Aerosol route to functional nanostructured inorganic and hybrid porous materials

Preparation of Hierarchical Porous Zeolite Particles with Multiscale Pore Architectures through a Template-Assisted Spray Process for Enhanced Toluene Adsorption Rate

Hierarchical porous zeolite particles featuring multiscale pore architectures have gained significant attention due to their enhanced mass transfer properties and superior adsorption capabilities. This study reports the first successful synthesis of hierarchical porous zeolites with integrated micropores, mesopores, and macropores using a template-assisted spray process, addressing the limitations of conventional zeolites in adsorbing large organic molecules such as toluene. By employing poly(methyl methacrylate) (PMMA) particles (about 350 nm in size) as a template, we achieved precise control over macropore formation, providing a new level of flexibility in tailoring zeolite pore architectures. The effect of the PMMA/zeolite mass ratio on the resulting macroporous structures and their toluene adsorption performance was systematically investigated. The results revealed that the hierarchical porous zeolite exhibited a significantly enhanced toluene adsorption rate compared to samples synthesized without the PMMA template. This improvement is attributed to the optimized macroporous structure, which facilitates efficient mass transfer. Importantly, this study addresses a critical gap in the literature by demonstrating the successful integration of macropores into zeolites through an environmentally friendly process, with significant implications for applications in volatile organic compound removal. This advancement in porous zeolite design could enable more efficient and practical solutions for industrial air purification and environmental remediation.

Nanocomposites for Multifunctional Sensors: A Comprehensive Bibliometric Exploration

Multifunctional nanocomposites have become critical components in advancing sensing technologies, owing to their exceptional integration of mechanical, electrical, thermal, and optical properties. The research landscape of nanocomposites for sensing applications from 2002 to 2024 is examined in this bibliometric review. It identifies key trends, influential works, prominent research areas, and global collaboration networks. This study highlights the creative significance of materials like metal-organic frameworks, carbon-based nanocomposites, and MXenes, which have been instrumental in advances, especially in hybrid systems that improve robustness and sensitivity. Offering an in-depth perspective on current research directions and emerging topics, this review explores areas like eco-friendly nanocomposites and additive manufacturing. Highlighting the relevance of biodegradable materials in supporting global sustainability efforts, it provides insights into future opportunities for advancing multifunctional nanocomposites in sensing technologies.

Spray-dried ternary bioactive glass microspheres: Direct and indirect structural effects of copper-doping on acellular degradation behavior

Silicate-based bioactive glass nano/microspheres hold significant promise for bone substitution by facilitating osteointegration through the release of biologically active ions and the formation of a biomimetic apatite layer. Cu-doping enhances properties such as pro-angiogenic and antibacterial behavior. While sol-gel methods usually yield homogeneous spherical particles for pure silica or binary glasses, synthesizing poorly aggregated Cu-doped ternary glass nano/microparticles without a secondary CuO crystalline phase remains challenging. This article introduces an alternative method for fabricating Cu-doped ternary microparticles using sol-gel chemistry combined with spray-drying. The resulting microspheres exhibit well-defined, poorly aggregated particles with spherical shapes and diameters of a few microns. Copper primarily integrates into the microspheres as Cu0 nanoparticles and as Cu2+ within the amorphous network. This doping affects silica network connectivity, as calcium and phosphorus are preferentially distributed in the glass network (respectively as network modifiers and formers) or involved in amorphous calcium phosphate nano-domains depending on the doping rate. These differences affect the interaction with simulated body fluid. Network depolymerization, ion release (SiO44-, Ca2+, PO43-, Cu2+), and apatite nanocrystal layer formation are impacted, as well as copper release. The latter is mainly provided by the copper involved in the silica network and not from metal nanoparticles, most of which remain in the microspheres after interaction. This understanding holds promising implications for potential therapeutic applications, offering possibilities for both short-term and long-term delivery of a tunable copper dose. STATEMENT OF SIGNIFICANCE: A novel methodology, scalable to industrial levels, enables the synthesis of copper-doped ternary bioactive glass microparticles by combining spray-drying and sol-gel chemistry. It provides precise control over the copper percentage in microspheres. This study explores the influence of synthesis conditions on the copper environment, notably Cu0 and Cu2+ ratios, characterized by EPR spectroscopy, an aspect poorly described for copper-doped bioactive glass. Additionally, copper indirectly affects silica network connectivity and calcium/phosphorus distribution, as revealed by SSNMR. Multiscale characterization illustrates how these features impact acellular degradation in simulated body fluid, highlighting the therapeutic potential for customizable copper dosing to address short- and long-term needs.

Comparative study on Al-SBA-15 prepared by spray drying and traditional methods for bulky hydrocarbon cracking: Properties, performance and influencing factors

Mesoporous aluminosilicates Al-SBA-15 with large pore sizes and suitable acid properties are promising substitutes to zeolites for catalytic cracking of bulky hydrocarbons without molecular diffusion limitation. The conventional processes to synthesize Al-SBA-15 are time-consuming and often suffer from low "framework" Al contents. Herein, Al-SBA-15 microspheres are synthesized using the rapid and scalable microfluidic jet spray drying technique. They possess uniform particle sizes (45-60 μm), variable surface morphologies, high surface areas (264-340 m2/g), uniform mesopores (3.8-4.9 nm) and rich acid sites (126-812 μmol/g) and high acid strength. Their physicochemical properties are compared with the counterparts synthesized using traditional hydrothermal and evaporation-induced self-assembly methods. The spray drying technique results in a higher incorporation of aluminum (Al) atoms into the silica "framework" compared to the other two methods. The catalytic cracking efficiencies of 1,3,5-triisopropylbenzene (TIPB) on the Al-SBA-15 materials synthesized using the three different methods and nanosized ZSM-5 are compared. The optimal spray-dried Al-SBA-15 exhibits the best performance with 100 % TIPB conversion, excellent selectivity (about 75 %) towards the formation of deeply cracked products (benzene and propylene) and high stability. The catalytic performances of the spray-dried Al-SBA-15 with varying Si/Al ratios are also compared. The reasons for the different performances of the different materials are discussed, where the mesopores, high acid density and strength are observed to play the most critical role. This work might provide a basis for the synthesis of mesoporous rich metal-substituted silica materials for different catalytic applications.

