Patents by Inventor Masaharu Senoue

Masaharu Senoue 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: 20240339627
    Abstract: A lithium-ion battery includes a positive electrode, a negative electrode, and a separator. The negative electrode forms a honeycomb core. The honeycomb core includes a first face, a second face, a partition, and a circumferential wall. The second face faces the first face. The partition is formed between the first face and the second face. The partition extends in a grid pattern to separate a plurality of hollow cells. The circumferential wall surrounds a circumference of the partition. The separator includes a first layer and a second layer. The first layer covers at least part of the partition. The second layer covers at least part of the first face and the second face. The positive electrode includes a first region and a second region. The first region is inserted in the hollow cells. The second region extends outwardly beyond the second layer of the separator.
    Type: Application
    Filed: June 21, 2024
    Publication date: October 10, 2024
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventor: Masaharu SENOUE
  • Patent number: 12057586
    Abstract: A battery includes a positive electrode, a negative electrode, and a separator. The negative electrode forms a honeycomb core. The honeycomb core includes a first face, a second face, a partition, and a circumferential wall. The second face faces the first face. The partition is formed between the first face and the second face. The partition extends in a grid pattern to separate a plurality of hollow cells. The circumferential wall surrounds a circumference of the partition. The separator includes a first layer and a second layer. The first layer covers at least part of the partition. The second layer covers at least part of the first face and the second face. The positive electrode includes a first region and a second region. The first region is inserted in the hollow cells. The second region extends outwardly beyond the second layer of the separator.
    Type: Grant
    Filed: July 1, 2021
    Date of Patent: August 6, 2024
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventor: Masaharu Senoue
  • Publication number: 20240250252
    Abstract: Disclosed is a negative electrode capable of improving cycle characteristics of a lithium-ion secondary battery. The negative electrode has the cross-sectional configuration comprising a negative electrode current collector, a plurality of first layers, and a second layer. Each of the first layers comprises a first negative electrode active material of at least one of elemental silicon, a silicon alloy, and a silicon oxide, and a first conductive material. The second layer comprises a second negative electrode active material of graphite and does not comprise silicon. In the cross-sectional configuration, the surface of one side of the negative electrode current collector has a plurality of first regions and a second region between the first regions, the first layers are in contact with the respective first regions, and the second layer is in contact with both the second region and surfaces of one side of the first layers.
    Type: Application
    Filed: December 18, 2023
    Publication date: July 25, 2024
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventor: Masaharu SENOUE
  • Publication number: 20240222679
    Abstract: The negative electrode forms a honeycomb core. The honeycomb core includes a first face, a second face, a partition, and a circumferential wall. The second face faces the first face. The partition is formed between the first face and the second face. In a cross section parallel to the first face, the partition separates a plurality of hollow cells. The separator includes a first layer. The first layer covers at least part of the partition. The cross section parallel to the first face includes a central part and an inner circumferential part. The central part is surrounded by the inner circumferential part. In the central part, the hollow cells have a first average filling factor. In the inner circumferential part, the hollow cells have a second average filling factor. The second average filling factor is 2.1 times or more the first average filling factor.
    Type: Application
    Filed: March 15, 2024
    Publication date: July 4, 2024
    Applicant: Toyota Jidosha Kabushiki Kaisha
    Inventor: Masaharu Senoue
  • Publication number: 20240195014
    Abstract: A battery includes a first electrode, a second electrode, and a separator. The first electrode includes a first main surface and a second main surface. A plurality of through holes is formed in the first electrode. The through holes penetrate the first electrode from the first main surface to the second main surface. The separator coats an inner wall of each of the through holes. The second electrode is disposed in the through holes. The separator includes a first layer and a second layer. The first layer is disposed between the inner wall and the second layer. The first layer contains a first inorganic particle group having a first average particle size. The second layer contains a second inorganic particle group having a second average particle size. The second average particle size is smaller than the first average particle size.
    Type: Application
    Filed: February 16, 2024
    Publication date: June 13, 2024
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventor: Masaharu SENOUE
  • Publication number: 20240170737
    Abstract: A lithium metal secondary battery comprises a positive electrode, a negative electrode, and an electrolyte. The negative electrode includes a negative electrode current collector and a pillar layer. The pillar layer is placed on a surface of the negative electrode current collector. The pillar layer includes a plurality of electrically-insulating pillars. Each of the plurality of electrically-insulating pillars extends in a direction heading from the surface of the negative electrode current collector toward the positive electrode. Lithium ions are dissolved in the electrolyte. A charging reaction of the negative electrode is a deposition reaction of a lithium metal occurring in a gap between the electrically-insulating pillars. A discharging reaction of the negative electrode is a dissolution reaction of the lithium metal occurring in the gap.
