Method of cleaning a substrate having an ultrahydrophilic and photocatalytic surface

Technical Field

The present invention relates broadly to the art of rendering and maintaining a surface of a substrate highly hydrophilic. More particularly, the present invention is concerned with the art wherein the surface of a building, windowpane, machinery or article is rendered highly hydrophilic in order to permit self-cleaning of or to facilitate cleaning of the surface.

Background Art

In the fields of architecture and painting, it has been pointed out that growing environmental pollution tends to inadvertently accelerate fouling, contamination or soiling of exterior building materials, outdoor buildings and the coatings thereof.

In this regard, air-borne grimes and dust particles are allowed under fair weather conditions to fall and deposit on roofs and outer walls of buildings. When it rains, the deposits are washed away by rainwater and are caused to flow along the outer walls of the buildings. Furthermore, the air-borne grimes are captured by rain and are carried thereby to flow down along the surface of the building's outer walls and outdoor structures and buildings. For these reasons, contaminant substances are caused to adhere onto the surface along the paths of rainwater. As the surface is dried, a striped pattern of dirt, stain or smudge will appear on the surface.

The dirt or stain thus formed on the exterior building materials and the coating thereof consists of contaminant substances which include combustion products such as carbon black, city grimes, and inorganic substances such as clay particles. The diversity of the fouling substances is considered to make the antifouling countermeasures complicated (<nplcit id="ncit0001" npl-type="s"><text>Yoshinori KITSUTAKA "Accelerated Test Method For Soiling on Finishing Materials of External Walls", Bulletin of Japan Architecture Society, vol. 404 (Oct. 1989), pages 15-24</text></nplcit>).

Hitherto, it has been commonly considered in the art that water-repellent paints such as those containing polytetrafluoroethylene (PTFE) are desirable to prevent fouling or soiling of exterior building materials and the like. Recently, however, it is pointed out that, in order to cope with city grimes containing a large amount of oleophilic components, it is rather desirable to render the surface of coatings as hydrophilic as possible (" <nplcit id="ncit0002" npl-type="s"><text>Highpolymer", vol. 44, May 1995, page 307</text></nplcit>).

Accordingly, it has been proposed in the art to coat a building with a hydrophilic graftcopolymer (<nplcit id="ncit0003" npl-type="s"><text>Newspaper "Daily Chemical Industry", Jan. 30, 1995</text></nplcit>). Reportedly, the coating film presents a hydrophilicityof 30-40° in terms of the contact angle with water.

However, in view of the fact that inorganic dusts, which may typically be represented by clay minerals, have a contact angle with water ranging from 20° to 50° so that they have affinity for graftcopolymer having a contact angle with water of 30-40°, it is considered that such inorganic dusts are apt to adhere to the surface of the graftcopolymer coating and, hence, the coating is not able to prevent fouling or contamination by inorganic dusts.

Also available in the market are various hydrophilic paints which comprise acrylic resin, acryl-silicone resin, aqueous silicone, block copolymers of silicone resin and acrylic resin, acrylstyrene resin, ethylene oxides of sorbitan fatty acid, esters of sorbitan fatty acid, acetates of urethane, cross-linked urethane of polycarbonatediol and/or polyisocyanate, or cross-linked polymers of alkylester polyacrylate. However, since the contact angle with water of these hydrophilic paints is as large as 50-70°, they are not suitable to effectively prevent fouling by city grimes which contain large amount of oleophilic components.

<patcit id="pcit0001" dnum="EP590477A"><text>EP-A-590477</text></patcit> discloses an architectural material having a base which is coated by a metal oxide layer having photocatalytic activity. Titanium dioxide is disclosed as photocatalytic material.

<patcit id="pcit0002" dnum="JP63000042A"><text>JP-63-000042</text></patcit> is directed to a glass product having its surface coated with a titanium dioxide thin film to which a minute amount of Pt, Rh or Pd is added. Upon irradiation with UV-light generated by a 500 W high pressure mercury lamp or a 400 W high pressure mercury lamp, said glass product has the ability of keeping the surface clean by rapidly and automatically decomposing and removing organic stains adhered to the glass surface.

Accordingly, it is an object of the invention to provide a method for rendering the surface of a substrate, for example of buildings, window glasses, machinery or articles, highly hydrophilic to thereby permit self-cleaning of or to facilitate cleaning of the surface.

Disclosure of the Invention

The present inventors have discovered for the first time in the world that, upon photoexcitation, a surface of a photocatalyst is rendered highly hydrophilic. Surprisingly, it has been discovered that, upon photoexcitation of photocatalytic titania with ultraviolet light, the surface thereof is rendered highly hydrophilic to the degree that the contact angle with water becomes less than 10°, more particularly less than 5°, and even reached about 0°.

Based on the foregoing new discovery, the present invention provides a method for cleaning a substrate, comprising the steps of: <ul id="ul0001" list-style="none"><li>preparing a substrate coated with a layer comprised of a photocatalytic semiconductor material; and,</li><li>subjecting said photocatalytic material to photoexcitation to thereby render the surface of said layer hydrophilic; and</li><li>rinsing said substrate with water whereby organic deposits and/or contaminants adhering on the surface of said layer are released therefrom and washed away by water,</li><li>wherein said layer comprises silica blended titania.</li></ul>

Preferably, the step of subjecting said photocatalytic material to photoexcitation is carried out until the water wettability of said layer becomes less than 10° in terms of the contact angle with water.

Upon irradiation for a sufficient time with a sufficient intensity of a light having a wavelength which has an energy higher than the bandgap energy of the photocatalytic semiconductor, the surface of the photocatalytic coating is rendered highly hydrophilic to exhibit a super-hydrophilicity. The term "super-hydrophilicity" or "super-hydrophilic" as used herein refers to a highly hydrophilic property (i.e., water wettability) of less than about 10°, preferably less than about 5°, in terms of the contact angle with water. Similarly, the term "superhydrophilification" or "superhydrophilify" refers to rendering a surface highly hydrophilic to the degree that the contact angle with water becomes less than about 10°, more preferably less than about 5°.

The process of superhydrophilification of a surface resulting from photoexcitation of a photocatalyst cannot be explained presently with any certainty. Seemingly, photocatalytic superhydrophilification is not necessarily identical with photodecomposition of a substance arising from photocatalytic redox process known hitherto in the field of photocatalyst. In this regard, the conventional theory admitted in the art regarding the photocatalytic redox process was that electron-hole pairs are generated upon photoexcitation of the photocatalyst, the electrons thus generated acting to reduce the surface oxygen to produce superoxide ions (O₂^-), the holes acting to oxidize the surface hydroxyl groups to produce hydroxyl radicals (OH), these highly active oxygen species (O₂^- and OH) then acting to decompose a substance through redox process.

However, it seems that the superhydrophilification phenomenon provoked by a photocatalyst is not consistent, in at least two aspects, with the conventional understanding and observation regarding the photocatalytic decomposition process of substances. First, according to a theory widely accepted hitherto, it has been believed that, in a certain photocatalyst such as rutile and tin oxide, the energy level of the conduction band is not high enough to promote the reduction process so that the electrons photoexcited up to the conduction band remain unused and become excessive whereby the electron-hole pairs once generated by photoexcitation undergo recombination without contributing in the redox process. In contrast, the present inventors have observed that the superhydrophilification process by a photocatalyst takes place even with rutile and tin oxide, as described later.

Secondly, the conventional wisdom was that the decomposition of substances due to photocatalytic redox process is not developed unless the thickness of a photocatalytic layer is greater than at least 100 nm. Conversely, the present inventors have found that photocatalytic superhydrophilification occurs even with a photocatalytic coating having a thickness on the order of several nanometers.

Accordingly, it is considered, though not predicable with any clarity, that the superhydrophilification process caused by a photocatalyst is a phenomenon somewhat different from photodecomposition of substances resulting from the photocatalytic redox process. However, as described later, it has been observed that superhydrophilification of a surface does not occur unless a light having an energy higher than the band gap energy of the photocatalyst is irradiated. It is considered that, presumably, the surface of a photocatalytic coating is rendered superhydrophilic as a result of water being chemisorbed thereon in the form of hydroxyl groups (OH^-) under the photocatalytic action of the photocatalyst.

