Synthesis of Macroporous Silica Particles by Continuous Generation of Droplets for Insulating Materials.

We report on the synthesis of porous silica particles by self-assembly routes in a continuous manner for application to thermal insulators. A continuous process was employed to produce tiny droplets containing precursor materials such as silica and organic templates for self-organization to fabricate particles with well defined pores. A rotating cylinder system or a spray drying process was adopted to form emulsions or aerosol droplets as micro-reactors for self-assembly, and the physical properties including the thermal conductivity of the resulting porous particles were compared between the two methods. The porous particles could be coated as a thick film by solution dripping, and the fluorination treatment using a silane coupling agent was performed to produce superhydrophobic surfaces of insulating layers by a lotus effect.