Hierarchical Zeolite with Cubic Mesopores
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Solution Overview
Problem
Current methods for producing hierarchically ordered zeolites lack control over long-range ordering and connectivity of mesopores, leading to poor diffusion and catalytic performance due to random mesopore sizes and locations.
Innovation Solution
A composition of hierarchically ordered crystalline microporous materials with well-defined long-range mesoporous ordering of cubic symmetry is achieved by using supramolecular templates and base-mediated reassembly, where the dissolution and self-assembly processes are controlled to induce cubic symmetry and improve mesopore connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional zeolite synthesis methods are used, then microporous structure is formed, but long-range mesoporous ordering and connectivity are poor
Solution Approach 1:
The patent applies preliminary action by using supramolecular templates (such as surfactants) that self-assemble into ordered mesoporous structures before the zeolite crystallization occurs. These templates pre-establish the long-range mesoporous ordering and connectivity, which then guide the subsequent zeolite framework formation around them, ensuring both precision and reliability of the mesoporous structure.
Solution Approach 2:
The patent uses supramolecular templates as intermediaries that mediate between the synthesis conditions and the final zeolite structure. These templates act as a bridging element that organizes the mesoporous framework during synthesis, enabling long-range order and good connectivity, and are later removed to leave the desired hierarchical pore structure.
2Speed
If mesoporous solids are used for larger species, then diffusion is improved, but structural order and symmetry are lost
Solution Approach 1:
The patent creates composite hierarchical structures that combine both microporous zeolite domains and ordered mesoporous domains within a single material framework. This composite approach allows the material to simultaneously provide the high diffusion rates of mesopores and the structural order of crystalline zeolites, resolving the contradiction between speed and stability.
Solution Approach 2:
The patent implements a nested hierarchical structure where microporous zeolite units are arranged within and around ordered mesoporous channels. This nesting allows larger species to diffuse rapidly through the outer mesoporous network while maintaining the internal microporous structure for selective interactions, preserving structural order while enhancing diffusion.
3Ease of manufacture
If random mesopores are formed, then synthesis is simpler, but catalytic performance deteriorates
Solution Approach 1:
The patent employs self-service by utilizing the spontaneous self-assembly of supramolecular templates into ordered mesoporous structures during synthesis. This self-organizing process automatically creates the long-range ordered hierarchical structure without requiring complex external control mechanisms, maintaining synthesis simplicity while achieving high catalytic performance through the ordered structure.
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 resulting materials exhibit enhanced diffusion, reduced coke formation, and improved catalytic performance, with well-defined mesoporous structures observable by XRD and microscopy, effectively addressing the limitations of traditional zeolites.
Implementation Method 1
the dissolution and self-assembly processes are controlled to induce cubic symmetry and improve mesopore connectivity
Implementation Method 2
using supramolecular templates and base-mediated reassembly, where the dissolution and self-assembly processes are controlled
Implementation Method 3
well-defined mesoporous structures observable by XRD and microscopy
Implementation Method 4
presence of secondary peaks in an X-ray diffraction (XRD) pattern
Data Source
AI summary
A composition of matter is provided comprising hierarchically ordered crystalline microporous material having well-defined long-range mesoporous ordering of cubic symmetry. The composition possesses mesopores having walls of crystalline microporous material and a mass of mesostructure between mesopores of crystalline microporous material. Long-range ordering is defined by presence of secondary peaks in an X-ray diffraction (XRD) pattern and/or cubic symmetry observable by microscopy.