Once the surface of the photocatalytic coating has been made highly hydrophilic upon photoexitation of the photocatalyst, the hydrophilicityof the surface will be sustained for a certain period of time even if the substrate is placed in the dark. As time elapses, the superhydrophilicity of the surface will be gradually lost because of contaminants adsorbed on the surface hydroxyl groups. However, the superhydrophilicity will be restored when the surface is again subjected to photoexcitation.

To initially superhydrophilify the photocatalytic coating, any suitable source of light may be used which has a wavelength of an energy higher than the band gap energy of the photocatalyst. In the case of titania in which the photoexciting wavelength pertains to the ultraviolet range of the spectrum, the ultraviolet light contained in the sunlight may advantageously be used in such a situation where the sunlight impinges upon the substrate coated by the photocatalytic coating. When the photocatalyst is to be photoexcited indoors or at night, an artificial light source may be used. In the present invention, where the photocatalytic coating is made of silica blended titania, the surface thereof can readily be rendered hydrophilic even by a weak ultraviolet radiation contained in the light emitted from a fluorescent lamp.

After the surface of the photocatalytic coating has once been superhydrophilified, the superhydrophilicity may be maintained or renewed by a relatively weak light. Maintenance and restoration of the superhydrophilicity may be accomplished to a satisfactory degree even by a weak ultraviolet light contained in the light of indoor illumination lamps such as fluorescent lamps.

The photocatalytic coating exhibits the super-hydrophilicity even if the thickness thereof is made extremely small. It presents a sufficient hardness and, therefore, the photocatalytic coating presents an adequate durability and abrasion resistivity.

In one aspect, this invention provides a method for self-cleaning a surface of a substrate wherein the surface is superhydrophilified and is self-cleaned by rainfall.

The substrate may include an exterior member, window sash, structural member, or windowpane of a building; an exterior member or coating of a vehicle such as automobile, railway vehicle, aircraft, and watercraft; an exterior member, dust cover or coating of a machine, apparatus or article; and an exterior member or coating of a traffic sign, various display devices, and advertisement towers, that are made, for example, of metal, ceramics, glass, plastics, wood, stone, cement, concrete, a combination thereof, a laminate thereof, or other materials. The surface of the substrate is coated with the photocatalytic coating.

Since the building, or machine or article disposed outdoors, is exposed to the sunlight during the daytime, the surface of the photocatalytic coating will be rendered highly hydrophilic. Furthermore, the surface will occasionally be subjected to rainfall. Each time the superhydrophilified surface receives a rainfall, dusts and grime and contaminants deposited on the surface of the substrate will be washed away by rain whereby the surface is self-cleaned.

As the surface of the photocatalytic coating is rendered highly hydrophilic to the degree that the contact angle with water becomes less than about 10°, preferably less than about 5°, particularly equal to about 0°, not only the city grime containing large amounts of oleophilic constituents but also inorganic dusts such as clay minerals will be readily washed away from the surface. In this manner, the surface of the substrate will be self-cleaned and kept clean to a high degree under the action of nature. This will permit, for instance, to eliminate or largely reduce cleaning of windowpanes of towering buildings.

The surface thus superhydrophilified will preclude contaminants from adhering to the surface as rainwater laden with contaminants such as air-borne dusts and grime flows down along the surface. Therefore, in combination with the above-mentioned self-cleaning function performed by rainfall, the surface of the building and the like will be maintained almost for ever in a high degree of cleanliness.

In a further aspect of the invention, a photocatalytic coating is provided on a surface of an apparatus or article, such as exterior or interior member of a building, windowpane, household, toilet bowl, bath tub, wash basin, lighting fixture, kitchenware, tableware, sink, cooking range, kitchen hood, and ventilation fan, which is made from metal, ceramics, glass, plastics, wood, stone, cement, concrete, a combination thereof, a laminate thereof, or other materials, and the surface is photoexcited as required.

When these articles which are fouled by oil or fat are rinsed by water, fatty dirt and contaminants will be released from the superhydrophilified surface of the photocatalytic coating and will be readily removed therefrom. Accordingly, for example, a tableware fouled by oil or fat may be cleansed without resort to a detergent.

These features and advantages of the invention as well as other features and advantages thereof will become apparent from the following description.

Brief Description of the Drawings

<ul id="ul0002" list-style="none" compact="compact"><li><figref idref="f0001">FIG. 1</figref> shows the energy level of the valance band and the conduction band of various semiconductor photocatalysts usable in the present invention;</li><li><figref idref="f0002">FIGS. 2A</figref> and <figref idref="f0003">2B</figref> are schematic cross-sectional views in a microscopically enlarged scale of the photocatalytic coating formed on the surface of a substrate and showing the hydroxyl groups being chemisorbed on the surface upon photoexcitation of the photocatalyst;</li><li><figref idref="f0008">FIG. 8</figref> is a graph showing the result of pencil hardness tests;</li><li><figref idref="f0004">FIGS. 3A</figref> and <figref idref="f0005">3B</figref> are front and side elevational views, respectively, of outdoor accelerated fouling testing equipment;</li><li><figref idref="f0006 f0007">FIGS. 4-7</figref> are graphs showing the contact angle with water versus the molar ratio of silica in silica-blended titania;</li><li><figref idref="f0009">FIG. 9</figref> is a graph showing to what degree various surfaces having different hydrophilicity are fouled by city grime and sludge.</li></ul>

Best Mode for Carrying Out the Invention

A substrate having a surface requiring superhydrophilification is prepared and is coated with a photocatalytic coating. In the case where the substrate is made from a heat resistive material such as metal, ceramics and glass, the photocatalytic coating may be fixed on the surface of the substrate by sintering particles of a photocatalyst as described later. Alternatively, a thin film of the amorphous form of a precursor of the photocatalyst may be first formed on the surface of the substrate and the amorphous photocatalyst precursor may then be transformed into photoactive photocatalyst by heating and crystallization.

In the case where the substrate is formed of a non heat-resistive material such as plastic or is coated with a paint, the photocatalytic coating may be formed by applying onto the surface a photooxidation-resistantcoating composition containing the photocatalyst and by curing the coating composition, as described later.

Photocatalyst

The photocatalyst used in the photocatalytic coating according to the invention is titania (TiO₂). Titania is harmless, chemically stable and available at a low cost. Furthermore, titania has a high band gap energy and, hence, requires ultraviolet (UV) light for photoexcitation. This means that absorption of the visible light does not occur during the course of photoexcitation so that the coating is free from the problem of coloring which would otherwise occur due to a complementary color component. Accordingly, titania is particularly suitable to coat on a transparent member such as glass, lens and mirror.

As titania, both anatase and rutile may be used. The advantage of the anatase form of titania is that a sol in which extremely fine particles of anatase are dispersed is readily available on the market so that it is easy to make an extremely thin film. On the other hand, the advantage of the rutile form of titania is that it can be sintered at a high temperature so that a coating excellent in strength and abrasion resistivity can be obtained. Although the rutile form of titania is lower in the conduction band level than the anatase form as shown in <figref idref="f0001">FIG. 1</figref>, it may be used as well for the purpose of photocatalytic superhydrophilification.

It is believed that, when a substrate 10 is coated with a photocatalytic coating 12 of titania and upon photoexcitation of titania by UV light, water is chemisorbed on the surface in the form of hydroxyl groups (OH^-) under the photocatalytic action as shown in <figref idref="f0002">FIG. 2A</figref> and, as a result, the surface becomes superhydrophilic.

Other photocatalysts are metal oxides, such as ZnO, SnO₂, SrTiO₃, WO₃, Bi₂O₃, and Fe₂O₃, as shown in <figref idref="f0001">FIG. 1</figref>. It is believed that, similar to titania, these metal oxides are apt to adsorb the surface hydroxyl groups (OH^-) because the metallic element and oxygen are present at the surface.

As shown in <figref idref="f0003">FIG. 2B</figref>, the photocatalytic coating may be formed by blending particles 14 of photocatalyst in a layer 16 of metal oxide. In particular, the surface can be hydrophilified to a high degree when silica is blended in the photocatalyst as described later.

