Aerosol synthesis of self-organized nanostructured hollow and porous carbon particles using a dual polymer system

Controllable Synthesis of Porous and Hollow Nanostructured Catalyst Particles and Their Soot Oxidation

The introduction of macroporous structures into three-way catalysts (TWCs) through polymer template-assisted spray drying has attracted attention because of its enhanced gas diffusion and catalytic performance. However, the surface charge effect of polymeric template components has not been investigated to control the structure of the TWC particles during synthesis. Thus, this study investigated the effect of template surface charges on the self-assembly behavior of TWC nanoparticles (NPs) during drying. The self-assembly of TWC NPs and polymer particles with different charges produced a hollow structure, whereas using the same charges generated a porous one. Consequently, the mechanism of particle self-assembly during drying and final structure particle formation is proposed in this study. Here, porous TWC particles demonstrated a faster oxidation of soot particles than that of hollow-structured particles. This occurred as a result of the larger contact area between the catalyst surface and the solid reactant. Our findings propose a fundamental self-assembly mechanism for the formation of different TWC structures, thereby enhancing soot oxidation performance using macroporous structures.

Communicating Supraparticles to Enable Perceptual, Information-Providing Matter

Materials are the fundament of the physical world, whereas information and its exchange are the centerpieces of the digital world. Their fruitful synergy offers countless opportunities for realizing desired digital transformation processes in the physical world of materials. Yet, to date, a perfect connection between these worlds is missing. From the perspective, this can be achieved by overcoming the paradigm of considering materials as passive objects and turning them into perceptual, information-providing matter. This matter is capable of communicating associated digitally stored information, for example, its origin, fate, and material type as well as its intactness on demand. Herein, the concept of realizing perceptual, information-providing matter by integrating customizable (sub-)micrometer-sized communicating supraparticles (CSPs) is presented. They are assembled from individual nanoparticulate and/or (macro)molecular building blocks with spectrally differentiable signals that are either robust or stimuli-susceptible. Their combination yields functional signal characteristics that provide an identification signature and one or multiple stimuli-recorder features. This enables CSPs to communicate associated digital information on the tagged material and its encountered stimuli histories upon signal readout anywhere across its life cycle. Ultimately, CSPs link the materials and digital worlds with numerous use cases thereof, in particular fostering the transition into an age of sustainability.

Synthesis of High Specific Surface Area Macroporous Pectin Particles by Template-Assisted Spray Drying

Many types of porous particles containing inorganic and organic substances, such as carbon, metals, metal oxides, inorganic-organic hybrids, and polymers, have been developed. However, natural polymer-derived particles are relatively rare. To our knowledge, this report describes the first synthetic method for obtaining meso-/macroporous particles made from pectin, which is a natural polymer with a wide range of biological activities suitable for active substance support applications. These porous particles were prepared using a template-assisted spray-drying method, followed by a chemical etching process. An organic template [i.e., poly(methyl methacrylate) (PMMA)] or an inorganic template [i.e., calcium carbonate (CaCO₃)] was used to evaluate the resulting formation of macroporous structures in the pectin particles. Furthermore, the concentration of the templates in the precursor solution was varied to better understand the mechanism of porous pectin particle formation. The results showed that the final porous particles maintained the characteristic properties of pectin. The differences between the two templates resulted in two distinct types of porous particles that differed in their particle morphologies (i.e., spherical or wrinkled), particle sizes (ranging from 3 to 8 μm), pore sizes (ranging from 80 to 350 nm), and pore volume (ranging from 0.024 to 1.40 cm³ g^-1). Especially, the porous pectin particles using the CaCO₃ template have a significantly high specific surface area of 171.2 m² g^-1, which is 114 times higher than that of nonporous pectin particles. These data demonstrated the potential for using PMMA and CaCO₃ templates to control and design desired porous materials.

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.