Effect of the Addition of Diblock Copolymer Nanoparticles on the Evaporation Kinetics and Final Particle Morphology for Drying Aqueous Aerosol Droplets

A deeper understanding of the key processes that determine the particle morphologies generated during aerosol droplet drying is highly desirable for spray-drying of powdered pharmaceuticals and foods, predicting the properties of atmospheric particles, and monitoring disease transmission. Particle morphologies are affected by the drying kinetics of the evaporating droplets, which are in turn influenced by the composition of the initial droplet as well as the drying conditions. Herein, we use polymerization-induced self-assembly (PISA) to prepare three types of sterically stabilized diblock copolymer nanoparticles comprising the same steric stabilizer block and differing core blocks with z-average diameters ranging from 32 to 238 nm. These well-defined nanoparticles enable a systematic investigation of the effect of the nanoparticle size and composition on the drying kinetics of aqueous aerosol droplets (20-28 μm radius) and the final morphology of the resulting microparticles. A comparative kinetics electrodynamic balance was used to obtain evaporation profiles for 10 examples of nanoparticles at a relative humidity (RH) of 0, 45, or 65%. Nanoparticles comprising the same core block with mean diameters of 32, 79, and 214 nm were used to produce microparticles, which were dried under different RH conditions in a falling droplet column. Scanning electron microscopy was used to examine how the drying kinetics influenced the final microparticle morphology. For dilute droplets, the chemical composition of the nanoparticles had no effect on the evaporation rate. However, employing smaller nanoparticles led to the formation of dried microparticles with a greater degree of buckling.

Eco-friendly and cost-effective adsorbent derived from blast furnace slag with black liquor waste for hazardous remediation

The current investigation concerns with preparation eco-friendly and cost-effective adsorbent (mesoporous silica nanoparticles (SBL)) based on black liquor (BL) containing lignin derived from sugarcane bagasse and combining it with sodium silicate derived from blast furnace slag (BFS) for thorium adsorption. Thorium ions were adsorbed from an aqueous solution using the synthesized bio-sorbent (SBL), which was then assessed by X-ray diffraction, BET surface area analysis, scanning electron microscopy with energy dispersive X-ray spectroscopy (EDX), and Fourier transforms infrared spectroscopy (FTIR). Th(IV) sorption properties, including the pH effect, uptake rate, and sorption isotherms across various temperatures were investigated. The maximum sorption capacity of Th(IV) on SBL is 158.88 mg/L at pH value of 4328 K, and 60 min contact time. We demonstrated that the adsorption processes comport well with pseudo-second-order and Langmuir adsorption models considering the kinetics and equilibrium data. According to thermodynamic inspections results, the Th(IV) adsorption process exhibited endothermic and random behavior suggested by positive ΔH° and ΔS° values, while the negative ΔG° values indicated a spontaneous sorption process. The maximum Th(IV) desorption from the loaded SBL (Th/SBL) was carried out at 0.25 M of NaHCO3 and 60 min of contact. Sorption/desorption processes have five successive cycles. Finally, this study suggests that the recycling of BFS and BL can be exploited for the procurement of a promising Th(IV) adsorbents.

Multifunctional, Hybrid Materials Design via Spray-Drying: Much more than Just Drying

Spray-drying is a popular and well-known "drying tool" for engineers. This perspective highlights that, beyond this application, spray-drying is a very interesting and powerful tool for materials chemists to enable the design of multifunctional and hybrid materials. Upon spray-drying, the confined space of a liquid droplet is narrowed down, and its ingredients are forced together upon "falling dry." As  detailed in this article, this enables the following material formation strategies either individually or even in combination: nanoparticles and/or molecules can be assembled; precipitation reactions as well as chemical syntheses can be performed; and templated materials can be designed. Beyond this, fragile moieties can be processed, or "precursor materials" be prepared. Post-treatment of spray-dried objects eventually enables the next level in the design of complex materials. Using spray-drying to design (particulate) materials comes with many advantages-but also with many challenges-all of which are outlined here. It is believed that multifunctional, hybrid materials, made via spray-drying, enable very unique property combinations that are particularly highly promising in myriad applications-of which catalysis, diagnostics, purification, storage, and information are highlighted.

Natural Biopolymers as Smart Coating Materials of Mesoporous Silica Nanoparticles for Drug Delivery

In recent years, the functionalization of mesoporous silica nanoparticles (MSNs) with different types of responsive pore gatekeepers have shown great potential for the formulation of drug delivery systems (DDS) with minimal premature leakage and site-specific controlled release. New nanotechnological approaches have been developed with the objective of utilizing natural biopolymers as smart materials in drug delivery applications. Natural biopolymers are sensitive to various physicochemical and biological stimuli and are endowed with intrinsic biodegradability, biocompatibility, and low immunogenicity. Their use as biocompatible smart coatings has extensively been investigated in the last few years. This review summarizes the MSNs coating procedures with natural polysaccharides and protein-based biopolymers, focusing on their application as responsive materials to endogenous stimuli. Biopolymer-coated MSNs, which conjugate the nanocarrier features of mesoporous silica with the biocompatibility and controlled delivery provided by natural coatings, have shown promising therapeutic outcomes and the potential to emerge as valuable candidates for the selective treatment of various diseases.

