Production of Zeolite-Based Composite Materials with Hierarchical Porosity

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The invention provides a method to produce composite materials consisting of a support structure coated with zeolite or zeolite-like crystals, where the coating has hierarchical porosity (micro-, meso-, and/or macropores among the crystals). This process avoids using traditional binders, instead forming the zeolite structure directly onto the support by applying a suspension containing nano-zeolites and their precursors, followed by heat and steam treatment, resulting in highly efficient, binder-free coatings with tailored porosity.

Use CasesContent extracted from patent full text and abstract with AI.

• Catalytic converters for automotive exhaust treatment (removal of NOx, hydrocarbons, etc.)
• Industrial gas purification and separation systems
• Adsorbers and filters in water and air treatment
• Structured catalysts in chemical processing and petrochemicals
• Adsorption-based cooling or refrigeration systems (e.g., adsorption chillers)
• Sensors that exploit the selective adsorption or catalytic properties of zeolites
• Pharmaceutical or fine-chemical processes requiring shape-selective catalysis
• Energy storage or transfer devices utilizing zeolite’s unique adsorption properties

BenefitsContent extracted from patent full text and abstract with AI.

• Eliminates the need for added binders, increasing the concentration and activity of the functional zeolite component.
• Allows precise control over pore size distribution (hierarchical porosity) for improved diffusion and performance.
• Highly versatile—coatings can be applied to a range of support structures (ceramic, metal, etc.).
• Enables the creation of multifunctional composite layers by introducing different active materials in a single process.
• Reduces material waste and processing steps compared to conventional methods.
• Facilitates efficient large-scale production with higher yield of active material.
• Enhances mechanical stability of coatings through intergrown zeolite crystals.
• Improves catalytic, adsorptive, and separation performance due to tailored porosity and high surface area.

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Inventors & Applicants

Patent Abstract

The invention relates to a method for producing a composite material with a support structure and a coating on the surface of the support structure. The coating comprises crystals of a zeolite material or a material similar to zeolite as active components, and inter-crystalline meso- and/or macro-pores are formed in the coating. The invention is characterized in that the method has the following steps: a) providing a suspension which contains nano-scale starting crystals made of a zeolite material or a material similar to zeolite and precursor compounds of the zeolite material or the material similar to zeolite, b) applying the suspension provided in step a) onto the surface of the support structure, c) solidifying the suspension applied in step b) by at least partly removing the solvent which forms the liquid phase of the suspension in order to obtain a coating which contains the starting crystals and the precursor compounds, and d) keeping the coating obtained in step c) on the surface of the support structure in a steam-containing atmosphere at an increased temperature such that the obtained precursor compounds are converted into a zeolite material or a material similar to zeolite and together with the starting crystals forms the coating which comprises the crystals of a zeolite material or a material similar to zeolite.