Multi-functional material with photocatalytic functions and method of manufacturing same

• US 6,294,247 B1
• Filed: 10/07/1998
• Issued: 09/25/2001
• Est. Priority Date: 12/10/1993
• Status: Expired due to Term

• Current Assignee: Toto Limited
• Original Assignee: Toto Limited
• Inventors: Hayakawa, Makoto, Watanabe, Toshiya, Kitamura, Atsushi, Kojima, Eiichi, Machida, Mitsuyoshi, Nakashima, Yasushi, Kuga, Tatsuhiko, Chikuni, Makoto, Norimoto, Keiichiro, Kimura, Tamon, Saeki, Yoshimitsu
• Primary Examiner(s): Copenheaver, Blaine
• Assistant Examiner(s): Kruer, Kevin R.
• Application Number:
  US09/167,327
• Time in Patent Office: 1,084 Days
• Field of Search: 428/312.8, 428/313.9, 428/317.1, 430/947, 502/242, 502/309, 502/439
• US Class Current: 428/312.8
• CPC Class Codes: B01J 21/063 Titanium; Oxides or hydroxides thereof
• CPC Class Codes: B01J 35/30 characterised by their physical properties
• CPC Class Codes: B01J 35/39 Photocatalytic properties
• CPC Class Codes: B01J 37/0215 Coating
• CPC Class Codes: C03C 17/007 containing a dispersed phase, e.g. particles, fibres or flakes, in a continuous phase
• CPC Class Codes: C03C 17/3411 with at least two coatings of inorganic materials C03C17/36, C03C17/42 take precedence
• CPC Class Codes: C03C 2217/42 consisting of particles only
• CPC Class Codes: C03C 2217/425 consisting of a porous layer
• CPC Class Codes: C03C 2217/475 Inorganic materials
• CPC Class Codes: C03C 2217/477 Titanium oxide
• CPC Class Codes: C03C 2217/71 Photocatalytic coatings
• CPC Class Codes: C04B 33/00 Clay-wares monolithic refractories or refractory mortars C04B35/66; porous products C04B38/00
• CPC Class Codes: C04B 35/10 based on aluminium oxide
• CPC Class Codes: C04B 41/0045 Irradiation; Radiation, e.g. with UV or IR C04B41/0036 takes precedence
• CPC Class Codes: C04B 41/009 characterised by the material treated
• CPC Class Codes: C04B 41/4535 applied as a solution, emulsion, dispersion or suspension
• CPC Class Codes: C04B 41/4537 by the sol-gel process
• CPC Class Codes: C04B 41/4539 as a emulsion, dispersion or suspension
• CPC Class Codes: C04B 41/455 the coating or impregnating process including a chemical conversion or reaction
• CPC Class Codes: C04B 41/4554 the coating or impregnating material being an organic or organo-metallic precursor of an inorganic material
• CPC Class Codes: C04B 41/4562 : Photographic methods, e.g. making use of photo-sensitive materials
• CPC Class Codes: C04B 41/5022 : with vitreous materials composition of vitreous glazes and enamels C03C; ceramic pigments C09C1/0009
• CPC Class Codes: C04B 41/5041 : Titanium oxide or titanates
• CPC Class Codes: C04B 41/505 : Tin oxide
• CPC Class Codes: C04B 41/51 : Metallising , e.g. infiltration of sintered ceramic preforms with molten metal covering materials with metals in general C23C; ceramic compositions containing free metal bonded to carbides, diamond, oxides, borides, nitrides, silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides or sulfides, other than as macroscopic reinforcing agents C22C; infiltration of preforms containing free metal, e.g. cermets C22C
• CPC Class Codes: C04B 41/5111 : Ag, Au, Pd, Pt or Cu
• CPC Class Codes: C04B 41/52 : Multiple coating or impregnating multiple coating or impregnating with the same composition or with compositions only differing in the concentration of the constituents, is classified as single coating or impregnation
• CPC Class Codes: C04B 41/81 : Coating or impregnation
• CPC Class Codes: C04B 41/89 : for obtaining at least two superposed coatings having different compositions
• CPC Class Codes: Y10S 430/148 : Light sensitive titanium compound containing
• CPC Class Codes: Y10T 428/24909 : Free metal or mineral containing
• CPC Class Codes: Y10T 428/24997 : Of metal-containing material
• CPC Class Codes: Y10T 428/249974 : Metal- or silicon-containing element
• CPC Class Codes: Y10T 428/249982 : With component specified as adhesive or bonding agent
• CPC Class Codes: Y10T 428/249985 : Composition of adhesive or bonding component specified

Abstract

Multi-functional materials which have a photocatalytic layer with a photocatalytic function disposed on the surface of a base through a 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.

Claims

1. A multi-functional material with a photocatalytic function, comprising:

a base;

a photocatalytic layer having a photocatalytic function disposed on a surface of said base, 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

particles filled in said interstices which are smaller than the interstices, said particles having a diameter of less than 0.1 μ

m;

said particles filled in the interstices defined between said photocatalytic particles having an average diameter which is ⅘

or less of the average diameter of said photocatalytic particles, and

said particles filled in the interstices defined between said photocatalytic particles are made of a material having a vapor pressure higher than the vapor pressure of a material of said photocatalytic particles, and are condensed on necks between the photocatalytic particles.

2. A multi-functional material according to claim 1, wherein said particles filled in the interstices defined between said photocatalytic particles are made of tin oxide.

3. A multi-functional material with a photocatalytic function, comprising:

a base;

a photocatalytic layer having a photocatalytic function 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

particles filled in said interstices which are smaller than the interstices, said particles having a diameter of less than 0.1 μ

m;

wherein said smaller particles comprise at least one of Cu in an amount of 0.7/g/cm²-10 g/cm² and Ag in an amount of 0.05 g/cm²-1 g/cm².