Multi-functional material with photocatalytic functions and method of manufacturing same
First Claim
1. A multi-functional material with a photocatalytic function, comprising:
- a base;
a photocatalytic layer having a photocatalytic function and disposed on a surface of said base, said photocatalytic layer including at least a surface layer exposed outwardly, said surface layer being composed of fine photocatalytic particles joined together with interstices defined therebetween at a predetermined porosity and electron-capturing particles fixed to surfaces of the photocatalytic particles;
an amorphous binder layer interposed between the surface of the base and the photocatalytic layer;
said photocatalytic layer further including a lower layer embedded in said binder layer; and
an intermediate layer interposed between the binder layer and said photocatalytic layer, said intermediate layer including components of said photocatalytic layer and said binder layer, and concentrations of said components varying continuously in said intermediate layer.
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Abstract
Multi-functional materials which have a photocatalytic layer with a photocatalytic function disposed on the surface of a base through an amorphous binder layer 6 interposed therebetween. Photocatalytic particles of the photocatalytic layer are joined together by a surface energy or solid-state sintering. The photocatalytic layer may have a structure in which fine particles fill interstices defined between photocatalytic particles or a structure in which no fine particles fill interstices defined between photocatalytic particles. A metal such as Ag, Pt, or the like may be fixed or not fixed to surfaces of the photocatalytic particles. A lower layer of the photocatalytic layer is embedded in the binder layer such that an intermediate layer is formed between the binder layer and the photocatalytic layer, the intermediate layer including components of the binder and photocatalytic layers in varying concentrations therethrough.
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Citations
19 Claims
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1. A multi-functional material with a photocatalytic function, comprising:
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a base;
a photocatalytic layer having a photocatalytic function and disposed on a surface of said base, said photocatalytic layer including at least a surface layer exposed outwardly, said surface layer being composed of fine photocatalytic particles joined together with interstices defined therebetween at a predetermined porosity and electron-capturing particles fixed to surfaces of the photocatalytic particles;
an amorphous binder layer interposed between the surface of the base and the photocatalytic layer;
said photocatalytic layer further including a lower layer embedded in said binder layer; and
an intermediate layer interposed between the binder layer and said photocatalytic layer, said intermediate layer including components of said photocatalytic layer and said binder layer, and concentrations of said components varying continuously in said intermediate layer. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19)
forming a binder layer on a surface of a base by coating a solution containing photocatalytic particles onto said binder layer, and firing the solution and the binder layer at an elevated temperature such that the binder layer is softened and the lower surface of the photocatalytic layer becomes embedded in said binder layer forming an intermediate layer between the photocatalytic layer and the binder layer;
forming a photocatalytic layer having a surface layer exposed from said binder layer and a lower layer embedded in said binder layer;
thereafter coating an aqueous solution of metal ions of at least one of Ni, Pd, and Pt, and photoreducing the coated solution to separate out and fix metal particles to surfaces of said photocatalytic particles.
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13. A method according to claim 12, wherein said binder layer is made of glaze, inorganic glass, thermoplastic resin, or thermoplastic material of solder.
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14. A method according to claim 12, wherein said intermediate layer has a thickness which is at least ⅓
- of the thickness of said photocatalytic layer.
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15. A method according to claim 12, further including the steps of coating a metal alkoxide or an organic metal salt on a surface of said photocatalytic layer, then drying and heating the coated metal alkoxide or organic metal salt to fill interstices defined between photocatalytic particles with particles smaller than the interstices.
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16. A method according to claim 15, wherein said metal alkoxide coated on the surface of said photocatalytic layer comprises a Ti alkoxide, said Ti alkoxide being coated in an amount of 10 g/cm2 or greater and 100 g/cm2 or smaller in terms of the amount of TiO2.
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17. A method according to claim 15, wherein said metal alkoxide coated on the surface of said photocatalytic layer comprises a Ti alkoxide, said Ti alkoxide being heated at a temperature of 400°
- C. or higher and 800°
C. or lower.
- C. or higher and 800°
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18. A method according to claim 15, wherein said metal alkoxide coated on the surface of said photocatalytic layer comprises a Ti alkoxide, said Ti alkoxide being contained in a coating solution which also contains hydrochloric acid in an amount of 1 weight % or more and 10 weight % or less with respect to the Ti alkoxide.
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19. A method according to claim 12, wherein said step of forming the photocatalytic layer occurs after the step of forming the binder layer on the surface of the base.
Specification