Patents by Inventor Kazuo Katai

Kazuo Katai 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: 7507435
    Abstract: An electrode production method has an active-material-containing layer forming step of applying an electrode-forming coating solution containing an electrode active material, a binder capable of binding the electrode active material, and a liquid capable of dissolving or dispersing the binder, onto a collector sheet, and thereafter removing the liquid to form an active-material-containing layer on the collector, thereby obtaining a electrode sheet; and an electrode forming step of cutting the electrode sheet with a slitter apparatus to obtain an electrode.
    Type: Grant
    Filed: June 27, 2005
    Date of Patent: March 24, 2009
    Assignee: TDK Corporation
    Inventors: Kazuo Katai, Yousuke Miyaki, Seiichi Endo
  • Publication number: 20080311476
    Abstract: An electrode has a current collector, and an active material-containing layer provided on the current collector and containing active material particles and ceramic particles, and a weight concentration of the ceramic particles to the active material particles in a surface part in the active material-containing layer on the opposite side to the current collector is higher than a weight concentration of the ceramic particles to the active material particles in a lower part in the active material-containing layer on the current collector side. Furthermore, the thickness of the surface part is not less than 30% nor more than 60% of the total thickness of the surface part and the lower part.
    Type: Application
    Filed: March 26, 2008
    Publication date: December 18, 2008
    Applicant: TDK CORPORATION
    Inventors: Kazuo KATAI, Yousuke MIYAKI, Kiyonori HINOKI, Tadashi SUZUKI
  • Publication number: 20080295765
    Abstract: A liquid applicator comprises a guide roll for guiding a sheet, and a slit die, having a slit with an opening extending in an axial direction of the guide roll, for applying a liquid to a surface of the sheet guided by the guide roll. On the rear side of the opening in a rotating direction of the guide roll, the slit die further includes a front lip having a concave surface corresponding to the guide roll. The front lip opposes the guide roll by such a length FA in the rotating direction RD of the guide roll as to have a central angle ? of 0.95° to 3.0° about an axis O of the guide roll.
    Type: Application
    Filed: May 19, 2008
    Publication date: December 4, 2008
    Applicant: TDK CORPORATION
    Inventors: Kazutoshi EMOTO, Kazuo KATAI, Kiyonori HINOKI, Yousuke MIYAKI
  • Publication number: 20080248387
    Abstract: An anode is provided as one capable of suppressing rapid entrance/exit of lithium ions during quick charge-discharge and ensuring sufficient safety in use as an anode of a lithium-ion secondary battery. The anode is an anode for lithium-ion secondary battery having a current collector, and an active material-containing layer formed on the current collector, wherein the active material-containing layer is comprised of an outermost layer disposed on the farthest side from the current collector, and a lower layer composed of at least one layer disposed between the outermost layer and the current collector, and wherein a degree of flexion of the outermost layer is larger than a degree of flexion of the lower layer.
    Type: Application
    Filed: March 24, 2008
    Publication date: October 9, 2008
    Applicant: TDK CORPORATION
    Inventors: Kiyonori Hinoki, Yousuke Miyaki, Kazuo Katai
  • Publication number: 20080241685
    Abstract: An anode for lithium-ion secondary battery is provided as one capable of ensuring sufficient safety (suppression of dendrites) while achieving a higher capacity (higher density of the electrode), and permitting formation of a lithium-ion secondary battery with excellent high-rate discharge performance. An anode for lithium-ion secondary battery has a current collector, and an active material-containing layer formed on the current collector, the active material-containing layer is comprised of an outermost layer disposed on the farthest side from the current collector, and a lower layer composed of at least one layer disposed between the outermost layer and the current collector, and a degree of flexion of the outermost layer is smaller than that of the lower layer.
    Type: Application
    Filed: March 21, 2008
    Publication date: October 2, 2008
    Applicant: TDK Corporation
    Inventors: Kiyonori Hinoki, Yousuke Miyaki, Kazuo Katai
  • Publication number: 20080241696
    Abstract: An electrode is provided as one capable of adequately maintaining voids in a surface layer and an electrochemical device is provided as one using the electrode. The electrode has a current collector, and an active material-containing layer provided on the current collector and containing active material particles, the number of peaks in a particle size distribution of the active material particles in a lower part on the current collector side in the active material-containing layer is larger than the number of peaks in a particle size distribution of the active material particles in a surface part on the opposite side to the current collector in the active material-containing layer, and a thickness of the lower part is not less than 50% nor more than 90% of a total thickness of the surface part and the lower part.