Thickness of Photocatalytic Coating

In the case that the substrate is made of a transparent material as in the case of glass, a lens and a mirror, it is preferable that the thickness of the photocatalytic coating is not greater than 0.2 µm. With such a thickness, coloring of the photocatalytic coating due to the interference of light can be avoided. Moreover, the thinner the photocatalytic coating is, the more transparent the substrate can be. In addition, the abrasion resistance of the photocatalytic coating is increased with decreasing thickness.

The surface of the photocatalytic coating may be covered further by an abrasion-resistant or corrosion-resistant protective layer or other functional film which is susceptible to hydrophilification.

Photocatalytic Layer of Silica-Blended Titania

A method of forming an abrasion resistant photocatalytic coating which exhibits the superhydrophilicity of such a degree that the contact angle with water is equal to 0° is to form on the surface of the substrate a photocatalytic coating comprised of a mixture of titania and silica. The rate of silica to the sum of titania and silica may be 5-90 % by mol, preferably 10-70 % by mol, more preferably 10-50 % by mol. Formation of photocatalytic coating comprised of silica-blended titania may be carried out by one of the following methods. <ol id="ol0001" compact="compact"><li>(1) A suspension containing particles of the anatase form or rutile form of titania and particles of silica is applied on the surface of the substrate, followed by sintering at a temperature less than the softening point of the substrate.</li><li>(2) A mixture of a precursor of amorphous silica (e.g., tetraalkoxysilane such as tetraethoxysilane, tetraisopropoxysilane, tetra-n-propoxysilane, tetrabuthoxysilane, and tetramethoxysilane; silanol formed by hydrolysis of tetraalkoxysilane; or polysiloxane having a mean molecular weight of less than 3000) and a crystalline titania sol is applied on the surface of the substrate and is subjected to hydrolysis where desired to form silanol, followed by heating at a temperature higher than about 100 °C to subject silanol to dehydration polymerization to thereby form a photocatalytic coating wherein titania particles are bound by amorphous silica. In this regard, if dehydration polymerization of silanol is carried out at a temperature higher than about 200 °C, polymerization of silanol is accomplished to a high degree so that the alkali resistance of the photocatalytic coating is enhanced.</li><li>(3) A suspension wherein particles of silica are dispersed in a solution of a precursor of amorphous titania (e.g., organic compound of titanium such as alkoxide, chelate or acetate of titanium; or inorganic compound of titanium such as TiCl₄ and Ti(SO₄)₂) is applied on the surface of the substrate and then the compound of titanium is subjected to hydrolysis and dehydration polymerization at a temperature ranging from the ambient temperature to 200 °C to thereby form a thin film of amorphous titania wherein particles of silica are dispersed. Then, the thin film is heated at a temperature higher than the crystallization temperature of titania but lower than the softening point of the substrate to thereby transform amorphous titania into crystalline titania by phase transition.</li><li>(4) Added to a solution of a precursor of amorphous titania (organic compound of titanium such as alkoxide, chelate or acetate of titanium; or inorganic compound of titanium such as TiCl₄ and Ti(SO₄)₂) is a precursor of amorphous silica (e.g., tetraalkoxysilane such as tetraethoxysilane, tetraisopropoxysilane, tetra-n-propoxysilane, tetrabuthoxysilane, and tetramethoxysilane; hydrolyzate thereof, i.e., silanol; or polysiloxane having a mean molecular weight of less than 3000) and the mixture is applied on the surface of the substrate. Then, these precursors are subjected to hydrolysis and dehydration polymerization to form a thin film made of a mixture of amorphous titania and amorphous silica. Thereafter, the thin film is heated at a temperature higher than the crystallization temperature of titania but lower than the softening point of the substrate to thereby transform amorphous titania into crystalline titania by phase transition.</li></ol>

Addition of Antibacterial Enhancer

The photocatalytic coating may be doped with a metal such as Ag, Cu and Zn.

Doping of the photocatalyst with Ag, Cu or Zn may be carried out by adding a soluble salt of such metal to a suspension containing particles of the photocatalyst, the resultant solution being used to form the photocatalytic coating. Alternatively, after forming the photocatalytic coating, a soluble salt of such metal may be applied thereon and may be subjected to irradiation of light to deposit metal by photoreduction.

The photocatalytic coating doped with Ag, Cu or Zn is capable of killing bacteria adhered to the surface. Moreover, such photocatalytic coating inhibits growth of microorganisms such as mold, alga and moss. As a result, the surface of a building, machine, apparatus, household, article and the like can be maintained clean for a long period.

Addition of Photoactivity Enhancer

The photocatalytic coating may additionally be doped with a metal of the platinum group such as Pt, Pd, Rh, Ru, Os and Ir. These metals may be similarly doped to the photocatalyst by photoreduction deposition or by addition of a soluble salt.

A photocatalyst doped with a metal of the platinum group develops an enhanced photocatalytic redox activity so that decomposition of contaminants adhering on the surface will be promoted.

Photoexcitation and UV Irradiation

The anatase form of titania may be photoexcited by a UV light having a wavelength less than 387 nm, with the rutile form of titania by a UV light having a wavelength less than 413 nm.

As a source of UV light, a fluorescent lamp, incandescent lamp, metal halide lamp, mercury lamp or other type of indoor illumination lamp may be used. In a situation where the photocatalytic coating is exposed to the sunlight as in the case of a rearview mirror of a vehicle, the photocatalyst will advantageously be photoexcited spontaneously by the UV light contained in the sunlight.

Photoexcitation may be carried out, or caused to be carried out, until the contact angle, with water, of the surface becomes less than about 10°, preferably less than about 5°, particularly equal to about 0°. Generally, by photoexciting at a UV intensity of 0.001 mW/cm², the photocatalytic coating will be superhydrophilified within several days to the degree that the contact angle with water becomes about 0°. Since the intensity of the UV light contained in the sunlight impinging upon the earth's surface is about 0.1-1 mW/cm², the surface will be superhydrophilified in a shorter time when exposed to the sunlight.

In the case that the surface of the substrate is to be self-cleaned by rainfall, the photocatalytic coating may be formed of a photocatalyst which can be photoexcitedby UV light or visible light. The articles covered by the photocatalytic coating are disposed outdoors and are subjected to irradiation of the sunlight and to rainfall.

Once the surface has been made highly hydrophilic, the hydrophilicity is sustained even during the night. Upon exposure again to the sunlight, the hydrophilicitywill be restored and maintained.

It is preferable that the photocatalytic coating is superhydrophilified in advance before the substrate coated by the photocatalytic coating according to the invention is offered for use to the user.

Examples

The following Examples illustrate the industrial applicability of the invention from various aspects.

Reference Example 1

Photocatalytic Coating with Interleaved Silica Layer

6 parts by weight of tetraethoxysilaneSi(OC₂H₅)₄ (Wako JunYaku, Osaka), 6 parts by weight of pure water, and 2 parts by weight of 36% hydrochloric acid as a hydrolysis inhibitor were added to 86 parts by weight of ethanol as a solvent and the mixture was stirred to obtain a silica coating solution. The solution was allowed to cool for about 1 hour since the solution evolved heat upon mixing. The solution was then applied on the surface of a soda-lime glass plate of 10cm square in size by the flow coating method and was dried at a temperature of 80 °C. As drying proceeds, tetraethoxysilane was hydrolyzed to first form silanol Si(OH)₄ which was then underwent dehydration polymerization to form a thin film of amorphous silica on the surface of the glass plate.

Then a titania coating solution was prepared by adding 0.1 parts by weight of 36% hydrochloric acid as a hydrolysis inhibitor to a mixture of 1 part by weight of tetraethoxy-titanium Ti(OC₂H₅)₄ (Merck) and 9 parts by weight of ethanol, and the solution was applied to the surface of the above-mentioned glass plate by the flow coating method in dry air. The amount of coating was 45 g/cm² in terms of titania. As the speed of hydrolysis of tetraethoxytitaniumwas so high, hydrolysis of tetraethoxytitanium partially commenced during the course of coating so that formation of titanium hydroxide Ti(OH)₄ started.

