Hierarchical Pore Beta Zeolite With Recyclable Polymer Template Removal

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Solution Overview

Problem

Existing methods for producing hierarchical pore Beta zeolite require high-temperature calcination to remove template agents, leading to structural damage, environmental pollution, and inability to recycle, while also being costly.

Innovation Solution

A recyclable polymer template agent with a specific molecular weight and chemical structure is used, allowing zeolite precursor locking and release via temperature sensitivity, enabling centrifugation-based removal without calcination.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If high-temperature calcination is used to remove template agents, then template agents are effectively removed, but the zeolite structure is damaged and energy consumption increases

Engineering Contradiction:

Improvetemplate agent removal completenessVSAvoidzeolite structure integrity

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent utilizes the phase transition of water from liquid to vapor at low temperature (below 100°C) to remove the template agent. The template agent is designed to be water-soluble, allowing it to be extracted from the zeolite structure through simple water washing without requiring high-temperature calcination, thus preserving the zeolite structure while achieving complete template removal.

Inventive Principle:

Principle #36Phase transitions

Solution Approach 2:

The patent changes the removal method parameter from high-temperature thermal decomposition to low-temperature aqueous extraction. By designing the template agent with specific water solubility parameters, the removal process occurs at temperatures below 100°C, avoiding structural damage while maintaining removal effectiveness.

Inventive Principle:

Principle #35Parameter changes

2Shape

If traditional template agents are used, then hierarchical pore structure is achieved, but the template agents cannot be recycled and production costs increase

Engineering Contradiction:

Improvehierarchical pore structureVSAvoidtemplate agent recyclability

Core Design Contradiction:

ShapeVSLoss of substance

Solution Approach 1:

The patent designs the template agent to be recoverable through water washing. After the template agent fulfills its function of directing hierarchical pore formation during synthesis, it is easily separated from the zeolite structure by water extraction. The recovered template agent can be reused in subsequent synthesis batches, reducing material loss and production costs while maintaining the hierarchical pore structure.

Inventive Principle:

Principle #34Discarding and recovering

Solution Approach 2:

The patent introduces water as an intermediary substance to facilitate the separation and recovery of the template agent. Water acts as a medium that selectively extracts the water-soluble template agent from the zeolite structure without damaging the zeolite framework, enabling easy recovery and reuse of the template agent.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If high-temperature calcination is used to remove template agents, then template agents are removed, but environmental pollution increases

Engineering Contradiction:

Improvetemplate agent removal completenessVSAvoidenvironmental pollution

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

Inventive Principle:

Principle #36Phase transitions

Solution Approach 2:

The patent converts the potential harm of high-temperature processing into benefit by using low-temperature water extraction. The water-soluble template agent can be easily removed by washing, and the waste water can be treated and reused, transforming what would have been a harmful high-temperature process into an environmentally friendly low-temperature process.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The method reduces energy consumption, lowers production costs, and minimizes environmental impact by allowing template agent reuse, while achieving a hierarchical pore structure with improved mass transfer properties.

Implementation Method 1

allowing zeolite precursor locking and release via temperature sensitivity

Methodology Applied

Scientific EffectTemperature sensitivity: Thermal Expansion

Data Source

PatentUS20260109614A1Recyclable polymer template agent, hierarchical gradient pore beta zeolite and preparation methods thereof

Publication Date: 2026.04.23 MINJIANG UNIV

AI summary

The present invention relates to the field of zeolite technology, and more particularly to a recyclable polymer template agent, a hierarchical gradient pore Beta zeolite, and a green preparation method thereof. By synthesizing a polymer template agent and utilizing the unique temperature sensitivity conferred by the combination of the hydrophilic quaternary amide group and the hydrophobic isopropyl group in the polyquaternary ammonium salt structure of the recyclable polymer template agent provided by the present invention, the zeolite precursor is locked inside the gel at the zeolite synthesis temperature, directing the formation of the zeolite crystal structure; after crystallization is complete, the reaction temperature is lowered to room temperature, the polymer shell opens, and the locked zeolite crystals inside are released via a diffusion mechanism, followed by centrifugation to separate the polymer from the zeolite for removal.