TECHNOLOGY LICENSING OPPORTUNITY: SCALABLE POROUS SILICA MATERIALS FOR SEPARATION, FILTRATION, AND CATALYSIS

A patented manufacturing process for producing porous silica materials with interconnected pore networks.

Manufacturers use porous silica materials in products ranging from chromatography columns and filters to catalyst supports and insulation. However, producing these materials with consistent internal structures can be expensive and difficult to scale.
Los Alamos researchers developed a patented process that converts silicone foam into porous silica while preserving its internal pore network. The approach uses common materials and conventional molding techniques, offering a scalable and potentially lower-cost route to high-performance porous silica materials.

Many applications rely on porous materials that contain large internal surface areas and pathways for liquids and gases to flow. Silica is particularly attractive because it is chemically stable, heat resistant, and already widely used in separation, filtration, and catalytic processes.

While porous silica is not new, manufacturing large or complex porous silica components can require specialized fabrication methods that are difficult to scale or expensive to implement.

Los Alamos researchers addressed this challenge by developing a process that begins with a silicone foam and converts it into porous silica through a controlled heating process. Because the material can be molded before conversion, manufacturers can produce porous silica components in a variety of sizes and shapes while maintaining the internal pore structure needed for many industrial applications.

Advantages
• Simple manufacturing process using readily available materials
• Produces porous silica parts in a wide range of sizes and shapes
• Preserves internal pore networks during conversion from silicone to silica
• Compatible with existing molding and manufacturing approaches
• Suitable for high-temperature applications
• Potentially lower production costs than more complex porous silica fabrication methods
• Supports applications in separation, filtration, catalysis, and insulation

Market Applications
• Chemical manufacturing and process industries
• Separation and purification technologies
• Industrial filtration systems
• Energy storage and electrochemical technologies
• Advanced catalyst manufacturing
• Environmental monitoring and sensing
• Advanced materials and specialty ceramics
• Aerospace, defense, and thermal management applications

Technology Description
The patented SWIFT-Si process begins by mixing silicone-based materials, water, and other common ingredients to create a foam. As the mixture cures, the silicone and water naturally separate into interconnected regions, creating a continuous network of pores throughout the material. This pore structure is locked into place as the foam hardens.

The foam can be poured into molds and formed into a variety of shapes and sizes before undergoing a controlled heating process. During heating, the silicone is converted into silica, a material commonly used in chromatography media, filtration systems, catalyst supports, and thermal insulation. The process is designed to preserve the original pore network while the material is converted from silicone to silica.

A final heat treatment removes any remaining organic material, leaving behind a porous silica part that retains much of the original internal structure.

Because the material is shaped before conversion, manufacturers can produce porous silica components using conventional molding techniques rather than more specialized fabrication methods. The result is a manufacturing process designed to simplify production of porous silica materials while preserving the pore structures needed for industrial applications.

TRL 4
U.S. Patent No. 12,129,351
LA-UR-26-26968

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