The question as to whether silicalite-1 grows via an aggregation of smaller particles or similar sized particles has been addressed by considering the fundamentals governing colloidal stability - the quantitative theory underlying colloidal stability being given by the extended Derjaguin-Landau and Verwey-Overbeek (DLVO) theory. Application of the extended DLVO theory to discrete colloidal particles in silicalite-1 precursor sols shows that a net repulsive interactive energy exists between the negatively charged particles. The thermal energy of the colloidal particles (1/2kT at 373 K, the crystallization temperature) is not sufficient to overcome the net repulsive energy barrier. The extended DLVO theory has been applied to two growth scenarios with similar results: growth by aggregation of particles of very different sizes and growth by aggregation of similar sized particles. The significance of these conclusions is that a proposed growth mechanism of MFI type zeolite (growth by aggregation of subcolloidal particles) is deemed not to be a reasonable description of molecular sieve growth. The conclusion that the colloidal crystals are stable with respect to aggregation is supported by experimental observations. The ideas presented in this study are based upon crystallization of molecular sieves from clear solutions in the presence of quaternary ammonium cations that play a significant role in the stabilization of the colloidal crystals. Extension of the ideas presented shows that the extended DLVO theory is equally applicable to wholly inorganic heterogeneous systems.

A novel method whereby dense thin microporous films less than 300 nm thick may be prepared on noble metal substrates is exemplified by the deposition of silicalite-1 on a gold surface in a three-step process. The gold surface is modified with a silane coupling agent, gamma-mercaptopropyltrimethoxysilane, after which the silane is hydrolyzed to yield a negatively charged interface. Positively charged colloidal silicalite-1 crystals are readily adsorbed as a monolayer upon this surface and are induced to crystallize further in a separate hydrothermal treatment step to yield a dense thin silicalite-1 film.