Formation of mesoporous silica particles with hierarchical morphology

The transformation of mesoporous silica morphology from monoliths to spherical particles was investigated at room temperature in Pluronic F127/TEOS system as a function of HCl acid catalyst concentration to understand and control the mechanism. It is shown that the specific surface area and the size of mesoporous spherical silica particles can simply be adjusted by the catalyst concentration without using any additives or post-treatment. Above 3 M acid concentration, novel monodisperse micron sized spherical silica with hierarchical order of two levels was obtained. These silica spheres were formed of densely packed distorted hexagonal platelets of 20–30 nm in diameter. Within these platelets mesoporous channels were oriented along a single direction, however the platelets were randomly oriented in the spherical particles. Controlling the agglomeration of mesoporous silica primary particles by the concentration of the acid catalyst to obtain micron-sized spherical particles is novel. This approach allows the synthesis of particles whose sizes can be controlled in the range of ~1–4 μm and specific surface area in the range of ~200–500 m2/g. The morphology of the particles transforms from spherical shape to mesoporous monoliths at acid concentrations below 1 M due to slow hydrolysis and condensation. These results are important in understanding the role of catalyst concentration on the formation mechanism of different morphologies of mesoporous silica.