Selective Low-Energy Carbon Dioxide Adsorption Using Monodisperse Nitrogen-Rich Hollow Carbon Submicron Spheres

Monodisperse, nitrogen-doped hollow carbon spheres of submicron size were synthesized using hexamethoxymethylmelamine as both a carbon and nitrogen source in a short (1 h) microwave-assisted synthesis. After carbonization at 550 °C, porous carbon spheres with a remarkably high nitrogen content of 37.1% were obtained, which consisting mainly of highly basic pyridinic moieties. The synthesized hollow spheres exhibited high selectivity for carbon dioxide (CO₂) over nitrogen and oxygen gases, with a capture capacity up to 1.56 mmol CO₂ g^-1. The low adsorption enthalpy of the synthesized hollow carbon spheres permits good adsorbent regeneration. Evaluation of the feasibility of scaling up shows their potential for large-scale applications.

Enhanced Electrocatalytic Activity of Pt/3D Hierarchical Bimodal Macroporous Carbon Nanospheres

Proton exchange membrane fuel cells require electrocatalysts with a high platinum (Pt) loading, large active surface area, and favorable hydrodynamic profile for practical applications. Here, we report the design of three-dimensional hierarchical bimodal macroporous carbon nanospheres with an interconnected pore system, which are applied as an electrocatalyst support. Carbon-supported Pt (Pt/C) catalysts were prepared by aerosol spray pyrolysis followed by microwave chemical deposition. The hierarchical porous structures not only increased the dispersion of Pt nanoparticles but also improved catalytic performance. A hierarchical bimodal macroporous Pt/C catalyst with a mixture of 30 and 120 nm size pores showed the best performance. The electrochemical surface area and mass activity values of this support were 96 m² g^-1-Pt and 378 mA mg^-1-Pt, respectively at a Pt loading of 15 wt %.

Role of Acetone in the Formation of Highly Dispersed Cationic Polystyrene Nanoparticles

A modified emulsion polymerisation synthesis route for preparing highly dispersed cationic polystyrene (PS) nanoparticles is reported. The combined use of 2,2′-azobis[2-(2-imidazolin- 2-yl)propane] di-hydrochloride (VA-044) as the initiator and acetone/water as the solvent medium afforded successful synthesis of cationic PS particles as small as 31 nm in diameter. A formation mechanism for the preparation of PS nanoparticles was proposed, whereby the occurrence of rapid acetone diffusion caused spontaneous rupture of emulsion droplets into smaller droplets. Additionally, acetone helped to reduce the surface tension and increase the solubility of styrene, thus inhibiting aggregation and coagulation among the particles. In contrast, VA-044 initiator could effectively regulate the stability of the PS nanoparticles including both the surface charge and size. Other reaction parameters i.e. VA-044 concentration and reaction time were examined to establish the optimum polymerisation conditions.

Tunable Synthesis of Mesoporous Silica Particles with Unique Radially Oriented Pore Structures from Tetramethyl Orthosilicate via Oil-Water Emulsion Process

Numerous studies of the synthesis of mesoporous silica (MPS) particles with tailored properties have been published. Among those studies, tetraethyl orthosilicate (TEOS) is commonly used as a silica source, but tetramethyl orthosilicate (TMOS) is rarely used because its reaction is fast and difficult to control. In this study, MPS particles were synthesized via one-step controlled polymerization of styrene and hydrolysis of TMOS, followed by the addition of hexadecyltrimethylammonium bromide (CTAB) and n-octane. The MPS particles obtained from TMOS generally have small inner pores, but the MPS particles obtained in this study had a unique radially oriented structure, a high surface area up to 800 m² g^-1, and large pores, of size 20 nm. The content of styrene in the emulsion system played a key role in increasing pore sizes of the MPS particles. A plausible mechanism for particle formation based on the phase behavior and type of the emulsion system is proposed. For further research, this material is expected to be useful for various applications, such as in drug delivery, filtration, and catalyst supports.

Improved porosity and ionic sorption capacity of carbon particles prepared by spray pyrolysis from an aqueous sucrose/NaHCO3/TEOS solution

Spherical carbon spheres with improved mesoporosity and ion sorption properties are synthesized by an ultrasonic spray pyrolysis process from an aqueous sucrose/NaHCO₃/TEOS solution.

Synthesis of nitrogen-functionalized macroporous carbon particles via spray pyrolysis of melamine-resin

In this study, we developed the first synthesis of macroporous carbon particles with high nitrogen content from a melamine resinviaspray pyrolysis.