Photocatalytic sheet or film and its manufacturing process

• US 6,890,645 B2
• Filed: 06/19/2001
• Issued: 05/10/2005
• Est. Priority Date: 06/21/2000
• Status: Expired due to Fees

• Current Assignee: Fujifilm Manufacturing Europe BV (Fujifilm Holdings Corporation)
• Original Assignee: Fuji Photo Film Co Limited (Fujifilm Holdings Corporation)
• Inventors: Satake, Seimi, Disse, Leo, Gillissen, Huub, Toda, Yuzo
• Primary Examiner(s): Le, H. Thi
• Application Number:
  US10/311,797
• Publication Number:
  US 20030165702A1
• Time in Patent Office: 1,421 Days
• Field of Search: 428/323, 428/336, 428/328, 428/329, 428/330, 428/331, 428/913
• US Class Current: 428/323
• 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: Y10S 428/913 Material designed to be responsive to temperature, light, moisture
• CPC Class Codes: Y10T 428/25 Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
• CPC Class Codes: Y10T 428/256 Heavy metal or aluminum or compound thereof
• CPC Class Codes: Y10T 428/257 Iron oxide or aluminum oxide
• CPC Class Codes: Y10T 428/258 Alkali metal or alkaline earth metal or compound thereof
• CPC Class Codes: Y10T 428/259 Silicic material
• CPC Class Codes: Y10T 428/265 1 mil or less
• CPC Class Codes: Y10T 428/3179 Next to cellulosic
• CPC Class Codes: Y10T 428/3188 Next to cellulosic

Abstract

The invention is directed to a photocatalytic sheet comprising a support, a photocalalytic layer comprising photocatalyst materials and binder, and at least one functional layer wherein said functional layer is in between said support and said photocatalytic layer, wherein said photocatalytic layer and said functional layer are brought on the support using extrusion coating technology or casting technology, as well as to a photocatalytic film sheet comprising: a photocatalytic layer comprising photocatalyst materials and binder, and at least one functional layer, wherein said film is formed by applying casting technology.

Claims

1. A photocatalytic sheet comprising:

a support,

a photocatalytic layer having a thickness of between 0.1 μ

m and 5 μ

m and comprising a particulate photocatalyst material and binder,

and at least one functional layer wherein said functional layer is in between said support and said photocatalytic layer,

wherein said photocatalytic layer and said functional layer are brought on the support using extrusion coating technology or casting technology.

2. The sheet of claim 1, further comprising one or more polymer resin layer(s) wherein said polymer resin layer or layers reside between the support and the said functional layer.

3. The sheet of claim 2 wherein said polymer resin is selected from thermoplastic polymers.

4. The sheet of claim 3 wherein said polymer resin is selected from the thermoplastic polymers that include polyolefin, polypropylene and polymethylpentene.

5. The sheet of claim 1, wherein co-extrusion technology is applied to extrude all said layers on the support.

6. The sheet of claim 1, wherein said support is a paper or polymeric film.

7. The sheet of claim 6, wherein said support is a polymeric film selected from the group consisting of triacetylcellulose, polyethyleneteraphthalate, polyethylenenaphthalate, polyamide and polypropylene.

8. The sheet of claim 1, wherein the total thickness of the photocatalytic sheet excluding the support is at least 10 μ

m.

9. The sheet of claim 1, wherein the functional layer comprises at least binders, polymer resins, extenders or fillers and pigments.

10. The sheet of claim 9 wherein said fillers or extenders are selected from the group of silicious particles, calcium carbonate, TiO₂, hydrated aluminum oxide and mixtures thereof.

11. The sheet of claim 9 wherein said pigments are selected from the group of TiO₂, zinc oxide, zinc sulfate, iron oxide pigments, ultramarine pigments, blue iron pigments, azo pigments, copper phthalocyanine, isoindolinone, perylene and mixtures thereof.

12. The sheet of claim 1, wherein said photocatalyst material is an oxide selected from the group consisting of SrTiO₃, TiO₂, ZnO, SnO₂, WO₃, Fe₂O₃ and Bi₂O₃.

