Lamellar Hierarchical Zeolites for Ordered Mesopore Diffusion

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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 diffusion limitations, which hinder their performance in catalytic and adsorption applications.

Innovation Solution

A method involving base-mediated reassembly of parent crystalline microporous materials using supramolecular templates and controlled dissolution to form hierarchically ordered crystalline microporous materials with well-defined lamellar symmetry, utilizing supramolecular templates to constrain diffusion and induce mesoporous ordering through controlled hydrothermal conditions and pH management.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If existing methods for producing hierarchically ordered zeolites are used, then zeolite synthesis is achieved, but control over long-range ordering and size of mesopores is lacking

Engineering Contradiction:

Improvecontrol over long-range ordering and size of mesoporesVSAvoidinterconnectivity and diffusion performance

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The patent employs base-mediated dissolution to control the size and distribution of mesopores by adjusting pH parameters and dissolution conditions. This enables precise control over long-range ordering and mesopore dimensions, directly resolving the contradiction between manufacturing precision and reliability by allowing tailored pore structures that maintain both order and interconnectivity

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses supramolecular templates as intermediaries to guide the formation of hierarchically ordered structures. These templates mediate between the crystalline microporous material and the desired mesoporous structure, enabling controlled long-range ordering while maintaining reliable interconnectivity through the templating mechanism

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If mesopore size is increased to improve diffusion, then mass transfer is enhanced, but structural order and crystallinity may be compromised

Engineering Contradiction:

Improvemass transfer and diffusion rateVSAvoidstructural order and crystallinity

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent creates a hierarchical pore structure with segmented mesopores distributed throughout the crystalline framework. This segmentation allows enhanced mass transfer through multiple pathways while maintaining the overall structural order and crystallinity of the zeolite, as the mesopores are integrated into the crystalline structure rather than disrupting it

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces mesopores with specific size and distribution characteristics at local regions within the zeolite crystal structure. This local quality approach allows optimization of diffusion properties in specific areas while preserving the global structural order and crystallinity, enabling enhanced mass transfer without compromising overall structural integrity

Inventive Principle:

Principle #3Local quality

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 produces zeolites with well-defined long-range mesoporous ordering, improving mass transfer and catalytic performance by enhancing diffusion and reducing coke formation, while maintaining high crystallinity and minimizing amorphous phases.

Implementation Method 1

base-mediated reassembly of parent crystalline microporous materials using supramolecular templates and controlled dissolution

Methodology Applied

Scientific EffectDissolution: Solvation

Implementation Method 2

supramolecular templates possess one or more dimensions larger than dimensions of micropores of the crystalline microporous material to constrain diffusion into micropores

Methodology Applied

Scientific EffectDiffusion constraint: Diffusion Barrier

Implementation Method 3

controlled hydrothermal conditions and pH management

Methodology Applied

Scientific EffectHydrothermal conditions: Heating

Implementation Method 4

base-mediated reassembly of parent crystalline microporous materials using supramolecular templates to form hierarchically ordered crystalline microporous materials

Methodology Applied

Scientific EffectCrystallization: Crystallisation

Data Source

PatentUS20260055000A1Hierarchically ordered crystalline microporous materials with long-range mesoporous order having lamellar symmetry

Publication Date: 2026.02.26 SAUDI ARABIAN OIL CO

AI summary

A composition of matter is provided comprising hierarchically ordered crystalline microporous material having well-defined long-range mesoporous ordering of lamellar 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 lamellar symmetry observable by microscopy.