Then the glass plate was held at a temperature of about 150 °C for 1-10 minutes to permit completion of the hydrolysis of tetraethoxy-titanium and to subject the resultant titanium hydroxide to dehydration polymerization whereby amorphous titania was formed. In this manner, a glass plate was obtained having a coating of amorphous titania overlying the coating of amorphous silica.

This specimen was then fired or calcined at a temperature of 500 °C in order to transform amorphous titania into the anatase form of titania. It is considered that, due to the presence of the coating of amorphous silica underlying the coating of amorphous titania, alkaline network-modifier ions such as sodium ions being present in the glass plate were prevented from diffusing from the glass substrate into the titania coating during calcination.

Then a reflective coating of aluminum was formed by vacuum evaporation deposition on the back of the glass plate to prepare a mirror to thereby obtain #1 specimen.

After the #1 specimen was kept in the dark for several days, a UV light was irradiated on the surface of the specimen for about one hour at the UV intensity of 0.5 mw/cm² (the intensity of UV light having an energy higher than the band gap energy of the anatase form of titania, i.e., the intensity of UV light having a wavelength shorter than 387 nm) by using a 20W blue-light-black (BLB) fluorescent lamp (Sankyo Electric, FL20BLB) to obtain #2 specimen.

For the purposes of comparison, a reflective coating of aluminum was formed by vacuum evaporation deposition on the back of a glass plate provided neither with silica nor titania coating, the product being placed in the dark for several days to obtain #3 specimen.

The contact angle, with water, of the #2 and #3 specimens was measured by a contact angle meter (Kyowa Kaimen Kagaku K.K. of Asaka, Saitama, Model CA-X150). The resolving power at the small angle side of this contact angle meter was 1°. The contact angle was measured 30 seconds after a water droplet was dripped from a micro-syringe onto the surface of the respective specimens. In the #2 specimen, the reading of the contact angle meter, indicating the contact angle with water of the surface, was 0° so that the surface exhibited superhydrophilicity. In contrast, the contact angle with water of the #3 specimen was 30-40°.

Reference Example 2

Photocatalytic Coating comprising Silica-Blended Titania

A thin film of amorphous silica was formed on the surface of a mirror (made by Nihon Flat Glass, MFL3) in a manner similar to Reference Example 1.

Then a coating solution was prepared by admixing 0.69g of tetraethoxysilane (Wako JunYaku), 1.07g of a sol of the anatase form of titania (Nissan Chemical Ind., TA-15, mean particle size of 0.01 m), 29.88g of ethanol, and 0.36g of pure water. The coating solution was applied on the surface of the mirror by spray coating process. The mirror was held at a temperature of about 150 °C for about 20 minutes to subject tetraethoxysilane to hydrolysis and dehydration polymerization to thereby form on the mirror surface a coating wherein particles of the anatase form of titania were bound by a binder of amorphous silica. The ratio by weight of titania to silica was 1.

After the mirror was kept in the dark for several days, a UV light was irradiated by the BLB fluorescent lamp for about one hour at the UV intensity of 0.5 mW/cm² to obtain #1 specimen. As the contact angle with water of the surface of the mirror was measured by the same contact angle meter as used in Reference Example 1, the reading of the contact angle meter was 0°.

Reference Example 3

UV Intensity of 800 Lux

A thin film of amorphous silica was formed on the surface of a 10cm square soda-lime glass plate in a manner similar to Reference Example 1.

Then the coating solution of Reference Example 2 was applied by spray coating on the surface of the glass plate. The glass plate was then held at a temperature of about 150 °C for about 20 minutes whereby a coating in which particles of the anatase form of titania were bound by a binder of amorphous silica was formed on the surface of the glass plate. The ratio by weight of titania to silica was 1.

After kept in the dark for several days, the glass plate was subjected to irradiation by a UV light for about one hour at the UV intensity of 0.5 mw/cm² by a BLB fluorescent lamp. After UV irradiation, the contact angle with water of the surface of the glass plate was measured by the contact angle meter (CA-X150) and it was found that the contact angle was 0°.

Thereafter, the specimen was subjected to irradiation by a UV light for 4 days at the UV intensity of 0.004 mW/cm² (800 lux) by using a white fluorescent lamp. While the specimen was under UV irradiation, the contact angle at the surface thereof was maintained less than 2°.

In this way, it was confirmed that, by a weak UV light available under indoor illumination achieved for example by a white fluorescent lamp, the surface of the glass plate was maintained highly hydrophilic.

Reference Example 4

Effect of Silica-to-Titania Blending Ratio

Next, tetraethoxysilane (Wako JunYaku), a sol of the anatase form of titania (Nissan Chemical Ind., TA-15), ethanol, and pure water were admixed in varying rate to prepare four kinds of coating solutions having different tetraethoxysilane-to-titania sol blending ratio. The rate of tetraethoxysilane to titania sol was so selected that, after tetraethoxysilane was converted into amorphous silica, the rate of silica with respect to the sum of silica plus titania was equal to 10% by mol, 30% by mol, 50% by mol, and 70% by mol, respectively.

Each of the coating solutions was applied by spray coating on the surface of a 10cm square soda-lime glass plate which was then held at a temperature of about 150 °C for about 20 minutes to subject tetraethoxysilane to hydrolysis and dehydration polymerization whereby a coating in which particles of the anatase form of titania were bound by a binder of amorphous silica was formed on the surface of the glass plate.

After being kept in the dark for a week, the specimens were subjected to irradiation by a UV light for about one hour at the UV intensity of 0.3 mW/cm² by a BLB fluorescent lamp. After UV irradiation, the contact angle with water of the surface of the respective specimens was measured by the contact angle meter (CA-X150). The contact angle was 0° throughout all the specimens.

Thereafter, two specimens with coatings having 30% by mol and 50% by mol of silica, respectively, were subjected to irradiation by a UV light for 3 days at the UV intensity of 0.004 mW/cm² by using a white fluorescent lamp. While the specimens were under irradiation, the contact angle at the surface thereof was maintained less than 3°.

Reference Example 5

Photocatalyst-Containing Silicone Coating

As substrates, aluminum plates of 10cm square in size were used. Each of the substrates was first coated with a silicone layer to smooth the surface. To this end, a first component "A" (silica sol) and a second component "B" (trimethoxymethylsilane) of the coating composition "Glaska" marketed by Japan Synthetic Rubber Co. (Tokyo) were mixed with each other in such a manner that the ratio by weight of silica to trimethoxymethylsilane was equal to 3. The resultant coating mixture was applied on the aluminum substrates and was subjected to curing at a temperature of 150 °C to obtain a plurality of aluminum substrates (#1 specimens) each coated with a base coating of silicone of 3 µm in thickness.

Then, the #1 specimens were coated with a high-molecular-weight coating composition containing a photocatalyst. In order to prevent a film forming element of the coating composition from being degraded by photooxidation action of the photocatalyst, silicone was selected as the film forming element.

More specifically, a sol of the anatase form of titania (Nissan Chemical Ind., TA-15) and the first component "A" (silica sol) of the above-mentioned "Glaska" were admixed. After dilution by ethanol, the above-mentioned second component "B" of "Glaska" was further added thereto to prepare a titania containing coating composition. The coating composition was comprised of 3 parts by weight of silica, 1 part by weight of trimethoxymethylsilane,and 4 parts by weight of titania.

The coating composition was applied onto the surface of the #1 specimen and was cured at a temperature of 150 °C to obtain #2 specimen coated with a top coating wherein particles of the anatase form of titania were dispersed throughout a coating film of silicone.

Then the #2 specimen was subjected to irradiation by a UV light for 5 days at the UV intensity of 0.5 mW/cm² by using a BLB fluorescent lamp to obtain #3 specimen. When the contact angle with water of the surface of this specimen was measured by the contact angle meter (made by ERMA), surprisingly the reading of the contact angle meter was less than 3°.

The contact angle of the #2 specimen measured prior to UV irradiation was 70°. The contact angle of the #1 specimen as measured was 90°. Then, the #1 specimen was subjected further to irradiation by a UV light for 5 days under the same condition as the #2 specimen and the contact angle thereof was measured, the contact angle as measured being 85°.

