Catalyst-supporting porous membrane, catalyst member, air cleaning device, and method for producing catalyst-supporting porous membrane

Patent metadata

Field	Value
Publication number	US-9321044-B2
Application number	US-201213982767-A
Country	US
Kind code	B2
Filing date	Jan 26, 2012
Priority date	Feb 2, 2011
Publication date	Apr 26, 2016
Grant date	Apr 26, 2016

Abstract

A catalyst-supporting porous film includes: a resin layer; and catalyst particles dispersed in the resin layer. The catalyst particles are unevenly distributed so as to be present at a surface of the resin layer. Preferably, the catalyst-supporting porous film includes a porous section and a supporting section for supporting the porous section. The number of catalyst particles per unit volume in the porous section is greater than the number of catalyst particles per unit volume in the supporting section. Thus, a catalyst-supporting porous film which has a high catalytic effect can be provided.

First claim

The invention claimed is:

1. A catalyst-supporting porous film, comprising:
an exposed surface having a moth-eye structure or inverted moth-eye structure;
a resin layer;
a plurality of through holes arranged in a matrix; and
catalyst particles dispersed in the resin layer,
wherein the exposed surface includes the catalyst particles unevenly distributed such that substantially all of a surface of the resin layer is covered with the catalyst particles.

2. The catalyst-supporting porous film of claim 1 , wherein
the catalyst-supporting porous film includes a porous section and a supporting section for supporting the porous section, and
the number of catalyst particles per unit volume in the porous section is greater than the number of catalyst particles per unit volume in the supporting section.

3. The catalyst-supporting porous film of claim 1 , wherein the surface has a plurality of minute raised portions and a saddle portion extending between vertexes of adjacent two of the plurality of minute raised portions.

4. The catalyst-supporting porous film of claim 1 , wherein the resin layer contains a photocurable resin.

5. The catalyst-supporting porous film of claim 1 , wherein the resin layer contains a plurality of thermoplastic resins which are phase-separated from one another.

6. The catalyst-supporting porous film of claim 1 , wherein the catalyst particles include titanium oxide particles.

7. The catalyst-supporting porous film of claim 1 , wherein the catalyst particles include zinc-supporting titanium oxide particles.

8. A catalyst member, comprising:
a base which has a principal surface; and
the catalyst-supporting porous film as set forth in claim 1 being provided on the principal surface of the base.

9. A catalyst member, comprising:
a base which has two principal surfaces; and
the catalyst-supporting porous film as set forth in claim 1 being provided on each of the two principal surfaces of the base.

10. An air cleaning device, comprising:
the catalyst-supporting porous film as set forth in claim 1 ; and
an ion generating device for generating a positive ion and a negative ion.

11. A manufacturing method of the catalyst-supporting porous film of claim 1 , comprising the steps of:
providing a mixture which contains catalyst particles, a resin, and a solvent;
applying the mixture on a base and drying the mixture; and
deforming a surface of the dried mixture into a porous shape,
wherein the step of drying includes forming a resin layer from the mixture, in which the catalyst particles are dispersed, and
the catalyst particles are unevenly distributed so as to be present at a surface of the resin layer.

12. The manufacturing method of claim 11 , wherein
in the step of providing, the resin contains a photocurable resin, and
the step of deforming into the porous shape further includes curing the photocurable resin with a mold being pressed against the mixture.

13. The manufacturing method of claim 12 , wherein
in the step of curing, the mold has a surface of a moth-eye structure or inverted moth-eye structure.

Assignees

• Horie Wataru
• Sharp Kk

Inventors

• Horie Wataru

Classifications

• B01J21/063 Primary

  Titanium; Oxides or hydroxides thereof · CPC title

• B01D69/145

  containing embedded catalysts · CPC title

• A61L9/16

  using physical phenomena · CPC title

• B01J31/06 Primary

  containing polymers {(organometallic polymers B01J31/123; polymer-bound organometallic complexes B01J31/165; coordination polymers B01J31/1691)} · CPC title

• B01D2257/90

  Odorous compounds not provided for in groups B01D2257/00 - B01D2257/708 · CPC title