High-Entropy-Alloy Nanocrystal Based Macro- and Mesoporous Materials

High-entropy-alloy (HEA) nanoparticles are attractive for several applications in catalysis and energy. Great efforts are currently devoted to establish composition-property relationships to improve catalytic activity or selectivity. Equally importantly, developing practical fabrication methods for shaping HEA-based materials into complex architectures is a key requirement for their utilization in catalysis. However, shaping nano-HEAs into hierarchical structures avoiding demixing or collapse remains a great challenge. Herein, we overcome this issue by introducing a simple soft-chemistry route to fabricate ordered macro- and mesoporous materials based on HEA nanoparticles, with high surface area, thermal stability, and catalytic activity toward CO oxidation. The process is based on spray-drying from an aqueous solution containing five different noble metal precursors and polymer latex beads. Upon annealing, the polymer plays a double role: templating and reducing agent enabling formation of HEA nanoparticle-based porous networks at only 350 °C. The formation mechanism and the stability of the macro- and mesoporous materials were investigated by a set of in situ characterization techniques; notably, in situ transmission electron microscopy unveiled that the porous structure is stable up to 800 °C. Importantly, this process is green, scalable, and versatile and could be potentially extended to other classes of HEA materials.

Facile and General Method to Synthesize Pt-Based High-Entropy-Alloy Nanoparticles

Pt-based high-entropy-alloy nanoparticles (HEA-NPs) have excellent physical and chemical properties due to the diversity of composition, complexity of surface structure, high mixing entropy, and properties of nanoscale, and they are used in a wide range of catalytic applications such as catalytic ammoxidation, the electrolysis of water to produce hydrogen, CO₂/CO reduction, and ethanol/methanol oxidation reaction. However, offering a facile, low-cost, and large-scale method for preparing Pt-based HEA-NPs still faces great challenges. In this study, we employed a spray drying technique combined with thermal decomposition reduction (SD-TDR) method to synthesize a single-phase solid solution from binary nanoparticles to denary Pt-based HEA-NPs containing 10 dissimilar elements loaded on carbon supports in an H₂ atmosphere with a moderate heating rate (3 °C/min), thermal decomposition temperature (300-850 °C), duration time (30 min), and low cooling rate (5-10 °C/min). The Pt autocatalytic behavior was found and investigated, confirming that Pt element could decrease the reduction temperature of other metals via autocatalytic behavior. Therefore, using the feature of Pt autocatalytic behavior, we have achieved Pt-based HEA-NPs at a minimum temperature of 300 °C. We not only prepared a series of Pt-based HEA-NPs with targetable ingredient, size, and phase using the SD-TDR method but also proved the expandability of the SD-TDR technique by synthesizing Pt-based HEA-NPs loaded on different supports. Moreover, we investigated methanol oxidation reaction (MOR) on as-synthesized senary PtCoCuRuFeNi HEA-NPs, which presented superior electrocatalytic performance over commercial Pt/C catalyst.

Hollow nanoparticles synthesized via Ostwald ripening and their upconversion luminescence-mediated Boltzmann thermometry over a wide temperature range

Upconversion nanoparticles (UCNPs) with hollow structures exhibit many fascinating optical properties due to their special morphology. However, there are few reports on the exploration of hollow UCNPs and their optical applications, mainly because of the difficulty in constructing hollow structures by conventional methods. Here, we report a one-step template-free method to synthesize NaBiF₄:Yb,Er (NBFYE) hollow UCNPs via Ostwald ripening under solvothermal conditions. Moreover, we also elucidate the possible formation mechanism of hollow nanoparticles (HNPs) by studying the growth process of nanoparticles in detail. By changing the contents of polyacrylic acid and H₂O in the reaction system, the central cavity size of NBFYE nanoparticles can be adjusted. Benefiting from the structural characteristics of large internal surface area and high surface permeability, NBFYE HNPs exhibit excellent luminescence properties under 980 nm near-infrared irradiation. Importantly, NBFYE hollow UCNPs can act as self-referenced ratiometric luminescent thermometers under 980 nm laser irradiation, which are effective over a wide temperature range from 223 K to 548 K and have a maximum sensitivity value of 0.0065 K^-1 at 514 K. Our work clearly demonstrates a novel method for synthesizing HNPs and develops their applications, which provides a new idea for constructing hollow structure UCNPs and will also encourage researchers to further explore the optical applications of hollow UCNPs.

The role of Laplace pressure in the maximal weight of pendant drops

HYPOTHESIS

The value of the maximal weight of a pendant drop formed at the end of a syringe needle is lower than the intensity of the corresponding capillary force. The balance of the external forces applied to the maximal pendant drop must be completed by the overpressure generated by the piston of the syringe. Inside the drop, the Laplace pressure corresponds to this overpressure.

EXPERIMENTS

Pendant drops are made with three liquids and five different needle diameters. The influence of Laplace pressure on the maximal weight is experimentally highlighted by modulating the drop curvatures thanks to glass beads placed at the apex of the pendant drop. Their maximal weight and curvatures are measured by image analysis.

FINDINGS

Experiments confirm that the balance of external forces must be completed by the force acting on the syringe piston. The overpressure on the piston has an impact on the drops via the Laplace pressure. A master curve between the mean curvature and the maximal volume of the pendant drops is observed. This result allows to validate an expression of the maximal weight which integrates the Laplace pressure. This work contributes to a better understanding of the maximal pendant drop properties and beyond, of the capillary phenomenon.