Reference Example 6

Antibacterial Enhancer - Ag-Added Photocatalyst

In a manner similar to Reference Example 1, a thin film of amorphous silica and a thin film of amorphous titania were formed in sequence on the surface of a 10cm-square soda-lime glass plate and the glass plate was then calcined at a temperature of 500 °C to transform amorphous titania into the anatase form titania whereby #1 specimen was obtained.

Then an aqueous solution containing 1 weight percent of silver lactate was applied onto the surface of the #1 specimen and the specimen was subjected to irradiation by a UV light for one minute by operating a 20W BLB fluorescent lamp positioned at a distance of 20 cm from the specimen whereby #2 specimen was obtained. Upon UV irradiation, silver lactate underwent photoreduction to form silver deposit and the surface of the specimen was rendered hydrophilic under the photocatalytic action of titania. The #1 specimen was also subjected to UV irradiation under the same conditions.

When the contact angle with water of the #1 and #2 specimens was measured by the contact angle meter (made by ERMA), the contact angle in both specimens was less than 3°. For the purposes of comparison the substrate of soda-lime glass as such was tested and it was found that the contact angle with water was 50°.

Then, the #1 and #2 specimens as well as the soda-lime glass plate as such were tested for antibacterial capability. A liquid culture prepared by shake cultivating colibacillus (Escherichia coli W3110 stock) for a night was subjected to centrifugal washing and was diluted with sterilized distilled water by 10,000 times to prepare a bacteria containing liquid. 0.15 ml of the bacteria containing liquid (equivalent to 10000-50000 CFU) was dripped on three slide glasses which were then brought into intimate contact with the #1 and #2 specimens and the soda-lime glass plate, respectively, which had previously been sterilized by 70% ethanol. These specimens and plate were then subjected to irradiation of a light of a white fluorescent lamp from in front of the slide glasses for 30 minutes at the intensity of 3500 lux. Thereafter, the bacteria containing liquid of respective specimens was wiped by a sterilized gauze and was recovered in 10 ml of physiological saline and the liquid thus recovered was applied for inoculation on a nutrient agar plate for culture at 37 °C for a day. Thereafter, the colonies of colibacillus formed on the culture was counted to calculate the survival rate of colibacillus. The result was that in the #1 specimen and the soda-lime glass plate the survival rate of colibacillus was greater than 70%, but the survival rate was less than 10% in the #2 specimen.

This experiment demonstrates that, when the photocatalyst is doped by Ag, the surface of the substrate is not only rendered highly hydrophilic but also is made to exhibit antibacterial function.

Reference Example 7

Antibacterial Enhancer - Cu-Added Photocatalyst

In a manner similar to Reference Example 1, a thin film of amorphous silica was formed, respectively, on the surface of 10cm-square soda-lime glass plates to obtain a plurality of #1 specimens.

Then, similar to Reference Example 1, a thin film of amorphous titania was formed on the surface of the #1 specimen which was then calcined at a temperature of 500 °C to transform amorphous titania into the anatase form titania. Then an ethanol solution containing 1 weight percent of copper acetate was applied by spray coating onto the surface of the specimen and, after drying, the specimen was subjected to irradiation by a UV light for one minute by a 20W BLB fluorescent lamp positioned at a distance of 20 cm from the specimen to thereby subject copper acetate to photoreduction deposition to obtain #2 specimen wherein crystals of titania were doped with copper. As inspected by the eye, the #2 specimen presented an adequate light transmittance.

With a soda-lime glass plate as well as the #2 specimen and the #1 specimen (without titania coating) immediately after fabrication the contact angle with water measured. The contact angle was measured by the contact angle meter (made by ERMA). The results are shown in Table 1. <tables id="tabl0001" num="0001"><table frame="all"><title>Table 1</title><tgroup cols="2"><colspec colnum="1" colname="col1" colwidth="34mm" /><colspec colnum="2" colname="col2" colwidth="43mm" /><thead><row><entry namest="col1" nameend="col2" align="center" valign="middle">Immediately After Preparation of Specimen</entry></row><row><entry align="center" valign="middle" /><entry align="center" valign="middle">Contact Angle with Water (°)</entry></row></thead><tbody><row><entry align="center" valign="middle">#2 Specimen</entry><entry align="center" valign="middle">10</entry></row><row><entry align="center" valign="middle">#1 Specimen</entry><entry align="center" valign="middle">9</entry></row><row><entry align="center" valign="middle">Soda-Lime Glass</entry><entry align="center" valign="middle">50</entry></row></tbody></tgroup></table></tables>

Further, after being subjected to irradiation by a UV light for a month at the UV intensity of 0.5 mW/cm² by a BLB fluorescent lamp, the #2 and #1 specimens and the soda-lime glass plate were tested in a similar manner for contact angle. The results are shown in Table 2. <tables id="tabl0002" num="0002"><table frame="all"><title>Table 2</title><tgroup cols="2"><colspec colnum="1" colname="col1" colwidth="29mm" /><colspec colnum="2" colname="col2" colwidth="43mm" /><thead><row><entry namest="col1" nameend="col2" align="center" valign="middle">After 1 Month of UV irradiation</entry></row><row><entry align="center" valign="middle" /><entry align="center" valign="middle">Contact Angle with Water (°)</entry></row></thead><tbody><row><entry align="center" valign="middle">#2 Specimen</entry><entry align="center" valign="middle">3</entry></row><row><entry align="center" valign="middle">#1 Specimen</entry><entry align="center" valign="middle">49</entry></row><row><entry align="center" valign="middle">Soda-Lime Glass</entry><entry align="center" valign="middle">53</entry></row></tbody></tgroup></table></tables>

Then, the #2 and #1 specimens immediately after preparation and the soda-lime glass plate were tested for antibacterial capability in a manner similar to Reference Example 6. The result was that in the soda-lime glass plate and the #1 specimen the survival rate of colibacillus was greater than 70%, but the survival rate was less than 10% in the #2 specimen.

Next, the #2 and #1 specimens immediately after preparation and the soda-lime glass plate were tested for deodorizing performance. The specimens were placed, respectively, in a desiccator of 11 liters in volume made of UV permeable quartz glass and nitrogen gas containing methyl mercaptan was introduced therein in such a manner that the methyl mercaptan concentration equaled 3 ppm. A 4W BLB fluorescent lamp was placed within the desiccator at a distance of 8 cm from the respective specimens to irradiate the specimens at the UV intensity of 0.3 mw/cm² By sampling gas in the desiccator 30 minutes later, the methyl mercaptan concentration was measured by gas chromatography and the removal rate of methyl mercaptan was calculated. With the #1 specimen and the soda-lime glass plate, the removal rate of methyl mercaptan was less than 10%. In contrast, the removal rate of the #2 specimen was more than 90% so that a good deodorizing performance was achieved.

Reference Example 8

Antibacterial Enhancer - Cu-Added Photocatalyst

The first and second components "A" (silica sol) and "B" (trimethoxymethylsilane)of "Glaska" of Japan Synthetic Rubber Co. were admixed such that the ratio by weight of silica to trimethoxymethylsilane was equal to 3, and the mixture was applied on the surface of a 10cm-square acrylic resin plate, followed by curing at a temperature of 100 °C to obtain an acrylic resin plate coated with a base coating of silicone of 3 µm in thickness.

Then, a sol of the anatase form of titania (TA-15) and an aqueous solution containing 3 weight percent of copper acetate were mixed and, after adding further the first component "A" (silica sol) of "Glaska" thereto, the mixture was diluted by propanol. Then the second component "B" of "Glaska" was further added to prepare a titania-containing coating composition. The coating composition was comprised of 3 parts by weight of silica, 1 part by weight of trimethoxymethylsilane, 4 parts by weight of titania, and 0.08 parts by weight of copper acetate in terms of metallic copper.

The coating composition was applied onto the surface of the acrylic resin plate and was cured at a temperature of 100 °C to form a top coating. Then the specimen was subjected to irradiation by a UV light for 5 days at the UV intensity of 0.5 mW/cm² by using a BLB fluorescent lamp to obtain #1 specimen.

