Patents by Inventor Katsuya Kase

Katsuya Kase 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: 11909039
    Abstract: The nickel-containing composite hydroxide disclosed herein contain secondary particles, which are formed from an aggregation of numerous primary particles, which have an average particle size of the primary particles is 0.01 ?m to 0.40 ?m. These secondary particles have a spherical or ellipsoidal shape, an average particle size of 20 ?m to 50 ?m, and a BET value of 12 m2/g to 50 m2/g after being roasted in air for 2 hours at 800° C.
    Type: Grant
    Filed: January 22, 2020
    Date of Patent: February 20, 2024
    Assignee: SUMITOMO METAL MINING CO., LTD.
    Inventors: Kazuomi Ryoshi, Kensaku Mori, Katsuya Kase, Yasutaka Kamata
  • Publication number: 20200161653
    Abstract: Provided is a nickel-containing composite hydroxide that is a precursor of a positive-electrode active material with which a nonaqueous-electrolyte secondary battery having a low irreversible capacity and a high energy density can be configured. An aqueous alkaline aqueous solution and a complexing agent are added to an mixed aqueous solution including at least nickel and cobalt to regulate the pH (measured at a reference liquid temperature of 25° C.) of this mixed aqueous solution to 11.0 to 13.0, the ammonium concentration to 4 to 15 g/L, and the reaction temperature to 20° C. to 45° C. Using stirring blades having an inclination angle of 20° to 60° with respect to a horizontal plane, the mixture is stirred to conduct a crystallization reaction under such conditions that when the nickel-containing composite hydroxide to be obtained is roasted in air at 800° C. for 2 hours, the roasted composite hydroxide has a BET value of 12 to 50 m2/g.
    Type: Application
    Filed: January 22, 2020
    Publication date: May 21, 2020
    Applicant: SUMITOMO METAL MINING CO., LTD.
    Inventors: Kazuomi RYOSHI, Kensaku MORI, Katsuya KASE, Yasutaka KAMATA
  • Patent number: 10629891
    Abstract: A non-aqueous electrolyte secondary battery is provided that has both good safety and durability characteristics while at the same time has high charge/discharge capacity. The cathode active material for a non-aqueous electrolyte secondary battery of the present invention is a lithium nickel composite oxide to which at least two or more kinds of metal elements including aluminum are added, and comprises secondary particles that are composed of fine secondary particles having an average particle size of 2 ?m to 4 ?m, and rough secondary particles having an average particle size of 6 ?m to 15 ?m, with an overall average particle size of 5 ?m to 15 ?m; where the aluminum content of fine secondary particles (metal mole ratio: SA) is greater than the aluminum content of rough secondary particles (metal mole ratio: LA), and preferably the aluminum concentration ratio (SA/LA) is within the range 1.2 to 2.6.
    Type: Grant
    Filed: February 6, 2018
    Date of Patent: April 21, 2020
    Assignees: SUMITOMO METAL MINING CO., LTD., Toyota Jidosha Kabushiki Kaisha
    Inventors: Syuhei Oda, Hiroyuki Toya, Katsuya Kase, Yutaka Oyama
  • Patent number: 10593942
    Abstract: Provided is a nickel-containing composite hydroxide that is a precursor of a positive-electrode active material with which a nonaqueous-electrolyte secondary battery having a low irreversible capacity and a high energy density can be configured. An aqueous alkaline aqueous solution and a complexing agent are added to an mixed aqueous solution including at least nickel and cobalt to regulate the pH (measured at a reference liquid temperature of 25° C.) of this mixed aqueous solution to 11.0 to 13.0, the ammonium concentration to 4 to 15 g/L, and the reaction temperature to 20° C. to 45° C. Using stirring blades having an inclination angle of 20° to 60° with respect to a horizontal plane, the mixture is stirred to conduct a crystallization reaction under such conditions that when the nickel-containing composite hydroxide to be obtained is roasted in air at 800° C. for 2 hours, the roasted composite hydroxide has a BET value of 12 to 50 m2/g.
    Type: Grant
    Filed: October 29, 2015
    Date of Patent: March 17, 2020
    Assignee: SUMITOMO METAL MINING CO., LTD.
