Zeolite Crystal Synthesis Using Fluorine Mineralizing Agent
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Solution Overview
Problem
There is a need for methods to produce small zeolite and zeolite-like crystals with a low amount of defects, which are essential for applications such as thin films, membranes, catalysts, and adsorbents, as existing methods often result in larger crystals with higher defect densities.
Innovation Solution
A method involving the mixing of starting materials, structure-directing agents, and water, followed by the removal of solubility-reducing components and the addition of a fluorine-containing compound to produce zeolite and zeolite-like crystals with reduced defect levels, achieving sizes equal to or less than 1.5 μm.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional synthesis methods are used to produce zeolite crystals, then crystal formation is achieved, but the crystals tend to be larger in size with higher defect densities
Solution Approach 1:
The invention changes the chemical composition parameters of the synthesis gel by incorporating fluorine-containing compounds and controlling the molar ratios of components (SiO2, Al2O3, F, H2O, and organic structure-directing agents). This parameter modification enables the formation of smaller crystals with fewer defects, directly resolving the contradiction between crystal size and defect density
2Manufacturing precision
If solubility-reducing components are present in the synthesis mixture, then crystal growth is facilitated, but defect density increases
Solution Approach 1:
The invention removes or minimizes solubility-reducing components from the synthesis mixture by optimizing the gel composition and using fluorine-containing compounds that do not introduce such impurities. This extraction of harmful elements reduces defect density while maintaining crystal growth efficiency through the fluorine-mediated crystallization process
3Manufacturing precision
If fluoride is added to the synthesis mixture, then crystal defects are reduced, but the process complexity increases
Solution Approach 1:
The fluorine-containing compounds serve multiple functions: they act as mineralizing agents, control crystal nucleation and growth, reduce defect density, and influence crystal morphology. This multi-functionality reduces the need for additional separate process steps, thereby managing process complexity while achieving low defect density
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 effectively synthesizes small zeolite crystals with fewer defects, suitable for applications in catalysts, adsorbents, and membranes, enhancing their performance and separation capabilities.
Implementation Method 1
forming zeolite and/or zeolite-like crystals from the mixture
Implementation Method 2
Templates or structure directing agents are added to the reaction mixture in the synthesis of zeolites and zeolite like materials to direct the crystallization to the desired framework
Data Source
AI summary
The present invention pertains to a method for producing zeolite or zeolite-like crystals using a composition comprising one or more fluorine-containing compounds as a mineralizing agent. Crystals produced by such a method are smaller in size than crystals available in the art and contain few defects. The invention also relates to zeolite and/or zeolite-like crystals obtainable by a method as provided herein as well as crystals defined by any of the structural characteristics provided herein, and the usage thereof such as in the manufacture of thin films and membranes, absorbents, catalysts etc.