The Role of Transmission Electron Microscopy in the Early Development of Mesoporous Materials for Tissue Regeneration and Drug Delivery Applications

For the last 20 years, silica-based mesoporous materials have provided a sound platform for the development of biomedical technology applied to tissue engineering and drug delivery. Their unique structural and textural characteristics, chiefly, the ordered distribution of homogeneous and tunable pores with high surface areas and large pore volume, and their excellent biocompatibility provide an excellent starting point for bone tissue regeneration on the mesoporous surface, and also to load species of interest inside the pores. Adequate control of the synthesis conditions and functionalization of the mesoporous surface are critical factors in the design of new systems that are suitable for use in specific medical applications. Simultaneously, the use of appropriate characterization techniques in the several stages of design and manufacture of mesoporous particles allows us to ascertain the textural, structural and compositional modifications induced during the synthesis, functionalization and post-in vitro assays processes. In this scenario, the present paper shows, through several examples, the role of transmission electron microscopy and associated spectroscopic techniques in the search for useful information in the early design stages of mesoporous systems, with application in the fields of tissue regeneration and drug delivery systems.

Interfacial Assembly and Applications of Functional Mesoporous Materials

Functional mesoporous materials have gained tremendous attention due to their distinctive properties and potential applications. In recent decades, the self-assembly of micelles and framework precursors into mesostructures on the liquid-solid, liquid-liquid, and gas-liquid interface has been explored in the construction of functional mesoporous materials with diverse compositions, morphologies, mesostructures, and pore sizes. Compared with the one-phase solution synthetic approach, the introduction of a two-phase interface in the synthetic system changes self-assembly behaviors between micelles and framework species, leading to the possibility for the on-demand fabrication of unique mesoporous architectures. In addition, controlling the interfacial tension is critical to manipulate the self-assembly process for precise synthesis. In particular, recent breakthroughs based on the concept of the "monomicelles" assembly mechanism are very promising and interesting for the synthesis of functional mesoporous materials with the precise control. In this review, we highlight the synthetic strategies, principles, and interface engineering at the macroscale, microscale, and nanoscale for oriented interfacial assembly of functional mesoporous materials over the past 10 years. The potential applications in various fields, including adsorption, separation, sensors, catalysis, energy storage, solar cells, and biomedicine, are discussed. Finally, we also propose the remaining challenges, possible directions, and opportunities in this field for the future outlook.

Low-Temperature Atmospheric Pressure Plasma Processes for the Deposition of Nanocomposite Coatings

Low-temperature atmospheric pressure (AP) plasma technologies have recently proven to offer a range of interesting opportunities for the preparation of a variety of nanocomposite (NC) coatings with different chemical compositions, structures, and morphologies. Since the late 2000s, numerous strategies have been implemented for the deposition of this intriguing class of coatings by using both direct and remote AP plasma sources. Interestingly, considerable progress has been made in the development of aerosol-assisted deposition processes in which the use of either precursor solutions or nanoparticle dispersions in aerosol form allows greatly widening the range of constituents that can be combined in the plasma-deposited NC films. This review summarizes the research published on this topic so far and, specifically, aims to present a concise survey of the developed plasma processes, with particular focus on their optimization as well as on the structural and functional properties of the NC coatings to which they provide access. Current challenges and opportunities are also briefly discussed to give an outlook on possible future research directions.

Metal-Organic Framework Photonic Balls: Single Object Analysis for Local Thermal Probing

Due to their high porosity and chemical versatility, metal-organic frameworks (MOFs) exhibit physical properties appealing for photonic-based applications. While several MOF photonic structures have been reported, examples of applications thereof are mainly limited to chemical sensing. Herein, the range of application of photonic MOFs is extended to local thermal and photothermal sensing by integrating them into a new architecture: MOF photonic balls. Micrometric-sized photonic balls are made of monodispersed MOFs colloids that are self-assembled via spray-drying, a low-cost, green, and high-throughput method. The versatility of the process allows tuning the morphology and the composition of photonic balls made of several MOFs and composites with tailored optical properties. X-ray nanotomography and environmental hyperspectral microscopy enable analysis of single objects and their evolution in controlled atmosphere and temperature. Notably, in presence of vapors, the MOF photonic balls act as local, label-free temperature probes. Importantly, compared to other thermal probes, the temperature detection range of these materials can be adjusted "on-demand." As proof of concept, the photonic balls are used to determine local temperature profiles around a concentrated laser beam. More broadly, this work is expected to stimulate new research on the physical properties of photonic MOFs providing new possibilities for device fabrication.

On the diatomite-based nanostructure-preserving material synthesis for energy applications

The present article overviews the current state-of-the-art and future prospects for the use of diatomaceous earth (DE) in the continuously expanding sector of energy science and technology. An eco-friendly direct source of silica and the production of silicon, diatomaceous earth possesses a desirable nano- to micro-structure that offers inherent advantages for optimum performance in existing and new applications in electrochemistry, catalysis, optoelectronics, and biomedical engineering. Silica, silicon and silicon-based materials have proven useful for energy harvesting and storage applications. However, they often encounter setbacks to their commercialization due to the limited capability for the production of materials possessing fascinating microstructures to deliver optimum performance. Despite many current research trends focusing on the means to create the required nano- to micro-structures, the high cost and complex, potentially environmentally harmful chemical synthesis techniques remain a considerable challenge. The present review examines the advances made using diatomaceous earth as a source of silica, silicon-based materials and templates for energy related applications. The main synthesis routes aimed at preserving the highly desirable naturally formed neat nanostructure of diatomaceous earth are assessed in this review that culminates with the discussion of recently developed pathways to achieving the best properties. The trend analysis establishes a clear roadmap for diatomaceous earth as a source material of choice for current and future energy applications.

The origin of the high electrochemical activity of pseudo-amorphous iridium oxides

Combining high activity and stability, iridium oxide remains the gold standard material for the oxygen evolution reaction in acidic medium for green hydrogen production. The reasons for the higher electroactivity of amorphous iridium oxides compared to their crystalline counterpart is still the matter of an intense debate in the literature and, a comprehensive understanding is needed to optimize its use and allow for the development of water electrolysis. By producing iridium-based mixed oxides using aerosol, we are able to decouple the electronic processes from the structural transformation, i.e. Ir oxidation from IrO₂ crystallization, occurring upon calcination. Full characterization using in situ and ex situ X-ray absorption spectroscopy, X-ray photoelectron spectroscopy, X-ray diffraction and transmission electron microscopy allows to unambiguously attribute their high electrochemical activity to structural features and rules out the iridium oxidation state as a critical parameter. This study indicates that short-range ordering, corresponding to sub-2nm crystal size for our samples, drives the activity independently of the initial oxidation state and composition of the calcined iridium oxides.

