, 2019
    Publication date: March 10, 2022
    Inventors: Charles A. Mason, Richard Gregory Taylor, Christopher Michael Friend
  • Publication number: 20220074045
    Abstract: The disclosure relates to a process for preparing particulate materials having high electrochemical capacities that are suitable for use as anode active materials in rechargeable metal-ion batteries. In one aspect, the disclosure provides a process for preparing a particulate material comprising a plurality of composite particles. The process includes providing particulate porous carbon frameworks comprising micro pores and/or mesopores, wherein the porous carbon frameworks have a D50 particle diameter of at least 20 ?m; depositing an electroactive material selected from silicon and alloys thereof into the micropores and/or mesopores of the porous carbon frameworks using a chemical vapour infiltration process in a fluidised bed reactor, to provide intermediate particles; and comminuting the intermediate particles to provide said composite particles.
    Type: Application
    Filed: December 20, 2019
    Publication date: March 10, 2022
    Inventors: Sefa Yilmaz, Charles A. Mason, Richard Gregory Taylor, David Bent