Integrating structure control over multiple length scales in porous high temperature ceramics with functional...

High temperature ceramics with porosity on multiple length scales offer great promise in high temperature catalytic applications for their high surface area and low flow resistance in combination with thermal and chemical stability. We have developed a bottom-up approach to functional, porous, high-temperature ceramics structured on eight distinct length scales integrating functional Pt nanoparticles from the near-atomic to the macroscopic level. Structuring is achieved through a combination of micromolding and multicomponent colloidal self-assembly. The resulting template is filled with a solution containing a solvent, a block copolymer, a ceramic precursor, and a nanoparticle catalyst precursor as well as a radical initiator. Heat treatment results in three-dimensionally interconnected, high-temperature ceramic materials functionalized with well-dispersed 1-2 nm Pt catalyst nanoparticles and very high porosity.