The origins of the superior catalytic activity of poorly crystallized Ir-based oxide material for the OER in acid is still under debate. Here, authors synthesize porous IrMo oxides to deconvolute the effect of Ir oxidation state from short-range ordering and show the latter to be a key factor.

A new approach for synthesizing plasmonic polymer nanocomposite thin films by combining a gold salt aerosol and an atmospheric pressure low-temperature plasma

The proof of the concept of a new, onestep and safe by design process to synthesize metal-polymer nanocomposites thin films on a large surface is presented. It is based on the injection of an aerosol of a solution of metal (gold) salts dissolved in a polymerizable solvent (isopropanol) into an argon atmospheric pressure dielectric barrier discharge. The main novelty of this method resides in the fact that the nanoparticles are formed in situ, inside the plasma reactor, in the gas phase. Consequently, the nanoparticle synthesis and deposition are concomitant with the solvent polymerization used to produce the matrix, which makes it possible to obtain homogeneous layers of non-agglomerated nanoparticles (NPs) with high NPs density. By toggling between low and high-frequency discharges, gold/polymer nanocomposites with different morphologies and optical properties are synthesized. The effect of the concentration of gold in the aerosol and the gas residence time in the plasma as well as the ratio of high and low-frequency discharge and their repetition rate are presented. The thin films are systematically characterized by AFM and UV-visible spectroscopy to analyze their morphologies along with their plasmonic resonances.

CO2 Hydrogenation to Methanol with Ga- and Zn-Doped Mesoporous Cu/SiO2 Catalysts Prepared by the Aerosol-Assisted Sol-Gel Process*

The preparation of copper-based heterogeneous catalysts dedicated to the hydrogenation of CO₂ to methanol typically relies on multi-step procedures carried out in batch. These steps are precisely tailored to introduce the active phase (Cu) and the promoters (e. g., zinc, gallium) onto a preformed support to maximize catalyst performance. However, each process step can be associated with the formation of waste and with the consumption of energy, thereby negatively impacting the environmental performance of the overall catalyst preparation procedure. Here, a direct and continuous production process is proposed for the synthesis of efficient catalysts for the CO₂ -to-methanol reaction. Gallium- and zinc-promoted mesoporous Cu-SiO₂ catalysts were prepared in one step by the aerosol-assisted sol-gel process. The catalysts consisted of spherical microparticles and featured high specific surface area and pore volume, with interconnected pores of about 6 nm. A strong promoting effect of Ga and Zn was highlighted, boosting the selectivity for methanol at the expense of CO. Upon calcination, it was shown that Cu species (initially trapped in the silica matrix) underwent a migration towards the catalyst surface and a progressive sintering. After optimization, the catalysts obtained via such direct, continuous, simple, and scalable route could compete with the best catalysts reported in the literature and obtained via multi-step approaches.

Nanoporous aluminum oxide micropatterns prepared by hydrogel templating

Micropatterned nanoporous aluminum oxide arrays are prepared on silicon wafer substrates by using photopolymerized poly(dimethylacrylamide) hydrogels as porogenic matrices. Hydrogel micropatterns are fabricated by spreading the prepolymer mixture on the substrate, followed by UV photopolymerization through a micropatterned mask. The hydrogel is covalently bonded to the substrate surface. Al₂O₃ is produced by swelling the hydrogel in a saturated aluminum nitrate solution and subsequent thermal conversion/calcination. As a result, micropatterned porous Al₂O₃ microdots with heights in µm range and large specific surface areas up to 274 m² g^-1 are obtained. Hence, the hydrogel fulfills a dual templating function, namely micropatterning and nanoporosity generation. The impact of varying the photopolymerization time on the properties of the products is studied. Samples are characterized by light and confocal laser scanning microscopy, scanning electron microscopy, energy-dispersive x-ray spectrometry, and Kr physisorption analysis.

3D printed graphene-based self-powered strain sensors for smart tires in autonomous vehicles

The transition of autonomous vehicles into fleets requires an advanced control system design that relies on continuous feedback from the tires. Smart tires enable continuous monitoring of dynamic parameters by combining strain sensing with traditional tire functions. Here, we provide breakthrough in this direction by demonstrating tire-integrated system that combines direct mask-less 3D printed strain gauges, flexible piezoelectric energy harvester for powering the sensors and secure wireless data transfer electronics, and machine learning for predictive data analysis. Ink of graphene based material was designed to directly print strain sensor for measuring tire-road interactions under varying driving speeds, normal load, and tire pressure. A secure wireless data transfer hardware powered by a piezoelectric patch is implemented to demonstrate self-powered sensing and wireless communication capability. Combined, this study significantly advances the design and fabrication of cost-effective smart tires by demonstrating practical self-powered wireless strain sensing capability.

Copolymerization of Mesoporous Styrene-Bridged Organosilica Nanoparticles with Functional Monomers for the Stimuli-Responsive Remediation of Water

For every mass product, there are problems associated with the resulting waste. Residues of hormones in urine cannot be removed sufficiently from wastewater, and this has undesired consequences. An ideal adsorbent would take up the impurity, enable a simple separation and recyclability. Polymer colloids with high affinity towards the drug, accessible porosity, high surface area, and stimuli-responsive properties would be candidates, but such a complex system does not exist. Here, porous vinyl-functionalized organosilica nanoparticles prepared from a styrene bridged sol-gel precursor act as monomers. Initiation of the polymerization at the pore walls and addition of functional monomers result in a special copolymer, which is covalently linked to the surface and covers it. An orthogonal modification of external surface was done by click attachment of a thermoresponsive polymer. The final core-shell system is able to remove quantitatively hydrophobic molecules such as the hormone progesterone from water. A change of temperature closes the pores and induces the aggregation of the particles. After separation one can reopen the particles and recycle them.