    Type: Application
    Filed: March 21, 2008
    Publication date: October 2, 2008
    Applicant: TDK CORPORATION
    Inventors: Kiyonori HINOKI, Yousuke MIYAKI, Kazuo KATAI
  • Patent number: 7307831
    Abstract: A method of manufacturing an electrode includes a preparatory step of preparing an electrode matrix comprising a collector and an active material containing layer formed on at least one face of the collector, at least one edge part of the collector including an exposed surface free of the active material containing layer, an edge part of the active material containing layer on a side close to the exposed surface including a thinner part having a thickness smaller than a maximum thickness of the active material containing layer; and a roll-pressing step of pressing the electrode matrix with a roll press.
    Type: Grant
    Filed: July 5, 2005
    Date of Patent: December 11, 2007
    Assignee: TDK Corporation
    Inventors: Hideki Tanaka, Yousuke Miyaki, Kazuo Katai, Kiyonori Hinoki
  • Patent number: 7256099
    Abstract: A first electrode and a second electrode to be used are electrodes each of which has a collector, and a porous material layer with electron conductivity placed between the collector and a separator, and each of which has a configuration wherein the porous material layer includes at least particles of a porous material with electron conductivity, and a thermoplastic resin being capable of binding the particles of the porous material together and having a softening point TB lower than a softening point TS of the separator. A production method includes a thermal treatment step of thermally treating a laminate at a thermal treatment temperature T1 satisfying a condition represented by Formula (1): TB?T1<TS, thereby bringing the collector of the first electrode, the porous material layer of the first electrode, the separator, the porous material layer of the second electrode, and the collector of the second electrode in the laminate into an integrated state.
    Type: Grant
    Filed: November 18, 2004
    Date of Patent: August 14, 2007
    Assignee: TDK Corporation
    Inventors: Tetsuya Takahashi, Kazuo Katai, Yousuke Miyaki
  • Patent number: 7251122
    Abstract: An electric chemical capacitor includes first and second electrodes each including a collector 111, 121, a polarized electrode layer 112, 122 and an undercoat layer 113, 123 for bonding the collector and the polarized electrode layer with each other, and a separator put between the first and second electrodes so that the polarized electrode layers 112 and 122 face each other, wherein an end portion of each undercoat layer 113, 123 is located in the same position as or on the outer side of an end portion of the corresponding polarized electrode layer 112, 122, and located on the inner side of an end portion of the separator 130. Thus, the polarized electrode layers can be prevented from peeling from the collector. Further, the undercoat layers can be prevented from abutting against each other, and the undercoat layer of one electrode and the collector of the other electrode can be prevented from abutting against each other.
    Type: Grant
    Filed: December 21, 2004
    Date of Patent: July 31, 2007
    Assignee: TDK Corporation
    Inventors: Kiyonori Hinoki, Yousuke Miyaki, Kazuo Katai, Hideki Tanaka, Tsuyoshi Ichiki
  • Publication number: 20070148335
    Abstract: An apparatus comprises a coating portion which forms, on a collector, a coated film comprising porous particles, a binder which binds the porous particles, and a solvent which dissolves the binder, a hot-air drying portion which forms a polarizable electrode layer by hot-air drying of the coated film, and an infrared ray drying portion which performs infrared ray drying of the polarizable electrode layer. By this means, solvent remaining after hot-air drying can be efficiently removed. Hence hot-air drying can be performed gently, and as a result, binder movement and similar can be prevented. Moreover, because infrared ray irradiation is performed in a state in which drying has been performed to some extent, bumping of solvent does not occur.
    Type: Application
    Filed: December 26, 2006
    Publication date: June 28, 2007
    Applicant: TDK CORPORATION
    Inventors: Hideki Tanaka, Kazuo Katai
  • Patent number: 7236349
    Abstract: The present invention is an electrode for an electrochemical capacitor provided with a collector having electronic conductivity and a porous body layer having electronic conductivity, the porous body layer containing porous particles having electronic conductivity and a binder which is able to bind the porous particles with one another, wherein the content of the porous particles in the porous body layer is in a range from 88 to 92% by mass on the basis of the total amount of the porous body layer, and the porous body layer has an apparent density in a range from 0.62 to 0.70 g/cm3.
