Combined emulsion and solvent evaporation (ESE) synthesis route to well-ordered mesoporous materials

Control over morphology and internal mesostructure of surfactant templated silicas remains a challenge, especially when considering scaling laboratory syntheses up to industrial volumes. Here we report a method combining emulsification with the evaporation-induced self-assembly (EISA) method for preparing spherical, mesoporous silica particles. This emulsion and solvent evaporation (ESE) method has several potential advantages over classic precipitation routes: it is easily scaled while providing superior control over stoichiometric homogeneity of templating surfactants and inorganic precursors, and particle sizes and distributions are determined by principles developed for manipulating droplet sizes within water-in-oil emulsions. To demonstrate the method, triblock copolymer P104 is used as a templating amphiphile, generating unusually well-ordered 2D hexagonal (P6mm) mesoporous silica, while particle sizes and morphologies were controlled by varying the type of emulsifier and the method for emulsification.