Advances in Ultrasonic Spray Pyrolysis Processing of Noble Metal Nanoparticles-Review

In the field of synthesis and processing of noble metal nanoparticles, the study of the bottom-up method, called Ultrasonic Spray Pyrolysis (USP), is becoming increasingly important. This review analyses briefly the features of USP, to underline the physical, chemical and technological characteristics for producing nanoparticles and nanoparticle composites with Au and Ag. The main aim is to understand USP parameters, which are responsible for nanoparticle formation. There are two nanoparticle formation mechanisms in USP: Droplet-To-Particle (DTP) and Gas-To-Particle (GTP). This review shows how the USP process is able to produce Au, Ag/TiO2, Au/TiO2, Au/Fe2O3 and Ag/(Y0.95 Eu0.05)2O3 nanoparticles, and presents the mechanisms of formation for a particular type of nanoparticle. Namely, the presented Au and Ag nanoparticles are intended for use in nanomedicine, sensing applications, electrochemical devices and catalysis, in order to benefit from their properties, which cannot be achieved with identical bulk materials. The development of new noble metal nanoparticles with USP is a constant goal in Nanotechnology, with the objective to obtain increasingly predictable final properties of nanoparticles.

Comprehensive understanding of the synthesis and formation mechanism of dendritic mesoporous silica nanospheres

The interest in the design and controlled fabrication of dendritic mesoporous silica nanospheres (DMSNs) emanates from their widespread application in drug-delivery carriers, catalysis and nanodevices owing to their unique open three-dimensional dendritic superstructures with large pore channels and highly accessible internal surface areas. A variety of synthesis strategies have been reported, but there is no basic consensus on the elucidation of the pore structure and the underlying formation mechanism of DMSNs. Although all the DMSNs show a certain degree of similarity in structure, do they follow the same synthesis mechanism? What are the exact pore structures of DMSNs? How did the bimodal pore size distributions kinetically evolve in the self-assembly? Can the relative fractions of small mesopores and dendritic large pores be precisely adjusted? In this review, by carefully analysing the structures and deeply understanding the formation mechanism of each reported DMSN and coupling this with our research results on this topic, we conclude that all the DMSNs indeed have the same mesostructures and follow the same dynamic self-assembly mechanism using microemulsion droplets as super templates in the early reaction stage, even without the oil phase.

Scalable Synthesis of Uniform Mesoporous Aluminosilicate Microspheres with Controllable Size and Morphology and High Hydrothermal Stability for Efficient Acid Catalysis

Mesoporous aluminosilicates are promising solid acid catalysts. They are also excellent supports for transition metal catalysts for various catalytic applications. Synthesis of mesoporous aluminosilicates with controllable particle size, morphology, and structure, as well as adjustable acidity and high hydrothermal stability, is very desirable. In this work, we demonstrate the scalable synthesis of Al-SBA-15 microspheres with controllable physicochemical properties by using the microfluidic jet-spray-drying technology. The productivity is up to ∼30 g of dried particles per nozzle per hour. The Al-SBA-15 microspheres possess uniform controllable micron sizes (27.5-70.2 μm), variable surface morphologies, excellent hydrothermal stability (in pure steam at 800 °C), high surface areas (385-464 m²/g), ordered mesopore sizes (5.4-5.8 nm), and desirable acid properties. The dependence of various properties, including particle size, morphology, porosity, pore size, acidity, and hydrothermal stability, of the obtained Al-SBA-15 microspheres on experimental parameters including precursor composition (Si/Al ratio and solid content) and processing conditions (drying and calcination temperatures) is established. A unique morphology transition from smooth to wrinkled microsphere triggered by control of the Si/Al ratio and solid content is observed. The particle formation and morphology-evolution mechanism are discussed. The Al-SBA-15 microspheres exhibit high acid catalytic performance for aldol-condensation reaction between benzaldehyde and ethyl alcohol with a high benzaldehyde conversion (∼56.3%), a fast pseudo-first-order reaction rate (∼0.1344 h^-1), and a high cyclic stability, superior to the commercial zeolite acid (H-ZSM-5). Several influencing factors on the catalytic performance of the obtained Al-SBA-15 microspheres are also studied.

Self-Assembled Collagen Microparticles by Aerosol as a Versatile Platform for Injectable Anisotropic Materials

Extracellular matrices (ECM) rich in type I collagen exhibit characteristic anisotropic ultrastructures. Nevertheless, working in vitro with this biomacromolecule remains challenging. When processed, denaturation of the collagen molecule is easily induced in vitro avoiding proper fibril self-assembly and further hierarchical order. Here, an innovative approach enables the production of highly concentrated injectable collagen microparticles, based on collagen molecules self-assembly, thanks to the use of spray-drying process. The versatility of the process is shown by performing encapsulation of secretion products of gingival mesenchymal stem cells (gMSCs), which are chosen as a bioactive therapeutic product for their potential efficiency in stimulating the regeneration of a damaged ECM. The injection of collagen microparticles in a cell culture medium results in a locally organized fibrillar matrix. The efficiency of this approach for making easily handleable collagen microparticles for encapsulation and injection opens perspectives in active tissue regeneration and 3D bioprinted scaffolds.

Recent advances in the shaping of metal–organic frameworks

In this review, the recent advances in the shaping of MOFs are overviewed, and some promising strategies recently developed are highlighted, including templated shaping, self-shaping, shaping on substrates, and shaping with sacrificial materials.