13. The sheet of claim 1, wherein said photocatalyst material comprises the anatase form of TiO₂.

14. The sheet of claim 1, wherein said photocatalytic layer contains a photocatalyst in an amount between 10 and 90 wt %.

15. The sheet of claim 14, wherein said photocatalytic layer contains a photocatalyst in an amount between 20 and 80 wt %.

16. The sheet of claim 1, wherein said photocatalytic layer contains said binder in the range between 10 and 90 wt %.

17. The sheet of claim 16, wherein said photocatalytic layer contains said binder in the range between 20 and 80 wt %.

18. The sheet of claim 1, wherein the thickness of said photocatalytic layer lies between 0.1 μ

m and 2.0 μ

m.

19. The sheet of claim 1, wherein the thickness of said photocatalytic layer lies between 0.3 μ

m and 1.0 μ

m.

20. The sheet of claim 1 wherein said binder is a polymer based on any combination of monomers selected from the group of tetrafluoroethylene, vinylenedifluoro-, hexafluoropropylene, perfluorovinylether and mixtures thereof.

21. Process for the manufacture of a photocatalytic sheet according to claim 1, said photocatalytic sheet comprising a support, a photocatalytic layer comprising photocatalyst materials and binder, and at least one functional layer wherein said functional layer is in between said support and said photocatalytic layer, wherein said photocatalytic layer and said functional layer are brought on the support using extrusion coating technology or casting technology.

22. The sheet of claim 1, wherein said photocatalytic layer and said functional layer are brought on the support without the use of solvent.

23. A photocatalytic film comprising:

a photocatalytic layer having a thickness of between 0.1 μ

m and 5 μ

m and comprising a particulate photocatalyst material and binder,

and at least one functional layer,

wherein said film is formed by applying casting technology.

24. The film of claim 23, further comprising one or more polymer resin layer(s) wherein said functional layer resides between the said polymer resin layer and the said photocatalytic layer.

25. The film of claim 23, wherein the thickness of said photocatalytic layer is between 0.1 and 2.0 μ

m.

26. The film of claim 23, wherein the thickness of said photocatalytic layer is between 0.3 and 1.0 μ

m.

27. The film of claim 23, wherein the functional layer comprises at least binders, polymer resins, extenders or fillers and pigments.

28. The film of claim 27 wherein said fillers or extenders are selected from the group of silicious particles, calcium carbonate, TiO₂, hydrated aluminum oxide and mixtures thereof.

29. The film of claim 27 wherein said pigments are selected from the group of TiO₂, zinc oxide, zinc sulfate, iron oxide pigments, ultramarine pigments, blue iron pigments, azo pigments, copper phthalocyanine, isoindolinone, perylene and mixtures thereof.

30. The film of claim 23, wherein said photocatalyst material is an oxide selected from the group consisting of SrTiO₃, TiO₂, ZnO, SnO₂, WO₃, Fe₂O₃ and Bi₂O₃.

31. The film of claim 23, wherein said photocatalyst material comprises the anatase form of TiO₂.

32. The film of claim 23, wherein said photocatalytic layer contains a photocatalyst in an amount between 10 and 90 wt %.

33. The film of claim 23, wherein said photocatalytic layer contains said binder in the range between 10 and 90 wt %.

34. The film of claim 23, wherein said photocatalytic layer contains a photocatalyst in an amount between 20 and 80 wt %.

35. The film of claim 23, wherein said photocatalytic layer contains said binder in the range between 20 and 80 wt %.

36. The film of claim 23 wherein said binder is a polymer based on any combination of monomers selected from the group of tetrafluoroethylene, vinylenedifluoro-, hexafluoropropylene, perfluorovinylether and mixtures thereof.

37. Process for the manufacture of a photocatalytic film comprising a photocatalytic layer having a thickness of between 0.1 μ

m and 5 μ

m and comprising photocatalyst materials and binder, and at least one functional layer, wherein said film is formed by applying casting technology.

38. The process of claim 37, further comprising laminating the sheet onto a support.