    Type: Application
    Filed: October 17, 2023
    Publication date: May 23, 2024
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Kohei MATSUNOBU, Masaharu SENOUE
  • Patent number: 11961953
    Abstract: The negative electrode forms a honeycomb core. The honeycomb core includes a first face, a second face, a partition, and a circumferential wall. The second face faces the first face. The partition is formed between the first face and the second face. In a cross section parallel to the first face, the partition separates a plurality of hollow cells. The separator includes a first layer. The first layer covers at least part of the partition. The cross section parallel to the first face includes a central part and an inner circumferential part. The central part is surrounded by the inner circumferential part. In the central part, the hollow cells have a first average filling factor. In the inner circumferential part, the hollow cells have a second average filling factor. The second average filling factor is 2.1 times or more the first average filling factor.
    Type: Grant
    Filed: June 29, 2021
    Date of Patent: April 16, 2024
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventor: Masaharu Senoue
  • Publication number: 20240097137
    Abstract: The battery includes a negative electrode composite material, a separator layer, a positive electrode composite material, a conductive layer, and a positive electrode current collector. A honeycomb structure of the negative electrode includes a first end surface, a second end surface, and a side wall. The side wall connects the first end surface and the second end surface. A plurality of through holes extending from the first end surface to the second end surface is formed. The separator layer covers at least a part of the inner wall of the through hole, and separates the positive electrode composite material from the negative electrode composite material. The positive electrode composite material is disposed inside the through hole. The conductive layer including a conductive material has a composition different from that of the positive electrode composite material, and connects the positive electrode composite material and the positive electrode current collector.
    Type: Application
    Filed: July 18, 2023
    Publication date: March 21, 2024
    Inventor: Masaharu SENOUE
  • Publication number: 20230246300
    Abstract: A battery includes a first electrode, a second electrode, and a separator. The first electrode includes a first main surface and a second main surface. A plurality of through holes is formed in the first electrode. The through holes penetrate the first electrode from the first main surface to the second main surface. The separator coats an inner wall of each of the through holes. The second electrode is disposed in the through holes. The separator includes a first layer and a second layer. The first layer is disposed between the inner wall and the second layer. The first layer contains a first inorganic particle group having a first average particle size. The second layer contains a second inorganic particle group having a second average particle size. The second average particle size is smaller than the first average particle size.
    Type: Application
    Filed: November 21, 2022
    Publication date: August 3, 2023
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventor: Masaharu SENOUE
  • Publication number: 20220336843
    Abstract: Provided is a honeycomb type lithium ion battery that makes it possible to suppress a short circuit. The honeycomb type lithium ion battery has an anode, a cathode, and a separator layer, wherein the anode has a plurality of through holes extending in one direction, the separator layer has Li ion permeability, and physically isolates the anode and the cathode from each other, at least inner walls of the through holes being covered with the separator layer, the cathode is disposed at least inside the through holes via the separator layer, the separator layer has a first layer with which the inner walls of the through holes are covered, and a second layer disposed between the first layer and the cathode, and the solubility of a binder contained in the first layer is lower than that contained in the second layer.
    Type: Application
    Filed: April 5, 2022
    Publication date: October 20, 2022
    Inventor: Masaharu SENOUE
  • Publication number: 20220311015
    Abstract: Provided is a honeycomb type lithium ion battery capable of suppressing short-circuiting due to cracks. The honeycomb type lithium ion battery has an anode, a cathode, and a separator layer, wherein the anode has a plurality of through holes extending in one direction, the separator layer has partition separator layers and insulating film separator layers, the cathode has inner areas disposed inside the through holes via the partition separator layers, intermediate areas disposed over faces of the inner areas and faces of the insulating film separator layers, and a surface area with which surfaces of the insulating film separator layers and the intermediate areas are covered, and the cathode contains a binder, wherein the proportion of the content of the binder in the surface area is high compared to the proportion of the content of the binder in the inner areas.
    Type: Application
    Filed: March 11, 2022
    Publication date: September 29, 2022
    Inventor: Masaharu SENOUE
  • Patent number: 11450890
    Abstract: A secondary battery made by laminating a separator layer and a second electrode to insides of a plurality of through holes of a first electrode, the first electrode having one face, an opposite face, a side face, and the through holes that penetrate from the one face to the opposite face, makes it possible to stably collect currents for the second electrode, and gives good cycle characteristics as a secondary battery.
    Type: Grant
    Filed: January 22, 2020
    Date of Patent: September 20, 2022
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventor: Masaharu Senoue
  • Patent number: 11424479
    Abstract: The solid electrolyte layer of the all-solid-state battery disclosed herein includes insulating inorganic filler particles (hollow particles) having a hollow shape at least before the initial charging. Preferably, Fs/Ns which is the ratio of an average particle diameter (Fs) of the filler particles to an average particle diameter (Ns) of the negative electrode active material is 0.25 or less at least before the initial charging. Also, preferably, Fp/Nv which is the ratio of a hollow volume (Fp) created by the hollow particles included in the solid electrolyte layer per unit area before the initial charging to an expansion volume (Nv), which is a difference between a volume after full charging and a volume before the initial charging in the negative electrode active material layer per unit area, is at least 0.1.