The #1 specimen and the acrylic resin plate were investigated for antifogging capability, contact angle with water, antibacterial performance and deodorizing function, in a manner similar to Reference Example 7. In the acrylic resin plate, the contact angle with water was 70°. In the #1 specimen, however, the contact angle with water was 3-9°. With regard to antibacterial property, in the acrylic resin plate the survival rate of colibacillus was greater than 70%, whereas the survival rate was less than 10% in the #1 specimen. Regarding the deodorizing property, while the removal rate of methyl mercaptan by the acrylic resin plate was less than 10%, the removal rate by the #1 specimen was more than 90%.

Reference Example 9

Photo-Redox Activity Enhancer - Pt-Added Photocatalyst

In a manner similar to Reference Example 1, a thin film of amorphous silica and then a thin film of amorphous titania were formed on the surface of a 10cm-square soda-lime glass plate and the glass plate was then calcined at a temperature of 500 °C to transform amorphous titania into the anatase form titania.

Then, 1 ml of aqueous solution of chloroplatinic acid 6-hydrate H₂PtCl₆·6H₂O containing 0.1 weight percent of platinum was applied onto the specimen which was then subjected to irradiation by a UV light for one minute at the UV intensity of 0.5 mw/cm² by a BLB fluorescent lamp to thereby form deposit of platinum by photoreduction of chloroplatinic acid hexahydrate to obtain a specimen wherein crystals of titania were doped with platinum.

The specimen thus obtained was left as such for a day and was thereafter subjected to irradiation by a UV light for a day at the UV intensity of 0.5 mW/cm² by using a BLB fluorescent lamp. The contact angle measured after UV irradiation was 0°. Furthermore, the removal rate of methyl mercaptan as measured and calculated in a manner similar to Reference Example 7 was 98%.

Reference Example 10

Self-Cleaning and Antifouling Capability

The #2 specimen of Reference Example 5 was subjected to irradiation by a UV light for 10 hours at the UV intensity of 0.5 mW/cm² by using a BLB fluorescent lamp to obtain #3 specimen. When the contact angle with water of the surface of this specimen was measured by the contact angle meter (made by ERMA), the reading of the contact angle meter was less than 3°.

An outdoor accelerated fouling test apparatus as shown in <figref idref="f0004">FIGS. 3A</figref> and <figref idref="f0005">3B</figref> was installed atop of a building located in Chigasaki City. Referring to <figref idref="f0004">FIGS. 3A</figref> and <figref idref="f0005">3B</figref>, this apparatus includes an inclined specimen mounting surface 22 supported by a frame 20 and adapted to affix specimens 24 thereto. A forwardly slanted roof 26 is fixed at the top of the frame. The roof is made of corrugated plastic sheet and is designed to permit collected rain water to flow down in a striped pattern along the surface of the specimens 24 affixed on the specimen mounting surface 22.

The #3 specimens, the #1 specimens of Reference Example 5, and the #2 specimens of Reference Example 5 were mounted to the specimen mounting surface 22 of the apparatus and were exposed to the weather conditions for 9 days starting from June 12, 1995. The weather and the amount of rain fall during this period were as shown in Table 3. <tables id="tabl0003" num="0003"><table frame="all"><title>Table 3</title><tgroup cols="4"><colspec colnum="1" colname="col1" colwidth="16mm" /><colspec colnum="2" colname="col2" colwidth="30mm" /><colspec colnum="3" colname="col3" colwidth="23mm" /><colspec colnum="4" colname="col4" colwidth="25mm" /><thead><row><entry align="center" valign="middle">Date</entry><entry align="center" valign="middle">Weather</entry><entry align="center" valign="middle">Rainfall (mm)</entry><entry align="center" valign="middle">Shining Hours</entry></row></thead><tbody><row><entry align="center" valign="middle">June 12</entry><entry align="center" valign="middle">cloudy</entry><entry align="center" valign="middle">0.0</entry><entry align="center" valign="middle">0</entry></row><row><entry align="center" valign="middle">June 13</entry><entry align="center" valign="middle">heavy rain</entry><entry align="center" valign="middle">53.0</entry><entry align="center" valign="middle">0</entry></row><row><entry align="center" valign="middle">June 14</entry><entry align="center" valign="middle">cloudy/rain</entry><entry align="center" valign="middle">20.5</entry><entry align="center" valign="middle">0</entry></row><row><entry align="center" valign="middle">June 15</entry><entry align="center" valign="middle">cloudy/fair</entry><entry align="center" valign="middle">0.0</entry><entry align="center" valign="middle">3.9</entry></row><row><entry align="center" valign="middle">June 16</entry><entry align="center" valign="middle">cloudy</entry><entry align="center" valign="middle">0.0</entry><entry align="center" valign="middle">0.2</entry></row><row><entry align="center" valign="middle">June 17</entry><entry align="center" valign="middle">fair/cloudy</entry><entry align="center" valign="middle">0.0</entry><entry align="center" valign="middle">9.6</entry></row><row><entry align="center" valign="middle">June 18</entry><entry align="center" valign="middle">fair to cloudy</entry><entry align="center" valign="middle">0.0</entry><entry align="center" valign="middle">7.0</entry></row><row><entry align="center" valign="middle">June 19</entry><entry align="center" valign="middle">rain to cloudy</entry><entry align="center" valign="middle">1.0</entry><entry align="center" valign="middle">0.2</entry></row><row><entry align="center" valign="middle">June 20</entry><entry align="center" valign="middle">cloudy/heavy rain</entry><entry align="center" valign="middle">56.0</entry><entry align="center" valign="middle">2.4</entry></row></tbody></tgroup></table></tables>

When inspected on June 14, dirt or smudge of a striped pattern was observed on the surface of the #1 specimen. Presumably, this is because during heavy rainfall on the preceding day the airborne hydrophobic contaminants such as combustion products like carbon black and city grime were carried by rain and were allowed to deposit on the specimen surface as rain water flowed down along the surface. In contrast, no dirt or smudge was observed in the #3 specimen. Believably, this is because, since the specimen surface was rendered highly hydrophilic, the hydrophobic contaminants were unable to adhere onto the surface as rain water containing contaminants flowed down and further because the contaminants were washed away by rainfall.

In the #2 specimen, dirt or smudge of a mottled pattern was observed. This is probably because, after the #2 specimen which had not been subjected to UV irradiation was mounted to the testing apparatus, the photocatalytic coating thereof was not yet exposed to UV light in the sunlight to a satisfactory degree so that the surface was unevenly hydrophilified.

When inspected on June 20, a smudge of a vertically striped pattern was remarkably noticed on the surface of the #1 specimen which was not provided with the photocatalytic coating. Conversely, no smudge was observed on the #3 and #2 specimens provided with the photocatalytic coating.

The contact angle with water as measured was 70° for the #1 specimen and was less than 3° for the #2 and #3 specimens. The fact that the contact angle of the #2 specimen became less than 3° demonstrates that, upon irradiation by UV light contained in the sunlight, the organic groups bonded to the silicon atoms of the silicone molecules of the top coating were substituted with hydroxyl groups under the photocatalytic action so that the top coating was rendered highly hydrophilic. It was also noted that in the #3 specimen a high degree of hydrophilicity was sustained by irradiation of the sunlight.

Reference Example 11

Color Difference Test

Prior to and 1 month after mounting to the outdoor accelerated fouling test apparatus, the #1 and #2 specimens of Reference Example 10 were tested by a color difference meter (Tokyo Denshoku) to measure a color difference. In compliance with the Japanese Industrial Standard (JIS) H0201, the color difference was indicated by the E* index. The variation in the color difference after mounting to the accelerated fouling test apparatus is shown in Table 4. <tables id="tabl0004" num="0004"><table frame="all"><title>Table 4</title><tgroup cols="3"><colspec colnum="1" colname="col1" colwidth="23mm" /><colspec colnum="2" colname="col2" colwidth="23mm" /><colspec colnum="3" colname="col3" colwidth="23mm" /><thead><row><entry align="center" valign="middle" /><entry align="center" valign="middle">Striped area</entry><entry align="center" valign="middle">Background</entry></row></thead><tbody><row><entry align="center" valign="middle">#1 Specimen</entry><entry align="center" valign="middle">4.1</entry><entry align="center" valign="middle">1.1</entry></row><row><entry align="center" valign="middle">#2 Specimen</entry><entry align="center" valign="middle">0.8</entry><entry align="center" valign="middle">0.5</entry></row></tbody></tgroup></table></tables>

As will be noted from Table 4, in the #1 specimen void of the photocatalytic coating, a large amount of smudge was caused to adhere to the vertical striped area corresponding to the flow path of rainwater, as compared with the #2 specimen provided with the photocatalytic coating. It will also be recognized that, between the #2 and #1 specimens, there was a substantial difference in the degree of fouling of the background area.

