Hierarchically Ordered Zeolites With Cubic Mesopore Networks
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Solution Overview
Problem
Existing methods for producing hierarchically ordered zeolites lack control over the long-range ordering and size of mesopores, leading to poor interconnectivity and hindered diffusion of larger species, which limits their performance in applications such as catalysis and adsorption.
Innovation Solution
A method involving base-mediated reassembly of zeolites using supramolecular templates and ionic co-solutes to create hierarchically ordered crystalline microporous materials with well-defined long-range mesoporous ordering of cubic symmetry, achieved through controlled dissolution and self-assembly of zeolite oligomers into mesostructures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional methods are used to produce hierarchically ordered zeolites, then the basic microporous structure is maintained, but the long-range ordering and size control of mesopores cannot be achieved, leading to poor interconnectivity
Solution Approach 1:
The patent applies preliminary action by using supramolecular templates (such as surfactants or block copolymers) that are introduced before zeolite crystallization to pre-organize the mesoporous structure. These templates self-assemble into ordered arrays that guide the subsequent formation of zeolite crystals, ensuring long-range ordering of mesopores is achieved from the outset rather than attempting to create it afterward
Solution Approach 2:
The patent uses supramolecular templates as intermediary structures that mediate between the desired mesoporous architecture and the zeolite crystal formation. These templates act as sacrificial structures that define the mesopore geometry and connectivity during synthesis, then are removed to leave behind the ordered hierarchical structure
2Productivity
If mesoporous structures are introduced to improve diffusion of larger species, then accessibility to internal sites is enhanced, but control over mesopore size and interconnectivity is lost
Solution Approach 1:
The patent applies parameter changes by systematically varying the molecular structure of supramolecular templates (such as changing the hydrophobic chain length, head group size, or block copolymer composition) to precisely control mesopore size. By adjusting these template parameters, the patent achieves both desired mesopore dimensions and improved diffusion capabilities for larger species
Solution Approach 2:
The patent uses segmented block copolymers as templates, where different blocks self-assemble into distinct regions that define specific mesopore characteristics. This segmentation allows independent control over mesopore size, shape, and interconnectivity, enabling precise manufacturing of hierarchical structures with optimized diffusion pathways
3Productivity
If hierarchically ordered structures are created to enhance catalytic performance, then mass transfer is improved, but the synthesis process becomes more complex
Solution Approach 1:
The patent applies self-service by utilizing the self-assembling properties of supramolecular templates that automatically organize into ordered structures under appropriate conditions. The templates self-direct the zeolite crystal formation and mesopore arrangement without requiring complex external manipulation, simplifying the overall manufacturing process while achieving hierarchical ordering
Solution Approach 2:
The patent exploits phase transitions of supramolecular templates (such as liquid crystalline phase transitions) during the synthesis process to drive the formation of ordered hierarchical structures. By controlling temperature, concentration, and pH to induce specific phase transitions, the patent achieves hierarchical ordering through thermodynamically driven self-organization rather than mechanically complex processes
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.