In this paper, we will thoroughly review a novel and versatile self-formation phenomenon that can be exploited to target porous hierarchies of materials without need of any external templates only on the basis of the chemistry of metal alkoxides and alkylmetals. These hierarchically porous materials have unique structures, which are made of either parallel funnel-like/straight macrochannels or 3D continuous interconnected macroporous foams with micro/mesoporous walls. The self-generated porogen mechanism has been proposed, leading to a series of techniques to tailor porous hierarchy, i.e. the use of different chemical precursors (single metal alkoxides, mixed metal alkoxides, single molecular precursors with two different alkoxide functionalities, alkylmetals, etc., …), the control of their hydrolysis and condensation rates (pH, chelating agents,…) and the addition of alkoxysilanes as co-reactant. Various chemical compositions from single or binary metal oxides, to aluminosilicates, aluminophosphates, silicoaluminophosphates, metallophosphates,… can be prepared, offering a panel of potential applications. Some perspectives have been proposed to transform the synthesized materials with a hierarchy of pore sizes to micro-meso-macroporous crystalline materials with zeolite architectures. The advantages of this self-formation preparation method have been discussed compared to traditional templating methods. The possibility to combine with other strategies, for example soft or hard templating, to target even more sophisticated hierarchically meso-macroporous materials with specific structure and function for various applications has been presented. The "hierarchical catalysis" concept has been re-visited.
Hierarchically porous materials displaying multimodal pore sizes are desirable for their improved flow performance coupled with high surface areas. In the last five years, a tremendous amount of research has focused upon the synthesis and applications of hierarchically porous materials. This review aims to open up a new avenue of research in this exciting field. At first, recent progress in the synthesis of hierarchically porous materials, targeted through templating methods, is reviewed. These synthesis methods involve a supermolecular assembly of amphiphilic polymers or surfactants combined with second surfactant systems or with macrotemplates such as solid particles, liquid drops, and air bubbles. The preparation procedures using surfactants combined with other chemical or physical methods, controlled phase-separation, or template replication will also be discussed. Subsequently, an innovative procedure concerning the self-formation of hierarchically porous materials is thoroughly examined. This self-formation procedure is based on a self-generated porogen mechanism. Porogens such as alcohol molecules can be precisely controlled at the molecular level to design new hierarchically porous materials. Most of these synthesis methods allow an easy and independent adjustment to the multiporosity of a material, i.e., its micro-, meso-, and macroporosity.
A facile and unique but versatile approach for the synthesis of highly organized mesoporous mixed‐element oxide materials with defined structure, high heteroatom content, and stable active sites is presented (see figure). Because of the high homogeneity of the Al sites, the controlled immobilization of (bio)molecules and nanoparticles and the controlled growth of nanowires with relevant new properties may be possible.
Hierarchically structured spongy meso-macroporous aluminosilicates with high tetrahedral aluminum content were synthesized from a mixture of single molecular alkoxide precursor, (sec-BuO)2-Al-O-Si(OEt)3, already containing Si-O-Al bonds, and a silica coreactant, tetramethoxysilane (TMOS). The spontaneous byproduct templated macroporous structure formation has been directly visualized using in situ high-resolution optical microscopy (OM), allowing the crucial observation of a microbubble dispersion which is directly correlated to the macrostructure observed by electronic microscopies (SEM and TEM). This discovery leads to a comparative study with meso-macroporous pure metal oxide and to a proposal of the formation mechanism of meso-macroporous aluminosilicates with 3D interconnectivity. The aluminosilicate phase/microbubbles emulsion is produced by a phase separation process occurring between the aluminosilicate nanoparticles and the liquid hydrolysis-condensation reaction byproducts (water, methanol, ethanol, and butanol). The use of alkoxysilane improves the heterocondensation rates between the highly reactive aluminum alkoxide part of the single precursor and added silica species but, above all, leads to the spontaneous generation of an unusual meso-macroporosity in alkaline media. The particles obtained at pH = 13.0 featured regular micrometer-sized macrospheres separated by very thin mesoporous walls and connected by submicrometric openings, providing a 3D interconnectivity. The slight increase in pH value to 13.5 induced significant modifications in morphology and textural properties due to the slower gelification process of the aluminosilicate phase, resulting in the formation of an aluminosilicate material constituted of 1-2 µm large independent hollow mesoporous spheres.
A novel yet facile synthesis pathway has been developed for the design of hierarchically structured macro-mesoporous aluminosilicates with high aluminum content at tetrahedral sites using a single molecular bifunctional alkoxide (sec-BuO)(2)-Al-O-Si(OEt)(3) precursor. The use of carboxylate ligands and a highly alkaline media slow down the polymerization rate of the aluminum alkoxide functionality, thus permitting the preservation of the intrinsic Al-O-Si linkage. The hierarchically structured porous aluminosilicate materials present an unprecedented low Si/Al ratio close to 1. Heat treatment applied to the synthesized material seems to favor the incorporation of aluminum into tetrahedral position (intraframework aluminum species). The macro-mesoporosity was spontaneously generated, without the use of any external templating agent, by the hydrodynamic flow of the solvents released during the rapid hydrolysis and condensation processes of this double alkoxide. This method results in materials with an open array of interconnected macrochannels. The synthesized aluminosilicate materials with tailorable macro-mesoporous hierarchy and very high Al content at tetrahedral position hold huge promise in various applications as catalysts, catalysts supports, or adsorbents.
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