    Inventors: Kazuomi Ryoshi, Kensaku Mori, Katsuya Kase, Yasutaka Kamata
  • Patent number: 10236510
    Abstract: To improve cycling characteristics of a non-aqueous electrolyte secondary battery by obtaining a nickel-cobalt composite hydroxide having a sharp particle size distribution as a precursor, a slurry including a nickel-cobalt composite hydroxide obtained by continuously supplying an aqueous solution that includes at least nickel and cobalt, an ammonium ion donor aqueous solution and a caustic alkali aqueous solution to a reaction vessel and reacting, is continuously extracted and separated into a large particle size portion and s small particle size portion by classification, and the small particle size portion is continuously returned to the reaction vessel. As a result, a nickel-cobalt composite hydroxide is obtained that is expressed by the general formula: Ni1?x?yCoxMy(OH)2 (where, 0.05?x?0.50, 0?y?0.10, 0.05?x+y?0.50, and M is at least one kind of metal element selected from among Al, Mg, Mn, Ti, Fe, Cu, Zn and Ga, and that satisfies the relationships (D50?D10)/D50?0.30, and (D90?D50)/D50?0.
    Type: Grant
    Filed: July 6, 2018
    Date of Patent: March 19, 2019
    Assignee: SUMITOMO METAL MINING CO., LTD.
    Inventors: Katsuya Kase, Yasutaka Kamata, Kazuomi Ryoshi
  • Patent number: 10141571
    Abstract: To improve cycling characteristics of a non-aqueous electrolyte secondary battery by obtaining a nickel-cobalt composite hydroxide having a sharp particle size distribution as a precursor, a slurry including a nickel-cobalt composite hydroxide obtained by continuously supplying an aqueous solution that includes at least nickel and cobalt, an ammonium ion donor aqueous solution and a caustic alkali aqueous solution to a reaction vessel and reacting, is continuously extracted and separated into a large particle size portion and s small particle size portion by classification, and the small particle size portion is continuously returned to the reaction vessel. As a result, a nickel-cobalt composite hydroxide is obtained that is expressed by the general formula: Ni1-x-yCoxMy(OH)2 (where, 0.05?x?0.50, 0?y?0.10, 0.05?x+y?0.50, and M is at least one kind of metal element selected from among Al, Mg, Mn, Ti, Fe, Cu, Zn and Ga, and that satisfies the relationships (D50?D10)/D50?0.30, and (D90?D50)/D50?0.
    Type: Grant
    Filed: September 27, 2013
    Date of Patent: November 27, 2018
    Assignee: SUMITOMO METAL MINING CO., LTD.
    Inventors: Katsuya Kase, Yasutaka Kamata, Kazuomi Ryoshi
  • Publication number: 20180323431
    Abstract: To improve cycling characteristics of a non-aqueous electrolyte secondary battery by obtaining a nickel-cobalt composite hydroxide having a sharp particle size distribution as a precursor, a slurry including a nickel-cobalt composite hydroxide obtained by continuously supplying an aqueous solution that includes at least nickel and cobalt, an ammonium ion donor aqueous solution and a caustic alkali aqueous solution to a reaction vessel and reacting, is continuously extracted and separated into a large particle size portion and s small particle size portion by classification, and the small particle size portion is continuously returned to the reaction vessel. As a result, a nickel-cobalt composite hydroxide is obtained that is expressed by the general formula: Ni1?x?yCoxMy(OH)2 (where, 0.05?x?0.50, 0?y?0.10, 0.05?x+y?0.50, and M is at least one kind of metal element selected from among Al, Mg, Mn, Ti, Fe, Cu, Zn and Ga, and that satisfies the relationships (D50?D10)/D50?0.30, and (D90?D50)/D50?0.
    Type: Application
    Filed: July 6, 2018
    Publication date: November 8, 2018
    Applicant: SUMITOMO METAL MINING CO., LTD.
    Inventors: KATSUYA KASE, YASUTAKA KAMATA, KAZUOMI RYOSHI
  • Publication number: 20180287147
    Abstract: Provided is a coated nickel hydroxide powder that is obtained by forming a coating mainly containing cobalt oxyhydroxide on the surface of particles of a nickel hydroxide powder so that the uniformity and adhesion properties of the coating are ensured, and is therefore suitable for a positive electrode active material of alkaline secondary battery. The pH of a suspension of a nickel hydroxide powder is kept at 8 to 11.5, and an aqueous cobalt salt solution and an aqueous alkali, solution are supplied to the suspension while the ratio of the supply rate ? of the aqueous cobalt salt solution to the product of the supply width d of the aqueous cobalt salt solution in a direction orthogonal to the flow direction of the suspension and the flow velocity v of the suspension in a contact portion between the suspension and the aqueous cobalt salt solution, that is, ?/(d×v) is controlled to be 3.8×10?4 mol/cm2 or less to coat the surface of nickel hydroxide particles with cobalt hydroxide.
