Patents by Inventor Toshitada Sato

Toshitada Sato 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: 7914930
    Abstract: A non-aqueous electrolyte secondary battery having both high capacity and long-life is provided by solving the problem of the large irreversible capacity of a negative electrode active material. The non-aqueous electrolyte secondary battery is produced by a method including the steps of: reacting lithium with a negative electrode active material by bringing a metal film that is composed mainly of lithium into contact with a surface of a negative electrode active material layer; and thereafter combining the negative electrode with a positive electrode to form an electrode assembly. The metal film composed mainly of lithium is preferably formed on a carrier that does not chemically react with lithium, and the metal film on the carrier is preferably brought into contact with the negative electrode active material layer while heating and applying a pressure thereto.
    Type: Grant
    Filed: November 16, 2006
    Date of Patent: March 29, 2011
    Assignee: Panasonic Corporation
    Inventors: Toshitada Sato, Hideharu Takezawa, Syoichi Imashiku, Kazuyoshi Honda
  • Patent number: 7862930
    Abstract: A negative electrode for a lithium ion battery with high capacity, excellent cycle performance, and discharge performance at high load. In the negative electrode for a lithium ion secondary battery including a current collector and an active material layer carried on the current collector: the active material layer includes silicon, and an element M incapable of forming an alloy with lithium; the proportion of element M is higher in a first side contacting the current collector than in a second side opposite to the first side, in the thickness direction of the active material layer; the element M is different from the element forming the current collector; and the active material layer does not include a binder.
    Type: Grant
    Filed: March 17, 2006
    Date of Patent: January 4, 2011
    Assignee: Panasonic Corporation
    Inventors: Yasutaka Kogetsu, Toshitada Sato
  • Patent number: 7858232
    Abstract: A non-aqueous electrolyte secondary battery that has a high electrical capacity and exhibits excellent cycle characteristics even when the battery is rapidly charged and discharged at a large current includes: a positive electrode capable of reversibly absorbing and desorbing Li; a negative electrode; and a non-aqueous electrolyte. The negative electrode includes an alloying material that is capable of electrochemically absorbing and desorbing Li, and includes an A phase composed mainly of Si and a B phase including an intermetallic compound of at least one transition metal element and Si. The transition metal element is selected from the group consisting of Ti, Zr, Ni, Cu, and Fe. At least one of the A phase and the B phase includes a microcrystalline or amorphous region. The weight percent of the A phase relative to the total weight of the A phase and the B phase is greater than 40% and not greater than 95%.
    Type: Grant
    Filed: November 9, 2005
    Date of Patent: December 28, 2010
    Assignee: Panasonic Corporation
    Inventors: Yasuhiko Bito, Toshitada Sato, Teruaki Yamamoto, Tomohiro Ueda
  • Patent number: 7824801
    Abstract: A negative electrode for a lithium ion secondary battery including a current collector and an active material layer carried on the current collector, wherein the active material layer includes a first layer and a second layer alternately laminated in a thickness direction of the active material layer, and wherein the first layer includes silicon or silicon and a small amount of oxygen and the second layer includes silicon and a larger amount of oxygen than the first layer. With the use of the negative electrode, it is possible to provide a high capacity lithium ion secondary battery having excellent high rate charge/discharge characteristics and superior cycle characteristics.
    Type: Grant
    Filed: December 13, 2005
    Date of Patent: November 2, 2010
    Assignee: Panasonic Corporation
    Inventors: Yasutaka Kogetsu, Kazuyoshi Honda, Toshitada Sato, Hiroshi Yoshizawa
  • Patent number: 7807294
    Abstract: A negative electrode for a non-aqueous electrolyte secondary battery, including: an active material layer capable of electrochemically absorbing and desorbing at least Li; and a current collector sheet that supports the active material layer thereon and that does not react with Li, wherein the active material layer includes a plurality of deposited films or sintered films supported on a surface of the current collector sheet, and each of the deposited films or sintered films is provided with at least one groove formed in a side surface thereof, the groove extending from a top surface side towards the current collector sheet side thereof. It is preferable that the plurality of deposited films or sintered films are arranged in a grid configuration, a staggered grid configuration or a honeycomb configuration on a surface of the current collector sheet.
