US 12420264 B1Patent grantUnited States

Porous Zirconia-Calcium Silicate Nanocomposite

Official patent title

Nanocomposite material

Arabic title: مادة مركبة نانوية

Invention

Problem

Multiphase nanomaterials can have unstable phases, inconsistent composition, broad particle-size distributions, weak morphology control, complex processing, and high production costs that hinder reproducible application development.

Why it matters

A structurally defined porous hybrid could support application-specific research in catalysis, remediation, or electrochemistry, but function, stability, durability, safety, and manufacturability require independent testing.

Approach

The material disperses spherical ZrO2 and CaSiO3 nanoparticles on g-C3N4 nanosheets, and the patent provides sequential hydrothermal, thermal, calcination, microwave, filtration, and drying steps for making it.

Who may benefit

Potential beneficiaries include advanced-materials laboratories, catalyst and adsorbent researchers, electrochemical-material groups, ceramic and carbon-nitride specialists, and manufacturers evaluating porous hybrid powders.

Potential value

The disclosure combines three distinct phases in a nanosheet-supported architecture and defines particle diameter, BET area, pore volume, pore-size distribution, and a detailed multi-stage fabrication route.

Background

Graphitic carbon nitride is studied for photocatalysis and electrochemical applications because its morphology, porosity, and precursor route can tune performance. Combining it with metal-oxide or silicate phases may add functionality, but multiphase materials can suffer from phase instability, uneven composition, inconsistent particle size, and costly or energy-intensive preparation. Single-phase and binary systems may also lack the desired combination of properties. The patent addresses material definition and manufacturing through a zirconia/calcium-silicate/carbon-nitride architecture with specified nanoscale and pore characteristics.

Technology overview

The composite contains spherical ZrO2- and CaSiO3-phase nanoparticles dispersed on g-C3N4 nanosheets, with a claimed average particle diameter of 3–18 nm and BET surface area of at least 55 m2·g−1. CaSiO3 is formed by autoclaving calcium nitrate and sodium metasilicate; g-C3N4 is formed by heating urea; and ZrO2 is prepared from a zirconium precursor and calcination. The three components are dispersed in ethylene glycol monomethyl ether, microwave-treated at 160–200 °C and 4–6 bar, washed, and dried.

Potential applications

Potential catalyst-support or photocatalyst-material research.
Potential porous adsorbent studies for environmental applications.
Potential electrochemical material characterization.
Potential multi-phase nanocomposite process-development platform.

Evidence-supported advantages

Combines ZrO2, CaSiO3, and g-C3N4 in one architecture.
Defines a 3–18 nm average particle-diameter range.
Specifies BET area, pore volume, and trimodal pore distribution.
Provides a detailed multi-stage synthesis sequence.

Development stage

Patent publication describing material synthesis and characterization; independent validation and commercialization were not established.

Commercial opportunity

The material may interest specialty-powder, catalyst, adsorbent, or electrochemical-material developers. Commercial assessment should establish batch consistency, phase purity, nanoparticle dispersion, pore reproducibility, target-application performance, stability and reuse, safety and leaching, microwave and autoclave scale-up, solvent recovery, process yield, energy demand, product integration, and comparative cost.

Patent classifications

WIPO IPC

B01J21/06Chemical or physical processes, e.g. catalysis or colloid chemistry; their relevant apparatus
B01J21/18Chemical or physical processes, e.g. catalysis or colloid chemistry; their relevant apparatus

CPC

B01J21/066Chemical or physical processes, e.g. catalysis or colloid chemistry; their relevant apparatus
B01J35/45Chemical or physical processes, e.g. catalysis or colloid chemistry; their relevant apparatus
B01J21/18Chemical or physical processes, e.g. catalysis or colloid chemistry; their relevant apparatus
B01J23/02Chemical or physical processes, e.g. catalysis or colloid chemistry; their relevant apparatus
B01J27/24Chemical or physical processes, e.g. catalysis or colloid chemistry; their relevant apparatus
B01J35/393Chemical or physical processes, e.g. catalysis or colloid chemistry; their relevant apparatus
B01J35/51Chemical or physical processes, e.g. catalysis or colloid chemistry; their relevant apparatus
B01J35/613Chemical or physical processes, e.g. catalysis or colloid chemistry; their relevant apparatus
B01J35/633Chemical or physical processes, e.g. catalysis or colloid chemistry; their relevant apparatus
B01J35/647Chemical or physical processes, e.g. catalysis or colloid chemistry; their relevant apparatus
B01J35/695Chemical or physical processes, e.g. catalysis or colloid chemistry; their relevant apparatus
B01J37/009Chemical or physical processes, e.g. catalysis or colloid chemistry; their relevant apparatus
B01J37/04Chemical or physical processes, e.g. catalysis or colloid chemistry; their relevant apparatus
B01J37/06Chemical or physical processes, e.g. catalysis or colloid chemistry; their relevant apparatus
B01J37/084Chemical or physical processes, e.g. catalysis or colloid chemistry; their relevant apparatus
B01J37/088Chemical or physical processes, e.g. catalysis or colloid chemistry; their relevant apparatus
B01J37/346Chemical or physical processes, e.g. catalysis or colloid chemistry; their relevant apparatus
B01J2235/30Chemical or physical processes, e.g. catalysis or colloid chemistry; their relevant apparatus

Inventors

First inventorMohamed Khairy Abdel Fattah Omran
InventorBabiker Yagoub Elhadi Abdulkhair

Keywords

ZrO2
CaSiO3
g-C3N4
nanocomposite
porous material
BET surface area
microwave synthesis
metal oxide

Patent document and drawings

The patent publication is mapped to this record. Patent drawings remain within that publication; no separately cleared public media package has been supplied.