Reference Example 12

Tile with Highly Hydrophilic Surface - Coating of Sintered Titania and Silica

A sol of the anatase form of titania (Ishihara Industries of Osaka, STS-11) and a sol of colloidal silica (Nissan Chemical Ind., "Snowtex O") were admixed at a ratio by mol of 88:12 in terms of solid matter and the mixture was applied by spray coating on the surface of a glazed tile (Toto Ltd., AB02E01) of 15cm square in size, followed by sintering for 1 hour at a temperature of 800 deg. C to obtain a specimen covered by a coating comprised of titania and silica. The thickness of the coating was 0.3 µm. The contact angle with water immediately after sintering was 5°.

The specimen was kept in the dark for a week but the contact angle measured thereafter was still 5°.

As the specimen surface was subjected to irradiation by a UV light for 1 day at the UV intensity of 0.03 mW/cm² by using a BLB fluorescent lamp, the contact angle with water became 0°.

Reference Example 13

Coating of Sintered Titania and Silica - Hydrophilification under Room Light

A sol of the anatase form of titania (STS-11) and a sol of colloidal silica (Nissan Chemical Ind., "Snowtex 20") were admixed at a ratio by mol of 80:20 in terms of solid matter and the mixture was applied by spray coating on the surface of a 15cm-square glazed tile (AB02E01), followed by sintering for 1 hour at a temperature of 800 °C to obtain a specimen covered by a coating comprised of titania and silica. The thickness of the coating was 0.3 µm. The contact angle with water immediately after sintering was 5°.

The contact angle with water as measured after keeping the specimen in the dark for 2 weeks was 14°.

As the specimen surface was subjected to irradiation by a UV light for 1 day at the UV intensity of 0.004 mW/cm² by a white fluorescent lamp, the contact angle with water became 4°.

Accordingly, it was found that the photocatalytic coating was rendered hydrophilic to a satisfactory degree even under indoor illumination.

Reference Example 14

Coating of Sintered Titania and Silica - Silica Content

A sol of the anatase form of titania (STS-11) and a sol of colloidal silica (Nissan Chemical Ind., "Snowtex 20") were admixed at a varying ratio to obtain a plurality of suspensions having a ratio by mol of silica to the solid matter of the suspension of 0%, 5%, 10%, 15%, 20%, 25% and 30%, respectively. 0.08g of each suspension was uniformly applied by spray coating on the surface of a 15cm-square glazed tile (AB02E01) and each tile was fired for 1 hour at a temperature of 800 °C to obtain a plurality of specimens each covered by a coating comprised of titania and silica.

The contact angle with water immediately after sintering of the respective specimens was as shown in the graph of <figref idref="f0006">FIG. 4</figref>. As will be apparent from the graph of <figref idref="f0006">FIG. 4</figref>, the initial contact angle was lowered by addition of silica.

The contact angle with water as measured after keeping the specimen in the dark for 8 days was plotted in the graph of <figref idref="f0006">FIG. 5</figref>. As will be noted by comparing the graph of <figref idref="f0006">FIG. 4</figref> with the graph of <figref idref="f0006">FIG. 5</figref>, the loss of hydrophilicity resulting from keeping the specimens in the dark is small in the specimens containing more than 10%, in the ratio by mol, of silica.

Thereafter, the specimens were subjected to irradiation by a UV light for 2 days at the UV intensity of 0.03 mw/cm² by using a BLB fluorescent lamp. The contact angle with water after irradiation is shown in the graph of <figref idref="f0007">FIG. 6</figref>. It will be noted from the graph that upon UV irradiation hydrophilicity is readily recovered in the case where silica is added to titania.

Then the specimens were kept in the dark for further 8 days and the contact angle with water was measured. The results are shown in <figref idref="f0007">FIG. 7</figref>. It will be noted from the graph that the loss of hydrophilicity resulting from keeping the specimens in the dark after UV irradiation is small in the case where silica is added to titania.

A pencil scratch test was carried out to examine the abrasion resistance of the sintered film comprised of titania and silica. The results are shown in the graph of <figref idref="f0008">FIG. 8</figref>. It will be understood that the abrasion resistivity is increased with increasing silica content.

Example 1

Sludge Test

A mixture of a sol of the anatase form of titania (STS-11) and a sol of colloidal silica (Snowtex 20) and having a silica content of 10% by weight in terms of solid matter was applied to a 15cm-square glazed tile (AB02E01) in an amount of 4.5 mg in terms of solid matter and the tile was then calcined for 10 minutes at a temperature of 880 °C. The specimen was then subjected to irradiation by a UV light for 3 hours at the UV intensity of 0.5 mW/cm² by using a BLB fluorescent lamp to obtain #1 specimen. The contact angle with water of the #1 specimen and the glazed tile (AB02E01) as such was 0° and 30°, respectively.

A mixture of powders of 64.3% by weight of yellow ochre, 21.4% by weight of calcined Kanto loam clay, 4.8% by weight of hydrophobic carbon black, 4.8% by weight of silica powder, and 4.7% by weight of hydrophilic carbon black was suspended in water at a concentration of 1.05 g/l to prepare a slurry.

150 ml of the thus prepared slurry was caused to flow down along the surface of the #1 specimen and the glazed tile (AB02E01) held inclined at 45°, followed by drying for 15 minutes, and 150 ml of distilled water was thereafter caused to flow down, followed by drying for 15 minutes, the cycle of the above-mentioned sequences being repeated for 25 times. A change in color difference and in glossiness after the sludge test was measured. The measurement of the glossiness was carried out according to the method laid down by the Japanese Industrial Standard (JIS) Z8741 and the variation in the glossiness was obtained by dividing the glossiness after testing by the glossiness before testing. The results are given in Table 5. <tables id="tabl0005" num="0005"><table frame="all"><title>Table 5</title><tgroup cols="3"><colspec colnum="1" colname="col1" colwidth="32mm" /><colspec colnum="2" colname="col2" colwidth="23mm" /><colspec colnum="3" colname="col3" colwidth="27mm" /><thead><row><entry align="center" valign="middle" /><entry align="center" valign="middle">#1 Specimen</entry><entry align="center" valign="middle">Tile (AB02E01)</entry></row></thead><tbody><row><entry align="center" valign="middle">Contact Angle (°)</entry><entry align="center" valign="middle">0</entry><entry align="center" valign="middle">30</entry></row><row><entry align="center" valign="middle">Color Diff. Change</entry><entry align="center" valign="middle">0.7</entry><entry align="center" valign="middle">5.6</entry></row><row><entry align="center" valign="middle">Glossiness Change</entry><entry align="center" valign="middle">93.6%</entry><entry align="center" valign="middle">74.1%</entry></row></tbody></tgroup></table></tables>

Example 2

Relationship between Contact Angle with Water and Self-Cleaning and Antifouling Capability