Hollow zeolite microspheres as a nest for enzymes: a new route to hybrid heterogeneous catalysts

In the field of heterogeneous catalysis, the successful integration of enzymes and inorganic catalysts could pave the way to multifunctional materials which are able to perform advanced cascade reactions. However, such combination is not straightforward, for example in the case of zeolite catalysts for which enzyme immobilization is restricted to the external surface. Herein, this challenge is overcome by developing a new kind of hybrid catalyst based on hollow zeolite microspheres obtained by the aerosol-assisted assembly of zeolite nanocrystals. The latter spheres possess open entry-ways for enzymes, which are then loaded and cross-linked to form cross-linked enzyme aggregates (CLEAs), securing their entrapment. This controlled design allows the combination of all the decisive features of the zeolite with a high enzyme loading. A chemo-enzymatic reaction is demonstrated, where the structured zeolite material is used both as a nest for the enzyme and as an efficient inorganic catalyst. Glucose oxidase (GOx) ensures the in situ production of H2O2 subsequently utilized by the TS-1 zeolite to catalyze the epoxidation of allylic alcohol toward glycidol. The strategy can also be used to entrap other enzymes or combination of enzymes, as demonstrated here with combi-CLEAs of horseradish peroxidase (HRP) and glucose oxidase. We anticipate that this strategy will open up new perspectives, leveraging on the spray-drying (aerosol) technique to shape microparticles from various nano-building blocks and on the entrapment of biological macromolecules to obtain new multifunctional hybrid microstructures.

Mesoporous Cu-Ce-Ox Solid Solutions from Spray Pyrolysis for Superior Low-Temperature CO Oxidation

Development of Pt group metal-free catalysts for low-temperature CO oxidation remains critical. In this work, active and stable mesoporous Cu-Ce-O_x solid solutions are prepared by using spray pyrolysis. The specific surface areas and pore volumes reach as high as 170 m²  g^-1 and 0.24 cm³  g^-1 , respectively. The results of CO oxidation study suggest that (1) the catalyst obtained by spray pyrolysis possesses much higher activity than those made by co-precipitation, sol-gel, and hydrothermal methods; (2) the optimal Cu_0.2 -Ce_0.8 -O_x solid solution presents a reactivity over 28 times that of both single-component CuO and CeO₂ at 70 °C. Based on the study of pure-phase Cu-Ce-O_x solid solutions by selective leaching of segregated CuO_x species, the active center for CO oxidation is confirmed as the bimetallic Cu-Ce-O site, whereas the individual CuO_x particles not only act as spectators but also block the active Cu-Ce-O sites. A low apparent activation energy of approximately 48 kJ mol^-1 is detected for CO oxidation at the Cu-Ce-O site, making Cu-Ce-O_x solid solutions able to present high activity at low temperature. Furthermore, the Cu-Ce-O_x catalysts exhibit excellent stability and thermal tolerance toward CO oxidation.

Advances in the synthesis and design of nanostructured materials by aerosol spray processes for efficient energy storage

The increasing demand for energy storage has motivated the search for highly efficient electrode materials for use in rechargeable batteries with enhanced energy density and longer cycle life. One of the most promising strategies for achieving improved battery performance is altering the architecture of nanostructured materials employed as electrode materials in the energy storage field. Among numerous synthetic methods suggested for the fabrication of nanostructured materials, aerosol spray techniques such as spray pyrolysis, spray drying, and flame spray pyrolysis are reliable, as they are facile, cost-effective, and continuous processes that enable the synthesis of nanostructured electrode materials with desired morphologies and compositions with controlled stoichiometry. The post-treatment of spray-processed powders enables the fabrication of oxide, sulfide, and selenide nanostructures hybridized with carbonaceous materials including amorphous carbon, reduced graphene oxide, carbon nanotubes, etc. In this article, recent progress in the synthesis of nanostructured electrode materials by spray processes and their general formation mechanisms are discussed in detail. A brief introduction to the working principles of each spray process is given first, and synthetic strategies for the design of electrode materials for lithium-ion, sodium-ion, lithium-sulfur, lithium-selenium, and lithium-oxygen batteries are discussed along with some examples. This analysis sheds light on the synthesis of nanostructured materials by spray processes and paves the way toward the design of other novel and advanced nanostructured materials for high performance electrodes in rechargeable batteries of the future.

Silver Nanoparticles-Decorating Manganese Oxide Hybrid Nanostructures for Supercapacitor Applications

A facile aerosol-based synthetic approach is demonstrated for the fabrication of silver-manganese oxide (Ag-MnO_x) and cetyltrimethylammonium bromide (CTAB)-templated silver-manganese oxide (c-Ag-MnO_x) hybrid nanostructures as the positive electrode materials of supercapacitors. Through gas-phase evaporation-induced self-assembly, silver nanoparticles are homogeneously decorated in the hybrid nanostructure to create a conductive path at the interface of the cluster of MnO_x crystallites. The utilization of the capacitance of MnO_x increases by the addition of Ag nanoparticles (>2 times for Ag-MnO_x and ∼1.7 times for c-Ag-MnO_x). An optimal specific capacitance is achieved when the concentration of the silver precursor (C_Ag) is 0.5 wt %, 118 F g^-1 for Ag-MnO_x, and 154 F g^-1 for c-Ag-MnO_x at a specific current of 1 A g^-1. The enhanced supercapacitive performance by the addition of CTAB at low C_Ag is attributed to the increased surface area (>19.4%) for electrochemical reactions. The prototype method with mechanistic understanding demonstrated in this study shows promise for the fabrication of a variety of MnO_x-based hybrid nanostructures for supercapacitor applications.