    Type: Application
    Filed: May 31, 2018
    Publication date: October 4, 2018
    Applicant: SUMITOMO METAL MINING CO., LTD.
    Inventors: Katsuya Kase, Ryuichi Kuzuo, Minoru Shiraoka, Hideo Sasaoka
  • Patent number: 10020498
    Abstract: A method for producing coated nickel hydroxide powder for a positive electrode of an alkaline secondary battery wherein the pH of a suspension of a nickel hydroxide powder is kept at 8 to 11.5, and an aqueous cobalt salt solution and an aqueous alkali solution are supplied to the suspension to coat the surface of nickel hydroxide particles with cobalt hydroxide. Then, the pH of a slurry of the cobalt hydroxide-coated nickel hydroxide powder is adjusted to 12.5 to 13.0, and oxygen is supplied to the slurry so that the total amount of oxygen supplied per mole of cobalt in the coating is 30 l/mol or more to oxidize the cobalt hydroxide.
    Type: Grant
    Filed: October 12, 2013
    Date of Patent: July 10, 2018
    Assignee: Sumitomo Metal Mining Co., Ltd.
    Inventors: Katsuya Kase, Ryuichi Kuzuo, Minoru Shiraoka, Hideo Sasaoka
  • Publication number: 20180159117
    Abstract: A non-aqueous electrolyte secondary battery is provided that has both good safety and durability characteristics while at the same time has high charge/discharge capacity. The cathode active material for a non-aqueous electrolyte secondary battery of the present invention is a lithium nickel composite oxide to which at least two or more kinds of metal elements including aluminum are added, and comprises secondary particles that are composed of fine secondary particles having an average particle size of 2 ?m to 4 ?m, and rough secondary particles having an average particle size of 6 ?m to 15 ?m, with an overall average particle size of 5 ?m to 15 ?m; where the aluminum content of fine secondary particles (metal mole ratio: SA) is greater than the aluminum content of rough secondary particles (metal mole ratio: LA), and preferably the aluminum concentration ratio (SA/LA) is within the range 1.2 to 2.6.
    Type: Application
    Filed: February 6, 2018
    Publication date: June 7, 2018
    Applicants: SUMITOMO METAL MINING CO., LTD., TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Syuhei ODA, Hiroyuki TOYA, Katsuya KASE, Yutaka OYAMA
  • Patent number: 9947916
    Abstract: A non-aqueous electrolyte secondary battery is provided that has both good safety and durability characteristics while at the same time has high charge/discharge capacity. The cathode active material for a non-aqueous electrolyte secondary battery of the present invention is a lithium nickel composite oxide to which at least two or more kinds of metal elements including aluminum are added, and comprises secondary particles that are composed of fine secondary particles having an average particle size of 2 ?m to 4 ?m, and rough secondary particles having an average particle size of 6 ?m to 15 ?m, with an overall average particle size of 5 ?m to 15 ?m; where the aluminum content of fine secondary particles (metal mole ratio: SA) is greater than the aluminum content of rough secondary particles (metal mole ratio: LA), and preferably the aluminum concentration ratio (SA/LA) is within the range 1.2 to 2.6.
    Type: Grant
    Filed: February 9, 2011
    Date of Patent: April 17, 2018
    Assignees: SUMITOMO METAL MINING CO., LTD., TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Syuhei Oda, Hiroyuki Toya, Katsuya Kase, Yutaka Oyama
  • Patent number: 9876228
    Abstract: Process for manufacturing nickel-cobalt composite represented by Ni1?x?yCoxMnyMz(OH)2 (where, 0.05?x?0.95, 0?y?0.55, 0?z?0.1, x+y+z<1, and M is at least one metal-element selected from Al, Mg, and the like), includes: forming seed particle, while reaction solution having mixed solution containing metal compounds and ammonia solution containing ammonium ion supply source at discharge head of an impeller from 50-100 m2/s2, the concentration of nickel ions is maintained within range 0.1-5 ppm by mass, whereby seed particles are formed; and growing seed particle wherein solution is obtained by supplying mixed and ammonium solutions to reaction solution is agitated with a concentration of nickel ions being maintained within range 5-300 ppm by mass and higher than the concentration of nickel ions in seed particle formation, whereby seed particles are grown up.
