Sanitary ware having photocatalyst layer

Patent metadata

Field	Value
Publication number	US-10010865-B2
Application number	US-201615263902-A
Country	US
Kind code	B2
Filing date	Sep 13, 2016
Priority date	Sep 15, 2015
Publication date	Jul 3, 2018
Grant date	Jul 3, 2018

Abstract

Disclosed is a sanitary ware having a photocatalyst layer which has excellent durability even in an environment where the photocatalyst layer is exposed to an acid and an alkali alternately. The sanitary ware comprises a glaze layer, an intermediate layer provided on the glaze layer, and a photocatalyst layer provided on the intermediate layer, wherein the photocatalyst layer comprises titanium oxide in the amount of 95 mass % to 75 mass % and zirconium oxide in the amount of 5 mass % to 25 mass % and the intermediate layer comprises silica in the amount of 98 mass % to 85 mass %, and titanium oxide and/or zirconium oxide in the amount of 2 mass % to 15 mass %.

First claim

What is claimed is:

1. A sanitary ware comprising a substrate, a glaze layer comprising natural mineral particles provided on the surface thereof, an intermediate layer provided on the glaze layer, and a photocatalyst layer provided on the intermediate layer,
wherein the photocatalyst layer comprises titanium oxide and zirconium oxide wherein the amount of titanium oxide is 95 mass % to 75 mass % and the amount of zirconium oxide is 5 mass % to 25 mass % and
the intermediate layer comprises silica and titanium oxide and/or zirconium oxide wherein the amount of silica is 98 mass % to 85 mass %, and the amount of titanium oxide or zirconium oxide is 2 mass % to 15 mass % when the intermediate layer comprises either of titanium oxide or zirconium oxide or the total amount of titanium oxide and zirconium oxide is 2 mass % to 15 mass % when the intermediate layer comprises both titanium oxide and zirconium oxide.

2. The sanitary ware according to claim 1 , wherein the intermediate layer comprises silica and titanium oxide, wherein the content of the silica is 90 to 98 mass %, and the content of the titanium oxide is 2 to 10 mass %.

3. The sanitary ware according to claim 2 , wherein the content of the silica is 90 to 95 mass %, and the content of the titanium oxide is 5 to 10 mass %.

4. The sanitary ware according to claim 1 , wherein the intermediate layer comprises silica and zirconium oxide, and the content of the silica is 90 to 98 mass %, and the content of the zirconium oxide is 2 to 10 mass %.

5. The sanitary ware according to claim 4 , wherein the content of the silica is 90 to 95 mass %, and the content of the zirconium oxide is 5 to 10 mass %.

6. The sanitary ware according to claim 1 , wherein, in the photocatalyst layer, the content of the titanium oxide is 90 to 80 mass %, and the content of the zirconium oxide is 10 mass % to 20 mass %.

7. The sanitary ware according to claim 1 , wherein the intermediate layer has a thickness Of 50 to 150 nm.

8. The sanitary ware according to claim 1 , wherein the photocatalyst layer has a thickness of 50 to 150 nm.

9. A method for producing the sanitary ware according to claim 1 , comprising the steps of:
coating a coating liquid on the glaze layer of the sanitary ware, the coating liquid being obtained by
mixing a silicon alkoxide or a hydrolysis product thereof, and a titanium alkoxide and/or a zirconium alkoxide;
further coating a coating liquid containing the precursor of titanium oxide and the precursor of zirconium oxide; and
firing the coating liquids at a temperature of 750 to 850° C.

Assignees

• Toto Ltd

Inventors

• Hino Takahiro
• Ichiki Tomoyasu
• Yagi Shinichi
• Takano Satoshi
• Higashi Mitoki

Classifications

• C04B41/009

  characterised by the material treated · CPC title

• C04B41/52 Primary

  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 title

• C04B41/5042

  Zirconium oxides or zirconates; Hafnium oxides or hafnates · CPC title

• C09D1/00

  Coating compositions, e.g. paints, varnishes or lacquers, based on inorganic substances · CPC title

• C04B41/5072 Primary

  with oxides or hydroxides not covered by C04B41/5025 (C04B40/0236 takes precedence; boron oxide C04B41/5006) · CPC title