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).
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Publication number: 20250174636Abstract: 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: ApplicationFiled: June 24, 2024Publication date: May 29, 2025Inventors: Charles A. Mason, Richard Gregory Taylor, Christopher Michael Friend
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Patent number: 12218341Abstract: 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: GrantFiled: November 8, 2019Date of Patent: February 4, 2025Assignee: Nexeon LimitedInventors: Charles A. Mason, Richard Gregory Taylor, James Farrell, William James Macklin, Christopher Michael Friend
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Patent number: 12203165Abstract: 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: GrantFiled: February 19, 2024Date of Patent: January 21, 2025Assignee: Nexeon LimitedInventors: Sefa Yilmaz, Charles A. Mason, Richard Gregory Taylor, David Bent
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Patent number: 12176521Abstract: 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: GrantFiled: November 8, 2019Date of Patent: December 24, 2024Assignee: Nexeon LimitedInventors: Charles A. Mason, Richard Gregory Taylor, James Farrell, William James Macklin
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Publication number: 20240384398Abstract: 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: ApplicationFiled: February 19, 2024Publication date: November 21, 2024Inventors: Sefa Yilmaz, Charles A. Mason, Richard Gregory Taylor, David Bent
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Patent number: 12021227Abstract: 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: GrantFiled: December 21, 2019Date of Patent: June 25, 2024Assignee: Nexeon LimitedInventors: Charles A. Mason, Richard Gregory Taylor, Christopher Michael Friend
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Patent number: 11905593Abstract: 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: GrantFiled: December 20, 2019Date of Patent: February 20, 2024Assignee: Nexeon LimitedInventors: Sefa Yilmaz, Charles A. Mason, Richard Gregory Taylor, David Bent
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Publication number: 20230395774Abstract: 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: ApplicationFiled: October 22, 2021Publication date: December 7, 2023Applicants: WACKER CHEMIE AG, NEXEON LIMITEDInventors: Jan TILLMANN, Christoph DRÄGER, Alena KALYAKINA, Sebastian KNEISSL, Thomas RENNER, Markus ANDERSON, Charles A. MASON, José MEDRANO-CATALAN, Richard Gregory TAYLOR, Joshua WHITTAM
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Publication number: 20220336791Abstract: 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: ApplicationFiled: September 10, 2020Publication date: October 20, 2022Inventors: Charles A. Mason, Richard Gregory Taylor, Sefa Yilmaz, Kseniia Katok, Joshua Whittam, Limunga Silo Meoto, Mauro Chiacchia
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Publication number: 20220336790Abstract: 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: ApplicationFiled: September 10, 2020Publication date: October 20, 2022Inventors: Charles A. Mason, Richard Gregory Taylor, Joshua Whittam, Limunga Silo Meoto, Mauro Chiacchia
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Publication number: 20220149349Abstract: 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: ApplicationFiled: November 8, 2019Publication date: May 12, 2022Inventors: Charles A. Mason, Richard Gregory Taylor, James Farrell, William James Macklin
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Publication number: 20220123282Abstract: 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: ApplicationFiled: November 8, 2019Publication date: April 21, 2022Inventors: Charles A. Mason, Richard Gregory Taylor, James Farrell, William James Macklin, Christopher Michael Friend
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Publication number: 20220077457Abstract: 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: ApplicationFiled: December 21, 2019Publication date: March 10, 2022Inventors: Charles A. Mason, Richard Gregory Taylor, Christopher Michael Friend
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Publication number: 20220074045Abstract: 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: ApplicationFiled: December 20, 2019Publication date: March 10, 2022Inventors: Sefa Yilmaz, Charles A. Mason, Richard Gregory Taylor, David Bent