    Type: Grant
    Filed: October 5, 2016
    Date of Patent: January 23, 2018
    Assignee: SUMITOMO METAL MINING CO., LTD.
    Inventors: Katsuya Kase, Yasutaka Kamata
  • Publication number: 20170324090
    Abstract: Provided is a nickel-containing composite hydroxide that is a precursor of a positive-electrode active material with which a nonaqueous-electrolyte secondary battery having a low irreversible capacity and a high energy density can be configured. An aqueous alkaline aqueous solution and a complexing agent are added to an mixed aqueous solution including at least nickel and cobalt to regulate the pH (measured at a reference liquid temperature of 25° C.) of this mixed aqueous solution to 11.0 to 13.0, the ammonium concentration to 4 to 15 g/L, and the reaction temperature to 20° C. to 45° C. Using stirring blades having an inclination angle of 20° to 60° with respect to a horizontal plane, the mixture is stirred to conduct a crystallization reaction under such conditions that when the nickel-containing composite hydroxide to be obtained is roasted in air at 800° C. for 2 hours, the roasted composite hydroxide has a BET value of 12 to 50 m2/g.
    Type: Application
    Filed: October 29, 2015
    Publication date: November 9, 2017
    Inventors: Kazuomi RYOSHI, Kensaku MORI, Katsuya KASE, Yasutaka KAMATA
  • Patent number: 9768444
    Abstract: A coated nickel hydroxide powder that has a cobalt compound coating having improved uniformity and adhesion properties on the surface of particles thereof and is therefore suitable for a positive electrode active material of an alkaline secondary battery is obtained by coating the surface of nickel hydroxide particles with a cobalt compound, and has a transmittance ratio of 30% or higher as determined by (A?Bmax)/(B0?Bmax). The transmittance A (coated nickel hydroxide powder), the transmittance B0 (nickel hydroxide powder), or the transmittance Bmax (nickel hydroxide powder and cobalt compound containing cobalt in an amount corresponding to the amount of cobalt contained in the coating) can be determined by measuring the transmittance of a tubular transparent cell after shaking the tightly-closed transparent cell containing each powder for a certain time and then taking the contents out of the transparent cell.
    Type: Grant
    Filed: October 12, 2013
    Date of Patent: September 19, 2017
    Assignee: Sumitomo Metal Mining Co., Ltd.
    Inventors: Katsuya Kase, Ryuichi Kuzuo, Minoru Shiraoka, Hideo Sasaoka
  • Publication number: 20170025679
    Abstract: Process for manufacturing nickel-cobalt composite represented by Ni1?x?yCoxMnyMz(OH)2 (where, 0.05?x?0.95, 0?y?0.55, 0?z?0.1, x+y+z<1, and M is at least one metal-element selected from Al, Mg, and the like), includes: forming seed particle, while reaction solution having mixed solution containing metal compounds and ammonia solution containing ammonium ion supply source at discharge head of an impeller from 50-100 m2/s2, the concentration of nickel ions is maintained within range 0.1-5 ppm by mass, whereby seed particles are formed; and growing seed particle wherein solution is obtained by supplying mixed and ammonium solutions to reaction solution is agitated with a concentration of nickel ions being maintained within range 5-300 ppm by mass and higher than the concentration of nickel ions in seed particle formation, whereby seed particles are grown up.
    Type: Application
    Filed: October 5, 2016
    Publication date: January 26, 2017
    Applicant: SUMITOMO METAL MINING CO., LTD.
    Inventors: Katsuya KASE, Yasutaka KAMATA
  • Patent number: 9553311
    Abstract: Provided is a cathode active material for a non-aqueous electrolyte secondary battery capable of obtaining high initial discharge capacity and good output characteristics at low temperature. In order to achieve this, a cathode active material that is a lithium nickel composite oxide composed of secondary particles that are an aggregate of primary particles is expressed by the general expression: Liw(Ni1-x-yCoxAly)1-zMzO2 (where 0.98?w?1.10, 0.05?x?0.3, 0.01?y?0.1, 0?z?0.05, and M is at least one metal element selected from a group consisting of Mg, Fe, Cu, Zn and Ga), and where the crystallite diameter at (003) plane of that lithium nickel composite oxide that is found by X-ray diffraction and the Scherrer equation is within the range of 1200 ? to 1600 ? is used as the cathode material.