    Type: Grant
    Filed: September 14, 2005
    Date of Patent: October 5, 2010
    Assignee: Panasonic Corporation
    Inventors: Toshitada Sato, Yasutaka Kogetsu, Hiroshi Yoshizawa
  • Publication number: 20100216033
    Abstract: A negative electrode material for non-aqueous electrolyte secondary batteries, characterized in that the negative electrode material comprises a composite particle including solid phases A and B, the solid phase A being dispersed in the solid phase B, and the ratio (IA/IB) of the maximum diffracted X-ray intensity (IA) attributed to the solid phase A to the maximum diffracted X-ray intensity (IB) attributed to the solid phase B satisfies 0.001?IA/IB?0.1, in terms of a diffraction line obtained by a wide-angle X-ray diffraction measurement of the composite particle.
    Type: Application
    Filed: May 6, 2010
    Publication date: August 26, 2010
    Applicant: Panasonic Corporation
    Inventors: Harunari SHIMAMURA, Toshitada Sato, Takayuki Nakamoto, Yasuhiko Bito, Yoshiaki Nitta
  • Publication number: 20100196623
    Abstract: The present invention provides a film forming method and a film forming apparatus each of which is capable of forming films at low cost. The film forming method of the present invention includes the steps of (i) melting a solid material 51 of a thin film to prepare a melted liquid, solidifying the melted liquid 51a to form a rod-shaped body 51b, and pulling out the rod-shaped body 51b, (ii) melting and supplying a part of the rod-shaped body 51b to a melted liquid (evaporation source) 51d, and (iii) using the melted liquid (evaporation source) 51d to form the thin film. The steps (i), (ii), and (iii) are carried out in vacuum.
    Type: Application
    Filed: September 9, 2008
    Publication date: August 5, 2010
    Inventors: Kazuyoshi Honda, Yuma Kamiyama, Kunihiko Bessho, Tomofumi Yanagi, Yasuharu Shinokawa, Toshitada Sato
  • Patent number: 7754390
    Abstract: A negative electrode for a nonaqueous electrolytic rechargeable battery capable of storing and discharging lithium ions is manufactured in the steps of forming a lithium metal layer on a carrier substrate by a gas phase method, superimposing the surface of the lithium metal layer formed on the carrier substrate on a negative electrode active material layer formed on a collecting body, storing the lithium metal layer into the negative electrode active material layer in nonaqueous electrolyte, and removing the carrier substrate from the negative electrode active material layer.
    Type: Grant
    Filed: February 21, 2007
    Date of Patent: July 13, 2010
    Assignee: Panasonic Corporation
    Inventors: Hideharu Takezawa, Toshitada Sato
  • Publication number: 20100167112
    Abstract: A lithium ion secondary battery including: a positive electrode current collector; a positive electrode active material layer that is provided in contact with the positive electrode current collector; a separator layer that is provided on a side of the positive electrode active material layer on which the positive electrode current collector is not provided; a negative electrode active material layer that is provided on a side of the separator layer on which the positive electrode active material layer is not provided, that primarily contains silicon or tin, and that includes a opposing portion opposing the positive electrode active material layer and a non-opposing portion not opposing the positive electrode active material layer, the opposing portion and the non-opposing portion containing lithium produced by a thin film-forming method; and a negative electrode current collector that is provided on a side of the negative electrode active material layer on which the separator layer is not provided.