    Type: Grant
    Filed: November 18, 2004
    Date of Patent: June 26, 2007
    Assignee: TDK Corporation
    Inventors: Yousuke Miyaki, Kazuo Katai, Hideki Tanaka, Kiyonori Hinoki
  • Publication number: 20070059869
    Abstract: A manufacturing method for an electrode for an electrochemical capacitor according to the present invention comprises a first process (steps S1-S3) for forming a polarizable electrode layer on a current collector, a second process (step S4) for subjecting the front surface of the polarizable electrode layer formed on the current collector, to an embossment work, and a third process (step S5) for flattening the front surface of the polarizable electrode layer as has undergone the embossment work. In this manner, in the invention, the front surface of the polarizable electrode layer undergoes the embossment work, so that the polarizable electrode layer is effectively compressed, and it is consequently permitted to achieve a high volume capacitance of at least 17 F/cm3. Moreover, after the embossment work, the resulting embossment is flattened, so that porous grains contained in the polarizable electrode layer are prevented from falling off, and it is permitted to ensure a high reliability.
    Type: Application
    Filed: October 31, 2006
    Publication date: March 15, 2007
    Applicant: TDK Corporation
    Inventors: Kiyonori Hinoki, Kazuo Katai, Yousuke Miyaki, Hideki Tanaka
  • Patent number: 7173806
    Abstract: An electrode for an electrochemical capacitor includes a sheet-like current collector and a polarizable electrode layer. The polarizable electrode layer is provided on the current collector with a predetermined bare portion left. The polarizable electrode layer has undergone an embossment work and at least part of the bare portion of the current collector has not undergone any embossment work.
    Type: Grant
    Filed: December 21, 2004
    Date of Patent: February 6, 2007
    Assignee: TDK Corporation
    Inventors: Kiyonori Hinoki, Kazuo Katai, Yosuke Miyaki, Hideki Tanaka
  • Publication number: 20070025062
    Abstract: A method is provided for enhancing the bond between the polarizable electrode layer and the undercoat layer. The method includes a first step for forming an undercoat layer on a collector and a second step for forming a polarizable electrode layer on said undercoat layer. The first step is performed by coating said collector with a coating solution for the undercoat layer that includes electroconductive particles, a first binder, and a first solvent. The second step is performed by coating said undercoat layer with a coating solution for the polarizable electrode layer that includes porous particles, a second binder, and a second solvent. The first solvent can dissolve or disperse said first and second binders. The second solvent can dissolve or disperse said first and second binders. The fusion of the interface between the undercoat layer and the polarizable electrode layer enhances the bond therebetween.
    Type: Application
    Filed: May 16, 2006
    Publication date: February 1, 2007
    Applicants: TDK Corporation, Honda Motor Co., Ltd.
    Inventors: Yousuke Miyaki, Kazuo Katai, Hitoshi Maro, Shigeki Oyama, Manabu Iwaida
  • Patent number: 7046503
    Abstract: The present invention provides an electrode for an electric double layer capacitor which enhances an adhesive property between an electrode layer and an etched aluminum foil current collector. An electrode for a capacitor, includes a current collector, an undercoat layer on the current collector, and an electrode layer on the undercoat layer, wherein the current collector is made of an aluminum foil; the undercoat layer includes at least electrically conductive particles (P) and a binder (B) in a weight ratio P/B of 0.25 to 2.33, and the binder (B) includes a fluorine-containing polymer as a main component; and the electrode layer includes at least a carbon material and a binder.
