Mesoporous Silica Particles via High-Pressure Emulsification
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Solution Overview
Problem
Existing methods for producing mesoporous silica particles struggle to achieve small average primary particle sizes and minimize coarse particles, leading to difficulties in forming uniform coatings and antireflection films with desired optical properties.
Innovation Solution
A high-pressure emulsification method is employed to create mesoporous silica particles with a silica-containing outer shell and hollow interior, involving a mixed solution of hydrophobic organic compounds, surfactants, and silica sources, which allows for the formation of emulsion droplets with precise size control and subsequent precipitation of composite silica particles, followed by removal of the droplets to achieve the desired particle characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a mixed solution containing surfactant, hydrophobic organic compound, and silica source is stirred to form emulsion droplets, then composite silica particles with mesoporous layer are formed, but the average primary particle size becomes large and coarse particles increase
Solution Approach 1:
The patent changes the emulsification method from conventional stirring to high-pressure emulsification, which fundamentally alters the physical parameters of the emulsion formation process. This high-pressure treatment creates finer emulsion droplets with more uniform size distribution, directly leading to smaller average primary particle size (0.2 μm or less) and reduced coarse particles in the final mesoporous silica product
Solution Approach 2:
The high-pressure emulsification process applies periodic pressure cycles to the mixed solution, creating repeated expansion and compression effects that generate fine and uniform emulsion droplets. This periodic high-pressure treatment is more effective than continuous stirring in controlling particle size distribution and minimizing coarse particles
2Manufacturing precision
If conventional stirring method is used to form emulsion droplets, then the process is simple, but it is difficult to produce particles with small average primary particle size and narrow size distribution
Solution Approach 1:
The patent replaces the conventional mechanical stirring system with a high-pressure emulsification system. This substitution uses high-pressure fluid dynamics instead of mechanical agitation to create emulsion droplets, achieving superior particle size uniformity and control while reducing the formation of coarse particles
3Reliability
If mesoporous silica particles with small average primary particle size are produced, then coatings with low refractive index and reflectance can be formed, but the production process becomes more difficult
Solution Approach 1:
By changing the emulsification parameters to high-pressure conditions, the patent achieves consistent production of fine particles with small average primary particle size (0.2 μm or less). This parameter change ensures reliable optical performance in coatings while making the production process more controllable and reproducible
Solution Approach 2:
The high-pressure emulsification process creates self-assembled fine emulsion droplets that naturally form uniform composite silica particles with controlled size distribution. This self-organizing effect during high-pressure treatment reduces the need for additional size-control steps, simplifying the overall manufacturing process while ensuring reliable optical properties
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
This approach enables the production of mesoporous silica particles with a small average primary particle size of 0.2 μm or less and a low ratio of coarse particles, resulting in a paint composition that forms coatings and antireflection films with low refractive index and reflectance, suitable for optical applications.
Implementation Method 1
pressurizing a mixed solution containing a hydrophobic organic compound, a surfactant, and an aqueous solvent by a high-pressure emulsification method so as to form an emulsion that includes emulsion droplets containing the hydrophobic organic compound
Implementation Method 2
adding a silica source to the emulsion so as to form a silica-containing outer shell portion with a mesoporous structure on a surface of the emulsion droplets
Implementation Method 3
precipitating composite silica particles including the outer shell portion and the emulsion droplets on an inner side relative to the outer shell portion
Implementation Method 4
a mixed solution containing a hydrophobic organic compound, a surfactant, and an aqueous solvent
Data Source
AI summary
The present invention relates to a method for producing mesoporous silica particles including a silica-containing outer shell portion with a mesoporous structure. The method includes the steps of: (I) pressurizing a mixed solution containing a hydrophobic organic compound, a surfactant, and an aqueous solvent by a high-pressure emulsification method so as to form an emulsion that includes emulsion droplets containing the hydrophobic organic compound; (II) adding a silica source to the emulsion so as to form a silica-containing outer shell portion with a mesoporous structure on a surface of the emulsion droplets, and precipitating composite silica particles including the outer shell portion and the emulsion droplets on an inner side relative to the outer shell portion; and (III) removing the emulsion droplets from the composite silica particles.According to the production method of the present invention, it is possible to produce easily mesoporous silica particles that have a small average particle size and include fewer coarse particles. Thus, the mesoporous silica particles produced by this method are useful in fields that handle a paint composition for an antireflection film and a coating film.