Sol-Gel Strategies for Controlled Porosity Ceramic Materials: Thin Film and Bulk

Using sol-gel processing techniques it is possible to vary the condensation pathway over wide ranges to form primary species ranging in structure from oligomers to polymers to particles. The porosity of the corresponding dry gels depends on the size and structure of the primary species, the organization of these structures, often by aggregation, to form a gel, and the collapse of the gel by drying. This paper reviews these ideas in the context of forming thin film or bulk specimens. Several strategies are introduced to control porosity on length scales of interest for catalysis and catalytic membrane reactors: 1) aggregation of fractals; 2) management of capillary pressure; 3) surface derivatization; 4) relative rates of condensation and evaporation; 5) the use of organic templates and 6) sintering. These strategies are contrasted with the more traditional particle packing approach to preparing controlled porosity materials.