    Type: Grant
    Filed: December 9, 2014
    Date of Patent: January 24, 2017
    Assignees: SUMITOMO METAL MINING CO., LTD, TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Katsuya Kase, Syuhei Oda, Ryuichi Kuzuo, Yutaka Oyama
  • Patent number: 9543580
    Abstract: Process for manufacturing nickel-cobalt composite represented by Ni1-x-yCoxMnyMz(OH)2 (where, 0.05?x?0.95, 0?y?0.55, 0?z?0.1, x+y+z<1, and M is at least one metal element selected from Al, Mg, and the like), includes: forming seed particle, while reaction solution having mixed solution containing metal compounds and ammonia solution containing ammonium ion supply source at discharge head of an impeller from 50-100 m2/s2, the concentration of nickel ions is maintained within range 0.1-5 ppm by mass, whereby seed particles are formed; and growing seed particle wherein solution is obtained by supplying mixed and ammonium solutions to reaction solution is agitated with a concentration of nickel ions being maintained within range 5-300 ppm by mass and higher than the concentration of nickel ions in seed particle formation, whereby seed particles are grown up.
    Type: Grant
    Filed: December 18, 2013
    Date of Patent: January 10, 2017
    Assignee: SUMITOMO METAL MINING CO., LTD.
    Inventors: Katsuya Kase, Yasutaka Kamata
  • Patent number: 9231250
    Abstract: The present invention provides nickel-cobalt-manganese composite hydroxide and a method for manufacturing same, the nickel-cobalt-manganese composite hydroxide as a precursor allowing a positive electrode active material having excellent battery characteristics and a high-density to be manufactured. The nickel-cobalt-manganese composite hydroxide is represented by a general formula: Ni1-x-y-zCoxMnyMz(OH)2 (wherein 0<x?1/3, 0<y?1/3, 0?z?0.1, and M is at least one element selected from Mg, Al, Ca, Ti, V, Cr, Zr, Nb, Mo, and W) and serves as a precursor of a positive electrode active material for nonaqueous electrolyte secondary batteries; wherein the specific surface area measured by a nitrogen adsorption BET method is 1.0 to 10.0 m2/g, the carbon content measured by a high frequency combustion infrared absorption method is not more than 0.1% by mass, and the half-value width of a plane in X-ray diffraction is not more than 1.5°.
    Type: Grant
    Filed: February 15, 2013
    Date of Patent: January 5, 2016
    Assignee: SUMITOMO METAL MINING CO., LTD.
    Inventors: Katsuya Kase, Yasutaka Kamata, Hideo Sasaoka, Tomomichi Nihei, Takuya Yamauchi
  • Publication number: 20150364759
    Abstract: Process for manufacturing nickel-cobalt composite represented by Ni1-x-yCoxMnyMz(OH)2 (where, 0.05?x?0.95, 0?y?0.55, 0?z?0.1, x+y+z<1, and M is at least one metal element selected from Al, Mg, and the like), includes: forming seed particle, while reaction solution having mixed solution containing metal compounds and ammonia solution containing ammonium ion supply source at discharge head of an impeller from 50-100 m2/s2, the concentration of nickel ions is maintained within range 0.1-5 ppm by mass, whereby seed particles are formed; and growing seed particle wherein solution is obtained by supplying mixed and ammonium solutions to reaction solution is agitated with a concentration of nickel ions being maintained within range 5-300 ppm by mass and higher than the concentration of nickel ions in seed particle formation, whereby seed particles are grown up.
    Type: Application
    Filed: December 18, 2013
    Publication date: December 17, 2015
    Inventors: Katsuya KASE, Yasutaka KAMATA
  • Publication number: 20150295231
    Abstract: Provided are a coated nickel hydroxide powder that has a cobalt compound coating having improved uniformity and adhesion properties on the surface of particles thereof and is therefore suitable for use as a positive electrode active material of alkaline secondary battery, and an evaluation method for the adhesion properties of the coating. The coated nickel hydroxide powder for a positive electrode active material of alkaline secondary battery is obtained by coating the surface of nickel hydroxide particles with a cobalt compound, and has a. transmittance ratio of 30% or higher as determined by (A?Bmax)/(B0?Bmax).
    Type: Application
    Filed: October 12, 2013
    Publication date: October 15, 2015
    Applicant: SUMITOMO METAL MINING CO., LTD.
    Inventors: Katsuya Kase, Ryuichi Kuzuo, Minoru Shiraoka, Hideo Sasaoka