Photocatalyst material and method for preparation thereof

• US 7,763,113 B2
• Filed: 06/14/2002
• Issued: 07/27/2010
• Est. Priority Date: 06/15/2001
• Status: Expired due to Fees

• Current Assignee: Andes Electric Co., Ltd.
• Original Assignee: Andre Andes Electric Company Limited
• Inventors: Nakamura, Yuko, Ikegami, Akira, Kudo, Takeshi, Kudo, Kazuhito, Kawanami, Fumie, Ruike, Azuma
• Primary Examiner(s): Lorengo; Jerry
• Assistant Examiner(s): Smith; Jennifer A
• Application Number:
  US10/481,204
• Publication Number:
  US 20050070429A1
• Time in Patent Office: 2,965 Days
• Field of Search: 117/4, 117/8, 117/9, 117/88, 117/920, 117/921, 117/923, 117/924, 148/240, 148/277, 148/281, 423/447.1, 423/447.2, 423/608, 423/609, 423/610, 428/34.1, 428/34.4, 428/34.5, 502/249, 502/350
• US Class Current: 117/88
• 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 35/58 Fabrics or filaments
• CPC Class Codes: B01J 37/0215 Coating
• CPC Class Codes: B01J 37/0238 via the gaseous phase-sublimation
• CPC Class Codes: B01J 37/033 Using Hydrolysis
• CPC Class Codes: Y10T 428/13 Hollow or container type article [e.g., tube, vase, etc.]
• CPC Class Codes: Y10T 428/131 Glass, ceramic, or sintered, fused, fired, or calcined metal oxide or metal carbide containing [e.g., porcelain, brick, cement, etc.]
• CPC Class Codes: Y10T 428/1314 Contains fabric, fiber particle, or filament made of glass, ceramic, or sintered, fused, fired, or calcined metal oxide, or metal carbide or other inorganic compound [e.g., fiber glass, mineral fiber, sand, etc.]

Abstract

The present invention provides a photocatalyst material, which can comprise a photocatalyst with an excellent adherence to a substrate and a high photocatalytic activity, and a production method thereof. The photocatalyst material (20) obtained by reacting crystal nuclei with a sol solution containing an organic metallic compound or the like and then carrying out gelation, solidification and heat treatment has a structure where more than one basic structures (10) are fixed to the surface of the substrate (1). The basic structure consists of abase portion (2) comprising crystal nuclei fixed to the surface of the substrate (1) and a photocatalyst crystalline body (3), which connects to and is extended from the base portion (2) and has a columnar structure having a hollow portion (5) formed therein. A cylindrical substrate may be used for the substrate (1). The above photocatalytic activity is further enhanced by the formation of an interior-exposing structure (8) in a shell portion (4).

Claims

1. A method for producing a photocatalyst material, characterized in that more than one columnar photocatalyst basic structure is fixed to the surface of a substrate, said columnar photocatalyst basic structure consisting of a base portion comprising crystal nuclei that are fixed to the surface of the substrate, and a columnar photocatalyst crystalline body that connects to and is extended from the base portion and has a columnar structure having a hollow portion formed therein, and

said columnar structure is quadra prismatic,

said base portion consists of crystal nuclei and the photocatalyst constituting said columnar photocatalyst crystalline body is titanium oxide,

said columnar photocatalyst crystalline body is formed by a shell portion consisting of a sidewall and an extension direction end and has a columnar shape such that a hollow portion is surrounded by said shell portion, wherein said shell portion is a polycrystalline body consisting of aggregated photocatalyst crystal grains, an aggregate of photocatalyst crystal grains in the hollow portion that is formed inside said columnar photocatalyst crystalline body, and

the shell portion of said columnar photocatalyst crystalline body has an interior-exposing structure to expose an internal structure that is the hollow portion of said columnar photocatalyst crystalline body, the method comprises:

a gelation step of immersing a substrate, to which crystal nuclei are fixed for use as a base portion of a columnar photocatalyst basic structure, in a sol solution comprising an organic metallic compound or inorganic metallic compound, or applying the sol solution comprising an organic metallic compound or inorganic metallic compound to said crystal nuclei fixed to said substrate, so as to obtain a prototype of a photocatalyst material by gelation;

a solidification step of drying and solidifying said prototype obtained by said gelation step; and

a heat treatment step of subjecting the solidified prototype to heat treatment so as to form a columnar photocatalyst crystalline body,

so that a photocatalyst material is obtained, and

said columnar photocatalyst basic structure is quadra prismatic and having a hollow portion formed therein.

2. A method for producing a photocatalyst material according to claim 1, characterized in that said gelation step is:

of using a substrate whose surface to which said base portion is to be fixed is a curved surface convex on the side of the extension direction of said columnar photocatalyst crystalline body, or a cylindrical substrate having a radius of 50 gm or shorter, fixing crystal nuclei for use as said base portion of said columnar photocatalyst basic structure to said substrate, immersing the substrate, to which said crystal nuclei are fixed, in a sol solution comprising an organic metallic compound or inorganic metallic compound, or applying the sol solution comprising an organic metallic compound or inorganic metallic compound to said crystal nuclei fixed to said substrate, so as to obtain a prototype of a photocatalyst material by gelation.

3. A method for producing a photocatalyst material according to claim 1, characterized in that ion etching or other types of dry etching is carried out on said columnar photocatalyst crystalline body obtained by said heat treatment step;

wet etching in which said columnar photocatalyst crystalline body is treated with an etching solution that acts to dissolve titanium oxide is carried out on said columnar photocatalyst crystalline body obtained by said heat treatment step;

or

a polishing treatment or other treatments to mechanically eliminate a part of said shell portion is carried out on said columnar photocatalyst crystalline body obtained by said heat treatment step, so as to obtain the photocatalyst aterial with the shell portion having said interior-exposing structure.

4. A method for producing a photocatalyst material according to claim 1, characterized in that, in said heat treatment step, heat treatment is carried out at a temperature increase rate of from 15°

C./min to 105°

C./min, so as to obtain the photocatalyst material.