Various specimens were subjected to a sludge test in a manner similar to Example 1. The tested specimens included the #1 specimen of Example 1, #2 specimen having a copper-doped titania coating, the glazed tile (AB02E01), an acrylic resin plate, an artificial marble plate (Toto Ltd., ML03) made of polyester resin matrix, and a polytetrafluoroethylene (PTFE) plate. The #2 specimen was prepared by spray coating 0.3g of an aqueous solution of copper acetate monohydrate having a copper concentration of 50 mol/g on the #1 specimen of Example 1 and, after drying, subjecting the specimen to irradiation by a UV light for 10 minutes at the UV intensity of 0.4 mW/cm² by a BLB fluorescent lamp to thereby subject copper acetate monohydrate to photoreduction deposition. The results of the sludge test are shown in Table 6. <tables id="tabl0006" num="0006"><table frame="all"><title>Table 6</title><tgroup cols="4"><colspec colnum="1" colname="col1" colwidth="23mm" /><colspec colnum="2" colname="col2" colwidth="45mm" /><colspec colnum="3" colname="col3" colwidth="40mm" /><colspec colnum="4" colname="col4" colwidth="37mm" /><thead><row><entry align="center">Specimen</entry><entry align="center">Contact Angle With Water (°)</entry><entry align="center">Color Difference Change</entry><entry align="center">Glossiness Change (%)</entry></row></thead><tbody><row><entry align="center" valign="bottom">#1 Specimen</entry><entry align="center" valign="bottom">0.0</entry><entry align="center" valign="bottom">0.7</entry><entry align="center" valign="bottom">93.8</entry></row><row><entry align="center" valign="bottom">#2 Specimen</entry><entry align="center" valign="bottom">4.0</entry><entry align="center" valign="bottom">2.0</entry><entry align="center" valign="bottom">81.5</entry></row><row><entry align="center" valign="bottom">Glazed Tile</entry><entry align="center" valign="bottom">19.4</entry><entry align="center" valign="bottom">4.6</entry><entry align="center" valign="bottom">68.3</entry></row><row><entry align="center" valign="bottom">Acrylic Plate</entry><entry align="center" valign="bottom">50.9</entry><entry align="center" valign="bottom">4.5</entry><entry align="center" valign="bottom">69.3</entry></row><row><entry align="center" valign="bottom">Artifi. Marble</entry><entry align="center" valign="bottom">54.8</entry><entry align="center" valign="bottom">3.2</entry><entry align="center" valign="bottom">85.2</entry></row><row><entry align="center" valign="bottom">PTFE Plate</entry><entry align="center" valign="bottom">105.1</entry><entry align="center" valign="bottom">0.9</entry><entry align="center" valign="bottom">98.2</entry></row></tbody></tgroup></table></tables>

Furthermore, various specimens were subjected for a period of a month to an accelerated fouling test similar to Reference Example 10. The specimens used included the #1 specimen of Example 1, the glazed tile (AB02E01), an acrylic resin plate, an aluminum plate covered by a base coating of silicone in a manner similar to Reference Example 5, and a PTFE plate. The results of the accelerated tests are shown in Table 7 wherein, similar to Reference Example 11, the change in the color difference represents that of the vertical striped area of the specimens. <tables id="tabl0007" num="0007"><table frame="all"><title>Table 7</title><tgroup cols="3"><colspec colnum="1" colname="col1" colwidth="27mm" /><colspec colnum="2" colname="col2" colwidth="43mm" /><colspec colnum="3" colname="col3" colwidth="40mm" /><thead><row><entry align="center" valign="top">Specimen</entry><entry align="center" valign="top">Contact Angle with Water (°)</entry><entry align="center" valign="top">Color Difference change</entry></row></thead><tbody><row><entry align="center">#+1 Specimen</entry><entry align="center">0.0</entry><entry align="center">0.9</entry></row><row><entry align="center">Glazed Tile</entry><entry align="center">19.4</entry><entry align="center">1.5</entry></row><row><entry align="center">Acrylic Plate</entry><entry align="center">50.9</entry><entry align="center">2.3</entry></row><row><entry align="center">Silicone coated</entry><entry align="center">90.0</entry><entry align="center">5.2</entry></row><row><entry align="center">PTFE Plate</entry><entry align="center">105.1</entry><entry align="center">7.8</entry></row></tbody></tgroup></table></tables>

To facilitate understanding, the contact angle with water as well as the variation in the color difference are plotted in the graph of <figref idref="f0009">FIG. 9</figref>. In the graph of <figref idref="f0009">FIG. 9</figref>, the curve A indicates the relationship between the contact angle with water and the color difference change caused by the contaminants such as airborne combustion products like carbon black and city grime as a result of the accelerated fouling test, with the curve B representing the relationship between the contact angle with water and the color difference change caused by sludge as a result of the sludge test.

Referring to the graph of <figref idref="f0009">FIG. 9</figref>, as the contact angle with water of the substrate increases, the dirt or stain due to combustion products and city grime becomes more conspicuous, as will be readily understood from the curve A. This is because the contaminants such as combustion products and city grime are generally hydrophobic and, hence, are apt to adhere to a hydrophobic surface.

In contrast, the curve B illustrates that the dirt or stain due to sludge peaks when the contact angle with water is in the range of 20-50°. This is because the inorganic substances such as loam and soil inherently have a hyrdophilicityon the order of 20-50° in terms of the contact angle with water so that they are apt to adhere to a surface having a similar hyrdophilicity. It will therefore be understood that, by rendering the surface hyrdophilic to the degree that the contact angle with water is less than 20° or, alternatively, by rendering the surface hyrdophobic to the degree that the contact angle with water is greater than 60°, the adherence of the inorganic substances to a surface can be prevented.

The reason why fouling by sludge is reduced as the contact angle with water is less than 20° is that, when the surface is rendered highly hydrophilic to the degree that the contact angle with water becomes less than 20°, the affinity of the surface for water exceeds the affinity for inorganic substances so that adherence of inorganic substances is blocked by water which preferentially adheres to the surface and any inorganic substances that have adhered to or are tending to adhere to the surface are readily washed away by water.

It will be noted from the foregoing that, in order to prevent both the hydrophobic and hydrophilic substances from adhering to the surface of a building and the like, or in order to ensure that dirt or smudge deposited on the surface is washed away by rain water so as to permit the surface to be self-cleaned, it is desirable to modify the surface to present a contact angle with water of less than 20°, preferably less than 10°, more preferably less than 5°.

Example 3

Glazed Tile - Cleansing Capability for oil Stains

A quantity of oleic acid was applied on the surface of the #1 specimen of Example 1. When the specimen was then immersed in water in a cistern with the specimen surface held in a horizontal position, oleic acid became rounded to form oil droplets which were then released from the surface of the tile to ascend to the top of the water.

This Example also illustrates that a surface of pottery, such as tile and tableware, fouled by oil or fat can be readily cleansed merely by soaking the object in water or by wetting it with water, provided that the surface thereof is provided with a photocatalytic coating and provided that the photocatalyst is photoexcited by UV irradiation.

Reference Example 15

Glazed Tile - Antibacterial Enhancer (Ag Doping)

A coating comprised of titania and silica was formed on the surface of a 15cm-square glazed tile (AB02E01) in a manner similar to Reference Example 12.

Then an aqueous solution containing 1 weight percent of silver lactate was applied onto the surface of the tile which was then subjected to irradiation by a UV light of a BLB fluorescent lamp to thereby subject silver lactate to photoreduction to form a silver deposit whereby a specimen coated with silver doped titania was obtained. The contact angle with water as measured was 0°.

When the tile was then tested for the antibacterial function in a manner similar to Reference Example 6, the survival rate of colibacillus was less than 10%.

Reference Example 16

Glazed Tile - Antibacterial Enhancer (Cu Doping)

A coating comprised of titania and silica was formed on the surface of a 15cm-square glazed tile (AB02E01) in a manner similar to Reference Example 12.

Then an aqueous solution containing 1 weight percent of copper acetate monohydrate was applied onto the surface of the tile which was then subjected to irradiation by a UV light of a BLB fluorescent lamp to thereby subject copper acetate monohydrate to photoreduction to form a copper deposit whereby a specimen coated with copper-doped titania was obtained. The contact angle with water as measured was less than 3°.

As the tile was then tested for the antibacterial function in a manner similar to Reference Example 6, the survival rate of colibacillus was less than 10%.

Reference Example 17

Glazed Tile - Photo-Redox Activity Enhancer

A coating comprised of titania and silica was formed on the surface of a 15cm-square glazed tile (AB02E01) in a manner similar to Reference Example 12.

Then, the surface of the specimen was doped with platinum in a manner similar to Reference Example 9. The contact angle with water as measured was 0°.

The removal rate of methyl mercaptan as measured in a manner similar to Reference Example 7 was 98%.