    Type: Application
    Filed: July 18, 2008
    Publication date: July 1, 2010
    Inventors: Kazuyoshi Honda, Toshitada Sato, Daisuke Suetsugu, Katsumi Kashiwagi, Kunihiko Bessho
  • Publication number: 20100151329
    Abstract: A method of manufacturing a negative electrode includes: a first step of forming a plurality of columnar active material blocks capable of electrochemically storing and releasing lithium ions on the surface of a current collector; and a second step of disposing particulate lithium in the gaps between the active material blocks.
    Type: Application
    Filed: September 25, 2007
    Publication date: June 17, 2010
    Inventors: Toshitada Sato, Kazuyoshi Honda
  • Publication number: 20100151322
    Abstract: Disclosed is a method for producing a negative electrode for nonaqueous electrolyte batteries, which comprises the following three steps: (A) a step for forming a negative electrode by depositing a negative electrode active material on a collector; (B) a step for subjecting the negative electrode to a heat treatment; and (C) a step for providing the negative electrode active material with lithium after the step (B).
    Type: Application
    Filed: October 11, 2007
    Publication date: June 17, 2010
    Inventors: Toshitada Sato, Daisuke Suetsugu, Katsumi Kashiwagi, Kazuyoshi Honda
  • Patent number: 7736806
    Abstract: A negative electrode material for non-aqueous electrolyte secondary batteries, characterized in that the negative electrode material comprises a composite particle including solid phases A and B, the solid phase A being dispersed in the solid phase B, and the ratio (IA/IB) of the maximum diffracted X-ray intensity (IA) attributed to the solid phase A to the maximum diffracted X-ray intensity (IB) attributed to the solid phase B satisfies 0.001?IA/IB?0.1, in terms of a diffraction line obtained by a wide-angle X-ray diffraction measurement of the composite particle.
    Type: Grant
    Filed: March 17, 2003
    Date of Patent: June 15, 2010
    Assignee: Panasonic Corporation
    Inventors: Harunari Shimamura, Toshitada Sato, Takayuki Nakamoto, Yasuhiko Bito, Yoshiaki Nitta
  • Publication number: 20100112451
    Abstract: A negative electrode 100 for a nonaqueous electrolytic secondary cell includes a current collector 1 and a plurality of active material bodies 2 formed on a surface of the current collector 1 at intervals; each active material body 2 contains a material for occluding or releasing lithium; and a plurality of projections 3 are formed on a part of a side surface of each active material body 2.
    Type: Application
    Filed: October 9, 2007
    Publication date: May 6, 2010
    Inventors: Satoshi Shibutani, Hideharu Takezawa, Kazuyoshi Honda, Toshitada Sato
  • Patent number: 7638239
    Abstract: In a negative electrode for a non-aqueous electrolyte secondary battery including an active material portion capable of electrochemically absorbing and desorbing Li, a current collector carrying the active material portion, and a buffer interposed between the active material portion and the current collector, the active material portion includes at least one selected from the group consisting of a Si simple substance, a Si alloy, and a Si compound, the current collector includes Cu, and the buffer has a first layer contacting the current collector and including a group A element which is at least one selected from the group A consisting of Sn, Al, and In, and a second layer contacting the active material portion and including a group B element which is at least one selected from the group B consisting of transition metal elements other than Cu.
    Type: Grant
    Filed: November 30, 2005
    Date of Patent: December 29, 2009
    Assignee: Panasonic Corporation
    Inventors: Toshitada Sato, Yasutaka Kogetsu, Hiroshi Yoshizawa
  • Patent number: 7635540
    Abstract: A negative electrode containing an alloying material and a graphite material for providing a non-aqueous electrolyte secondary battery with a high capacity and excellent cycle characteristics. The negative electrode includes graphite and an alloying material capable of electrochemically absorbing and desorbing Li. The alloying material includes an A phase composed mainly of Si and a B phase including an intermetallic compound of a transition metal element and Si. The A phase and/or the B phase include a microcrystalline or amorphous region. The weight percentage of the A phase relative to the total weight of the A phase and the B phase is greater than 40% and not greater than 95%. The weight percentage of the graphite relative to the total weight of the alloying material and the graphite is not less than 50% and not greater than 95%.
