Shaped zeolite nanocrystals and larger zeolite particles with three-dimensionally ordered mesoporous (3DOm) features hold exciting technological implications for manufacturing thin, oriented molecular sieve films and realizing new selective, molecularly accessible and robust catalysts. A recognized means for controlled synthesis of such nanoparticulate and imprinted materials revolves around templating approaches, yet identification of an appropriately versatile template has remained elusive. Because of their highly interconnected pore space, ordered mesoporous carbon replicas serve as conceptually attractive materials for carrying out confined synthesis of zeolite crystals. Here, we demonstrate how a wide range of crystal morphologies can be realized through such confined growth within 3DOm carbon, synthesized by replication of colloidal crystals composed of size-tunable (about 10-40 nm) silica nanoparticles. Confined crystal growth within these templates leads to size-tunable, uniformly shaped silicalite-1 nanocrystals as well as 3DOm-imprinted single-crystal zeolite particles. In addition, novel crystal morphologies, consisting of faceted crystal outgrowths from primary crystalline particles have been discovered, providing new insight into constricted crystal growth mechanisms underlying confined synthesis.

No abstract

Multipodal nanoparticles (NPs) with controlled tethers are promising principal building blocks, useful for constructing more complex materials, much like atoms are connected into more complex molecules. Here we report colloidal sphere templating as a viable means to create tetrapodal NPs with site-specific tethers. Amorphous sol-gel materials were molded by the template into shaped NPs that mimic tetravalent atoms but on the length scale of colloids. Synthetic methods were developed to modify only the tips of the tetrapods with a range of possible functional groups to generate anisotropic NPs capable of directional bonding to other NPs. We also illustrate that sets of tethered "colloidal atoms" can assemble themselves into "colloidal molecules" with precise placement of the modifying colloids. The templating and tethering approaches to these anisotropic colloidal building blocks and the assembly methods are applicable to many compositions regardless of crystal structure, therefore lending themselves to the fabrication of complex assemblies, analogous to those found in the molecular regime.

Zeolite nanocrystals were prepared from three-dimensionally ordered mesoporous-imprinted (3DOm-i) silicalite-1 by a fragmentation method involving sonication and dissolution within a certain pH range. 3DOm-i silicalite-1 with spherical elements with diameters ranging from 10 to 40 nm and a wide range of crystal sizes (100-200 nm, 500-600 nm, and 1-2 μm) was used as the starting material. The highest yield (57%) of isolated nanocrystals was obtained for 3DOm-i silicalite-1 with a crystal size of 100-200 nm and a spherical element diameter of 40 nm. The smallest nanocrystals obtained, albeit in very low yields, had a 10 nm diameter. Preparation of stable silicalite-1 nanocrystal suspensions fragmented from 20 and 40 nm 3DOm-i silicalite-1 was demonstrated. Cryogenic transmission electron microscopy showed that the isolated zeolite nanocrystals can be used as seeds for the epitaxial growth of silicalite-1. An application of these findings was demonstrated: silicalite-1 nanocrystal suspensions were used to deposit seed layers on porous α-alumina disks, which were converted to continuous thin (300-400 nm) films by secondary growth that exhibited both high permeances and separation factors (3.5 × 10(-7) mol m(-2) s(-1) Pa(-1) and 94-120, respectively, at 150 °C) for p- and o-xylene.

The effects of confinement on the morphological development of the zeolite silicalite-1 were studied during hydrothermal synthesis in three-dimensionally ordered macroporous (3DOM) carbon monoliths. By scheduling multiple infiltration/hydrothermal reaction (IHT) steps using precursor solutions with high (H) or low nutrient content (L) in specific sequences, it was possible to obtain various zeolite morphologies of interest for technological applications. The special morphologies are also functions of shaping and templating effects by the 3DOM carbon reactor and functions of limited mass transport in the confined reaction environment. IHT steps employing high nutrient concentrations favor nucleation, whereas those using low nutrient concentrations provide growth-dominant conditions. Observed product morphologies include polycrystalline sphere arrays for the sequence HHH..., single crystal domains spanning dozens of macropores for the sequence LLL..., and faceted silicalite-1 crystallites with dimensions less than 100 nm with the sequence HLLL.... Most of these crystallites have dimensions less than 100 nm and would be suitable building blocks for seeded zeolite membrane growth. Finally, the sequence LLL...H introduces a secondary population of particles with smaller size, so that the size distribution of zeolite crystallites in the combined population may be tuned, for example, to optimize packing of particles. Hence, by choosing the appropriate infiltration program, it is possible to control grain sizes in polycrystalline particles (spheres and opaline arrays of spheres), which alters the concentration of grain boundaries in the particles and is expected to influence transport properties through the zeolite.