Growth and Functionalization of Particle-Based Mesoporous Silica Films and Their Usage in Catalysis

We report the formation of mesoporous films consisting of SBA-15 particles grown directly onto substrates and their usage as catalysts in esterification of acetic acid and ethanol. The film thickness was altered between 80 nm and 750 nm by adding NH₄F to the synthesis solution. The salt also affects the formation rate of the particles, and substrates must be added during the formation of the siliceous network in the solution. Various substrate functionalizations were tested and hydrophobic substrates are required for a successful film growth. We show that large surfaces (> 75 cm²), as well as 3D substrates, can be homogenously coated. Further, the films were functionalized, either with acetic acid through co-condensation, or by coating the films with a thin carbon layer through exposure to furfuryl alcohol fumes followed by carbonization and sulfonation with H₂SO₄. The carbon-coated film was shown to be an efficient catalyst in the esterification reaction with acetic acid and ethanol. Due to the short, accessible mesopores, chemical variability, and possibility to homogenously cover large, rough surfaces. the films have a large potential for usage in various applications such as catalysis, sensing, and drug delivery.