    Type: Grant
    Filed: May 2, 2005
    Date of Patent: December 22, 2009
    Assignee: Panasonic Corporation
    Inventors: Toshitada Sato, Masaki Hasegawa, Teruaki Yamamoto, Yasuhiko Bito
  • Patent number: 7597997
    Abstract: A nonaqueous electrolyte secondary battery with excellent charging/discharging cycle characteristics is provided, more specifically a nonaqueous electrolyte secondary battery in which deterioration of the conductivity of a negative electrode due to charging/discharging cycle is suppressed and a method for manufacturing the same are provided. The nonaqueous electrolyte secondary battery includes: a positive electrode and a negative electrode that are capable of reversibly absorbing and desorbing Li ions; and a nonaqueous electrolyte having lithium ion conductivity. The negative electrode includes a collector and active material particles that are disposed on a surface of the collector. The active material particles include Si and at least one element R selected from the group consisting of Sn, In, Ga, Pb and Bi. Metallic bond including the element R is formed between the active material particles.
    Type: Grant
    Filed: May 21, 2004
    Date of Patent: October 6, 2009
    Assignee: Panasonic Corporation
    Inventors: Toshitada Sato, Harunari Shimamura, Hideaki Ohyama, Yasuhiko Bito
  • Patent number: 7537862
    Abstract: A negative electrode containing an alloying material and a graphite material for providing a non-aqueous electrolyte secondary battery with a high capacity and excellent cycle characteristics. The negative electrode includes graphite and at least one alloying material capable of electrochemically absorbing and desorbing Li. The alloying material includes an A phase composed mainly of Si and a B phase including an intermetallic compound of at least one transition metal element and Si. At least one of the A phase and the B phase includes a microcrystalline or amorphous region. The weight percentage of the A phase relative to the total weight of the A phase and the B phase is greater than 40% and not greater than 95%. The weight percentage of the graphite relative to the total weight of the alloying material and the graphite is not less than 50% and not greater than 95%.
    Type: Grant
    Filed: October 26, 2005
    Date of Patent: May 26, 2009
    Assignee: Panasonic Corporation
    Inventors: Toshitada Sato, Masaki Hasegawa, Teruaki Yamamoto, Yasuhiko Bito
  • Publication number: 20090104536
    Abstract: A negative electrode for a lithium ion secondary battery including a current collector and an active material layer carried on the current collector, wherein the active material layer includes an active material represented by the general formula: LiaSiOx where 0.5?a?x?1.1 and 0.2?x?1.2; and the active material is obtained by vapor-depositing lithium on a layer including an active material precursor containing silicon and oxygen to cause reaction between the active material precursor and the lithium.
    Type: Application
    Filed: July 19, 2006
    Publication date: April 23, 2009
    Inventors: Yasutaka Kogetsu, Kazuyoshi Honda, Toshitada Sato
  • Publication number: 20090098459
    Abstract: A method for manufacturing an electrode of an electrochemical element includes: (A) forming an active material layer on a current collector; and (B) providing lithium to the active material layer. The A step and the B step are carried out in continuous space.
    Type: Application
    Filed: December 27, 2007
    Publication date: April 16, 2009
    Inventors: Hideharu Takezawa, Toshitada Sato, Kazuyoshi Honda
  • Publication number: 20080268343
    Abstract: A method for manufacturing an electrode of an electrochemical element includes providing lithium and an element that has a larger atomic weight than that of lithium and is other than a constituting material of the electrode to an electrode by using a lithium vapor and a vapor of the element.
    Type: Application
    Filed: March 28, 2008
    Publication date: October 30, 2008
    Inventors: Toshitada Sato, Kazuyoshi Honda, Shinya Fujimura