Architecture and Preparation of Hollow Catalytic Devices

Since pioneering work done in the late 1990s, synthesis of functional hollow materials has experienced a rapid growth over the past two decades while their applications have been proven to be advantageous across many technological fields. In the field of heterogeneous catalysis, the development of micro- and nanoscale hollow materials as catalytic devices has also yielded promising results, because of their higher activity, stability, and selectivity. Herein, the architecture and preparation of these catalysts with tailorable composition and morphology are reviewed. First, synthesis of hollow materials is introduced according to the classification of template mediated, template free, and combined approaches. Second, different architectural designs of hollow catalytic devices, such as those without functionalization, with active components supported onto hollow materials, with active components incorporated within porous shells, and with active components confined within interior cavities, are evaluated respectively. The observed catalytic performances of this new class of catalysts are correlated to structural merits of individual configuration. Examples that demonstrate synthetic approaches and architected configurations are provided. Lastly, possible future directions are proposed to advance this type of hollow catalytic devices on the basis of our personal perspectives.

Spray-drying water-based assembly of hierarchical and ordered mesoporous silica microparticles with enhanced pore accessibility for efficient bio-adsorption

The fast and scalable spray-drying-assisted evaporation-induced self-assembly (EISA) synthesis of hierarchically porous SBA-15-type silica microparticles from a water-based system is demonstrated. The SBA-15-type silica microparticles has bowl-like shapes, uniform micro-sizes (∼90 µm), large ordered mesopores (∼9.5 nm), hierarchical meso-/macropores (20-100 nm) and open surfaces. In the synthesis, soft- and hard-templating approaches are combined in a single rapid drying process with a non-ionic tri-block copolymer (F127) and a water-insoluble polymer colloid (Eudragit RS, 120 nm) as the co-templates. The RS polymer colloid plays three important roles. First, the RS nanoparticles can be partially dissolved by in-situ generated ethanol to form RS polymer chains. The RS chains swell and modulate the hydrophilic-hydrophobic balance of F127 micelles to allow the formation of an ordered mesostructure with large mesopore sizes. Without RS, only worm-like mesostructure with much smaller mesopore sizes can be formed. Second, part of the RS nanoparticles plays a role in templating the hierarchical pores distributed throughout the microparticles. Third, part of the RS polymer forms surface "skins" and "bumps", which can be removed by calcination to enable a more open surface structure to overcome the low pore accessibility issue of spray-dried porous microparticles. The obtained materials have high surface areas (315-510 m² g^-1) and large pore volumes (0.64-1.0 cm³ g^-1), which are dependent on RS concentration, HCl concentration, silica precursor hydrolysis time and drying temperature. The representative materials are promising for the adsorption of lysozyme. The adsorption occurs at a >three-fold faster rate, in a five-fold larger capacity (an increase from 20 to 100 mg g^-1) and without pore blockage compared with the adsorption of lysozyme onto spray-dried microparticles of similar physicochemical properties obtained without the use of RS.

Nanoparticle-based hollow microstructures formed by two-stage nematic nucleation and phase separation

Rapid bulk assembly of nanoparticles into microstructures is challenging, but highly desirable for applications in controlled release, catalysis, and sensing. We report a method to form hollow microstructures via a two-stage nematic nucleation process, generating size-tunable closed-cell foams, spherical shells, and tubular networks composed of closely packed nanoparticles. Mesogen-modified nanoparticles are dispersed in liquid crystal above the nematic-isotropic transition temperature (TNI). On cooling through TNI, nanoparticles first segregate into shrinking isotropic domains where they locally depress the transition temperature. On further cooling, nematic domains nucleate inside the nanoparticle-rich isotropic domains, driving formation of hollow nanoparticle assemblies. Structural differentiation is controlled by nanoparticle density and cooling rate. Cahn-Hilliard simulations of phase separation in liquid crystal demonstrate qualitatively that partitioning of nanoparticles into isolated domains is strongly affected by cooling rate, supporting experimental observations that cooling rate controls aggregate size. Microscopy suggests the number and size of internal voids is controlled by second-stage nucleation.

Tailoring porous carbon spheres for supercapacitors

The last decade has witnessed significant breakthroughs in the synthesis of porous carbon spheres (PCSs). This Review provides an updated summarization on the controlled synthesis of PCSs for supercapacitors. The synthetic methodologies can be generally categorized into (i) hard templating, (ii) soft templating, (iii) the modified Stöber method, (iv) hydrothermal carbonization (HTC), and (v) aerosol-assisted methods. The obtained PCSs include microporous/mesoporous/macroporous carbon spheres, single-/multi-shelled hollow carbon spheres, and yolk@shell carbon spheres. The structure-electrochemical performance correlation is discussed. Finally, the future research directions on the rational design of PCSs for supercapacitors are predicted.

Tuning the Coupled-Domain Response for Efficient Ultrasonic Droplet Generation

Acoustic microfluidic devices encompass mechanical, fluidic, and electromechanical domains. Complicated multidomain interactions require the consideration of each individual material domain, as well as coupled behaviors to achieve optimal performance. Herein, we report the co-optimization of components comprising an ultrasonic droplet generator to achieve the high-efficiency liquid atomization for operation in the 0.5-2.5-MHz frequency range. Due to the complexity of the real system, simplified 2-D representations of the device are investigated using an experimentally validated finite element analysis model. Ejection modes (i.e., frequencies at which droplet generation is predicted) are distinguished by maxima in the local pressure at the tips of an array of triangular nozzles. Resonance behaviors of the transducer assembly and fluid-filled chamber are examined to establish optimal geometric combinations concerning the chamber pressure field. The analysis identifies how domain geometries affect pressure field uniformity, broadband operation, and tip pressure amplitude. Lower frequency modes are found to focus the acoustic energy at the expense of field uniformity within the nozzle array. Resonance matching yields a nearly threefold increase in maximum attainable tip pressure amplitude. Significantly, we establish a set of design principles for these complex devices, which resembles a classical half-wave transducer, quarter-wave matching layer, and half-wave chamber layered system.