    Type: Grant
    Filed: December 21, 2004
    Date of Patent: May 16, 2006
    Assignee: TDK Corporation
    Inventors: Kiyonori Hinoki, Yousuke Miyaki, Kazuo Katai, Katsuo Naoi, Eiji Horigome, Yuukichi Morita
  • Patent number: 6995970
    Abstract: The method of making an electrochemical capacitor electrode in accordance with the present invention comprises a coating liquid preparing step of preparing a porous layer forming coating liquid containing a solid component including a porous particle having an electronic conductivity and a binder adapted to bind the porous particle, a liquid adapted to dissolve or disperse the binder, and an aggregate made of the solid component, such that the aggregate has a degree of dispersion of 10 to 200 ?m in the coating liquid; a porous layer forming step of applying the porous layer forming coating liquid onto a surface of a collector and then removing the liquid so as to form a porous layer; and a pressing step of pressing the aggregate against the collector by pressing the collector and the porous layer, so as to form a depression and a projection on the surface of the collector formed with the porous layer.
    Type: Grant
    Filed: December 22, 2004
    Date of Patent: February 7, 2006
    Assignee: TDK Corporation
    Inventors: Kazuo Katai, Yousuke Miyaki, Hideki Tanaka, Kiyonori Hinoki
  • Publication number: 20060016308
    Abstract: A slitter apparatus has a rotary shaft provided with one or more upper blades, and a rotary shaft provided with one or more lower blades, the rotary shafts being arranged in parallel with each other and at such a spacing as to achieve a predetermined engagement depth with contact between side face of peripheral part of upper blades and side face of peripheral part of lower blades, wherein a thickness of upper blades is not less than 1 mm, an included angle of upper blades is in a range of 75 to 88°, hardnesses of upper blades and lower blades are in a range of 6.9×103 to 8.8×103 N/mm2, a difference between the hardness of upper blades and the hardness of lower blades is not more than 4.9×102 N/mm2, surface roughnesses of upper blades and lower blades are not more than 4 ?m, and a difference between the surface roughness of upper blades and the surface roughness of lower blades is not more than 2 ?m.
    Type: Application
    Filed: June 27, 2005
    Publication date: January 26, 2006
    Applicant: TDK CORPORATION
    Inventors: Kazuo Katai, Yousuke Miyaki, Seiichi Endo
  • Publication number: 20060006063
    Abstract: A method of manufacturing an electrode includes a preparatory step of preparing an electrode matrix comprising a collector and an active material containing layer formed on at least one face of the collector, at least one edge part of the collector including an exposed surface free of the active material containing layer, an edge part of the active material containing layer on a side close to the exposed surface including a thinner part having a thickness smaller than a maximum thickness of the active material containing layer; and a roll-pressing step of pressing the electrode matrix with a roll press.
    Type: Application
    Filed: July 5, 2005
    Publication date: January 12, 2006
    Applicant: TDK CORPORATION
    Inventors: Hideki Tanaka, Yousuke Miyaki, Kazuo Katai, Kiyonori Hinoki
  • Publication number: 20050214647
    Abstract: The present invention is an electrode manufacturing method comprising a cutting step wherein an electrode sheet formed by an active substance-containing layer on a charge collector is cut to obtain an electrode element which is part of the electrode sheet, and a heating/pressurizing step which gives heating/pressurizing treatment to at least the edge part of the active substance-containing layer in the electrode element.
    Type: Application
    Filed: March 24, 2005
    Publication date: September 29, 2005
    Applicant: TDK CORPORATION
    Inventors: Hideki Tanaka, Kazuo Katai, Yousuke Miyaki, Kiyonori Hinoki
  • Publication number: 20050204527
    Abstract: The present invention provides a method of producing an electrode for electric double layer capacitor, which yields the electrode having excellent electrode characteristics with good production suitability, using a coating material exhibiting a good dispersion state. A method of producing an electrode for a capacitor, the method comprising the steps of: applying an undercoat layer coating material which comprises at least electrically conductive particles, a binder and a solvent onto the current collector to form the undercoat layer; and applying an electrode layer coating material which comprises at least a carbon material, a binder and a solvent onto the undercoat layer to form the electrode layer. In the preparation of the undercoat layer coating material and/or in the preparation of the electrode layer coating material, dispersing treatment is conducted with ceramic beads as a dispersing medium.
    Type: Application
    Filed: December 21, 2004
    Publication date: September 22, 2005
    Applicant: TDK Corporation
    Inventors: Kiyonori Hinoki, Kazuo Katai, Yousuke Miyaki, Hideki Tanaka, Tadashi Suzuki