    Type: Grant
    Filed: March 27, 2019
    Date of Patent: August 23, 2022
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventor: Masaharu Senoue
  • Publication number: 20220181701
    Abstract: Provided are a honeycomb type lithium ion battery capable of suppressing the DC resistance, and a method of manufacturing this honeycomb type lithium ion battery. The honeycomb type lithium ion battery has an anode, a cathode, and separator layers, wherein the anode has a plurality of through holes extending in one direction, the separator layers have Li ion permeability, the separator layers being at least disposed on inner walls of the through holes to physically isolate the anode and the cathode from each other, and the cathode is disposed inside the through holes at least via the separator layers, the cathode containing a rod-like conductive additive, the rod-like conductive additive being oriented in a penetrating direction of the through holes.
    Type: Application
    Filed: November 22, 2021
    Publication date: June 9, 2022
    Inventor: Masaharu SENOUE
  • Publication number: 20220006113
    Abstract: The negative electrode forms a honeycomb core. The honeycomb core includes a first face, a second face, a partition, and a circumferential wall. The second face faces the first face. The partition is formed between the first face and the second face. In a cross section parallel to the first face, the partition separates a plurality of hollow cells. The separator includes a first layer. The first layer covers at least part of the partition. The cross section parallel to the first face includes a central part and an inner circumferential part. The central part is surrounded by the inner circumferential part. In the central part, the hollow cells have a first average filling factor. In the inner circumferential part, the hollow cells have a second average filling factor. The second average filling factor is 2.1 times or more the first average filling factor.
    Type: Application
    Filed: June 29, 2021
    Publication date: January 6, 2022
    Inventor: Masaharu Senoue
  • Publication number: 20220006095
    Abstract: A battery includes a positive electrode, a negative electrode, and a separator. The negative electrode forms a honeycomb core. The honeycomb core includes a first face, a second face, a partition, and a circumferential wall. The second face faces the first face. The partition is formed between the first face and the second face. The partition extends in a grid pattern to separate a plurality of hollow cells. The circumferential wall surrounds a circumference of the partition. The separator includes a first layer and a second layer. The first layer covers at least part of the partition. The second layer covers at least part of the first face and the second face. The positive electrode includes a first region and a second region. The first region is inserted in the hollow cells. The second region extends outwardly beyond the second layer of the separator.
    Type: Application
    Filed: July 1, 2021
    Publication date: January 6, 2022
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventor: Masaharu SENOUE
  • Patent number: 11075366
    Abstract: Disclosed is a sulfide solid-state battery produced via a first step of doping at least one material selected from graphite and lithium titanate with lithium, to obtain a predoped material; a second step of mixing the sulfide solid electrolyte, the silicon-based active material, and the predoped material, to obtain the anode mixture; and a third step of layering the anode mixture over the surface of the anode current collector that contains copper, to obtain the anode.
    Type: Grant
    Filed: November 6, 2018
    Date of Patent: July 27, 2021
    Assignee: Toyota Jidosha Kabushiki Kaisha
    Inventor: Masaharu Senoue
  • Patent number: 10998540
    Abstract: A method for producing a sulfide solid-state battery in which, an anode mixture (a) is layered over a surface of an anode current collector, to form an anode mixture layer A1, the anode mixture (a) containing a polyamic acid, and silicon-based active material but not containing a sulfide solid electrolyte; the anode mixture layer A1 is heated to imidize the polyamic acid, to make an anode mixture layer A2; a sulfide solid electrolyte is layered over a surface of the anode mixture layer A2; to be pressed to insert the sulfide solid electrolyte into a void in the anode mixture layer A2, to make an anode mixture layer A3; and thereafter an anode mixture (b) is layered over a surface of the anode mixture layer A3, to form an anode mixture layer B, the anode mixture (b) containing carbonaceous active material and binder.
    Type: Grant
    Filed: November 21, 2018
    Date of Patent: May 4, 2021
    Assignee: Toyota Jidosha Kabushiki Kaisha
    Inventor: Masaharu Senoue
  • Patent number: 10826073
    Abstract: A separator layer of the all-solid-state battery disclosed herein has a protruding portion protruding outward beyond end portions of opposed portions of a positive electrode and a negative electrode, and at least a part of the protruding portion layer is formed of a dense structure portion that is dense enough to prevent contact between the positive electrode and the negative electrode. The dense structure portion is formed at a position satisfying A<B, where A denotes a shortest distance from the end portion of the opposed portions of the positive electrode and the negative electrode to the dense structure portion, and B denotes a shortest distance from a surface of the negative electrode active material layer at the end portion of the opposed portions of the positive electrode and the negative electrode to the positive electrode current collector at the end portion of the opposed portions.
    Type: Grant
    Filed: March 27, 2019
    Date of Patent: November 3, 2020
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventor: Masaharu Senoue
  • Publication number: 20200243897
    Abstract: A secondary battery made by laminating a separator layer and a second electrode to insides of a plurality of through holes of a first electrode, the first electrode having one face, an opposite face, a side face, and the through holes that penetrate from the one face to the opposite face, makes it possible to stably collect currents for the second electrode, and gives good cycle characteristics as a secondary battery.
    Type: Application
    Filed: January 22, 2020
    Publication date: July 30, 2020
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventor: Masaharu Senoue