Mesoporous microparticles are an
attractive platform to deploy
high-surface-area nanomaterials in a convenient particulate form that
is broadly compatible with diverse device manufacturing methods. The
applications for mesoporous microparticles are numerous, spanning
the gamut from drug delivery to catalysis and energy storage. For
most applications, the performance of the resulting materials depends
upon the architectural dimensions including the mesopore size, wall
thickness, and microparticle size, yet a synthetic method to control
all these parameters has remained elusive. Furthermore, some mesoporous
microparticle reports noted a surface skin layer which has not been
tuned before despite the important effect of such a skin layer upon
transport/encapsulation. In the present study, material precursors
and block polymer micelles are combined to yield mesoporous materials
in a microparticle format due to phase separation from a homopolymer
matrix. The skin layer thickness was kinetically controlled where
a layer integration via diffusion (LID) model explains its production
and dissipation. Furthermore, the independent tuning of pore size
and wall thickness for mesoporous microparticles is shown for the
first time using persistent micelle templates (PMT). Last, the kinetic
effects of numerous processing parameters upon the microparticle size
are shown.