Photocatalyst-supporting structure

Patent metadata

Field	Value
Publication number	US-9925531-B2
Application number	US-201715416313-A
Country	US
Kind code	B2
Filing date	Jan 26, 2017
Priority date	Nov 25, 2011
Publication date	Mar 27, 2018
Grant date	Mar 27, 2018

Abstract

A method for producing a photocatalyst-carrying structure includes coating a carrier with a composition for forming an adhesive layer, followed by drying, to form the adhesive layer; and coating the adhesive layer with a composition for forming a photocatalyst layer. The composition for forming the adhesive layer is formed by mixing an aqueous silicone-modified resin, 2% by weight to 15% by weight of a deposition assistant, 10% by weight to 40% by weight of an organic solvent, and water. The aqueous silicone-modified resin is formed by emulsion polymerization of a monomer in the presence of an emulsifier in an aqueous medium, and by further modification with silicone using a compound having a silicone structure.

First claim

The invention claimed is:

1. A method for producing a photocatalyst-carrying structure, the method comprising:
coating a carrier with a composition for forming an adhesive layer, followed by drying, to form the adhesive layer; and
coating the adhesive layer with a composition for forming a photocatalyst layer,
wherein:
the composition for forming the adhesive layer is formed by mixing an aqueous silicone-modified resin, 2% by weight to 15% by weight of a deposition assistant, 10% by weight to 40% by weight of an organic solvent, and water,
the aqueous silicone-modified resin is formed by emulsion polymerization of a monomer in the presence of an emulsifier in an aqueous medium, and by further modification with silicone using a compound having a silicone structure,
the deposition assistant is at least one selected from the group consisting of (poly)ethylene glycol, (poly)ethylene glycol monoalkyl ethers, (poly)ethylene glycol esters, (poly)ethylene glycol ether esters, (poly)propylene glycol, (poly)propylene glycol monoalkyl ethers, (poly) propylene glycol esters and (poly) propylene glycol ether esters, and
the organic solvent is at least one selected from the group consisting of methanol, ethanol, isopropanol, n-propanol and n-butanol.

2. The method for producing a photocatalyst-carrying structure according to claim 1 , wherein the aqueous silicone-modified resin is an aqueous silicone-modified (meth) acrylic resin.

3. The method for producing a photocatalyst-carrying structure according to claim 1 , wherein the monomer consists of a (meth)acrylate monomer selected from the group consisting of acrylic acid esters, methacrylic acid esters, and mixtures thereof, and at least one comonomer selected from the group consisting of acrylamide monomers, methacrylamide monomers, vinyl monomers, ethylenic unsaturated monomers having a carboxylic acid group, vinyl cyanides, aromatic vinyl monomers, vinyl halides, butadiene, and ethylene that is capable of copolymerizing with the (meth)acrylate monomer.

4. The method for producing a photocatalyst-carrying structure according to claim 3 , wherein an amount of the (meth)acrylate monomer in the monomer is 90% by weight to 100% by weight, an amount of the comonomer is 0% by weight to 10% by weight based on a total weight of the (meth)acrylate monomer and the comonomer, and the (meth)acrylate monomer contains a cycloalkyl ester of acrylic acid or (meth)acrylic acid having 5 to 12 carbon atoms, or a mixture thereof, in an amount equal to 5% by weight or more based on a total weight of the monomer.

5. The method for producing a photocatalyst-carrying structure according to claim 1 , wherein the emulsifier is at least one selected from the group consisting of an ethylenic unsaturated monomer having a sulfonic acid group or sulfonate group, an ethylenic unsaturated monomer having a sulfuric acid ester group, and a mixture thereof.

6. The method for producing a photocatalyst-carrying structure according to claim 1 , wherein the compound having a silicone structure is:
a cyclic polysiloxane; or
at least one selected from the group of compounds represented by the following formula (I):
(R 1 ) n Si(OR 2 ) 4-n   (I)

wherein:
R 1 represents a hydrogen atom, an aliphatic hydrocarbon group having 1 to 16 carbon atoms, an aryl group having 6 to 10 carbon atoms, a heteroaryl group having 4 to 5 carbon atoms, an aralkyl group having 7 to 11 carbon atoms, a cycloalkyl group having 5 to 6 carbon atoms, a vinyl group or a (meth)acroyloxyalkyl group having 1 to 10 carbon atoms,
R 2 represents an alkyl group having 1 to 8 carbon atoms, an acyl group, or a hydrogen atom,
n represents 1 or 2, and
in the case n is 2, R 1 may be the same or different or R 1 may mutually bond to form a ring, and R 2 may be the same or different.

7. The method for producing a photocatalyst-carrying structure according to claim 6 , wherein the compound having a silicone structure is a mixture of at least one selected from the group consisting of compounds in which n is 1 in formula (I) and at least one selected from the group consisting of compounds in which n is 2.

8. The method for producing a photocatalyst-carrying structure according to claim 7 , wherein, in the compound having a silicone structure, a ratio between the at least one selected from the group consisting of compounds in which n is 1 in formula (I) and the at least one selected from the group consisting of compounds in which n is 2 is a molar ratio of 1/10 or more.

9. The method for producing a photocatalyst-carrying structure according to claim 1 , wherein the photocatalyst layer is composed of a photocatalyst particle complex containing 25% by weight to 95% by weight of a metal oxide gel or metal hydroxide gel.

10. The method for producing a photocatalyst-carrying structure according to claim 1 , wherein a solid content of the aqueous silicone-modified resin in the composition for forming the adhesive layer is from 5% by weight to 30% by weight.

11. The method for producing a photocatalyst-carrying structure according to claim 1 , wherein a thickness of the adhesive layer is 0.5 μm to 5 μm.

12. The method for producing a photocatalyst-carrying structure according to claim 1 , wherein the composition for forming the adhesive layer contains 20% by weight to 30% by weight of the organic solvent.

Assignees

• Nippon Soda Co

Inventors

• Saito Kazunori

Classifications

• B01J31/26 Primary

  containing in addition, inorganic metal compounds not provided for in groups B01J31/02 - B01J31/24 · CPC title

• B01J37/0244

  Coatings comprising several layers · CPC title

• B01J31/06

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

• B01J35/004 Primary

  Operations & Transport · mapped topic

• C09J183/10

  Block or graft copolymers containing polysiloxane sequences (obtained by polymerising a compound having a carbon-to-carbon double bond on to a polysiloxane C09J151/08, C09J153/00) · CPC title