Preparation of macroporous carbon foams using a polyurethane foam template replica method without curing step

Gimin Nam; Seongcheol Choi; Haebong Byun; Young-Mok Rhym; Sang Eun Shim

Macromolecular Research, Vol.21, No.9, 958-964, September, 2013

DOI10.1007/s13233-013-1114-6 Export Citation

Preparation of macroporous carbon foams using a polyurethane foam template replica method without curing step

Gimin Nam, Seongcheol Choi, Haebong Byun, Young-Mok Rhym¹, and Sang Eun Shim^†

Department of Chemical Engineering, Inha University, Incheon, 402-751, Korea
¹Korea Institute of Materials Science, Gyeongnam, 641-841, Korea

E-mail:

Macroporous carbon foams were synthesized without a curing step using polyurethane (PU) foam as the sacrificial template and resorcinol-formaldehyde (RF), phenol-formaldehyde (PF), and phenol-resorcinol-formaldehyde (PRF) resins as the carbon precursors. PU foam was impregnated with these three aqueous resin solutions and carbonized directly at 830 °C in an inert atmosphere for 3 h without a pre-curing step. During heating to carbonization temperature, the impregnated resins were cured and subsequently carbonized. The curing, degradation of PU foam and carbonization mechanism were examined by differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA). The pore structure, electrical conductivity, and compressive strength of the prepared carbon foams using the RF, PF, and PRF resin carbon precursors were measured. Among them, the carbon foam fabricated from PF resin had a surface area, electric conductivity and compressive strength of 63 m2/g, 3.409 S/m and 0.25 MPa, respectively.

Keywords:carbon foam;polyurethane;template;impregnation;carbonization

[References]

Lee J, Kim J, Hyeon T, Adv. Mater., 18(16), 2073 (2006)
Zhu M, Diao G, Nanoscale, 3, 2748 (2011)
Subramoney S, Adv. Mater., 10(15), 1157 (1998)
Kyotani T, Carbon, 38, 269 (2000)
Hao GP, Li WC, Qian D, Lu AH, Adv. Mater., 22(7), 853 (2010)
Ford W, US Patent 3,121,050 (1964).
Stiller AH, Yocum A, Plucinski J, US Patent 6,183,854 (2001).
Stiller AH, Stansberry PG, Zondlo JW, US Patent 5,888,469 (1999).
Wan Y, Yang HF, Zhao DY, Acc. Chem. Res., 39, 423 (2006)
Xu H, Gao Q, Guo H, Wang H, Microporous Mesoporous Mater., 133, 106 (2010)
Ozaki J, Endo N, Carbon, 35, 1031 (1997)
Sakintuna B, Akta Z, Yurum Y, Prepr. Pap.-Am. Chem. Soc. Div. Fuel Chem., 48, 614 (2003)
Guo T, Zhu J, Chen X, J. Non-Cryst. Solids, 353, 2893 (2007)
Lee J, Sohn K, Hyeon T, Chem. Commun., 2674 (2002)
Inagaki M, Morishita T, Kuno A, Kito T, Hirano M, Carbon, 42, 497 (2004)
Kyotani T, Nagai T, Inoue S, Tomita A, Chem. Mater., 9, 609 (1997)
Costa L, di Montelera LR, Camino G, Weil ED, Pearce EM, Polym. Degrad. Stabil., 56, 23 (1997)
Javni I, Petrovic ZS, Guo A, Fuller R, J. Appl. Polym. Sci., 77(8), 1723 (2000)
Morterra C, Low MJDIR, Carbon, 23, 525 (1985)
Camino G, Luda MP, Costa L, Trossarelli L, in Thermal Analysis, Miller B, Ed., Wiley, New York, 1982, Vol. 2, p 1137.
Jha V, Banthia AK, Paul A, J. Therm. Anal., 35, 1229 (1989)
Jackson WM, Conley RT, J. Appl. Polym. Sci., 8, 2163 (1964)
Bark LS, Moran D, Percival SJ, Wear, 34, 131 (1975)
Ozaki JI, Ohizumi W, Oya A, Carbon, 38, 1515 (2000)
Fyfe CA, McKinnon MS, Rudin A, Tchir WJ, Macromolecules, 16, 1216 (1983)
Morterra C, Low MJD, Langmuir, 1, 320 (1985)
Lisperguer J, Drouguett C, Ruf B, Nunez M, J. Chil. Chem. Soc., 50, 451 (2005)

[Referenced By]

[Related Articles]

[1] Lee J, Kim J, Hyeon T, Adv. Mater., 18(16), 2073 (2006)

[2] Zhu M, Diao G, Nanoscale, 3, 2748 (2011)

[3] Subramoney S, Adv. Mater., 10(15), 1157 (1998)

[4] Kyotani T, Carbon, 38, 269 (2000)

[5] Hao GP, Li WC, Qian D, Lu AH, Adv. Mater., 22(7), 853 (2010)

[6] Ford W, US Patent 3,121,050 (1964).

[7] Stiller AH, Yocum A, Plucinski J, US Patent 6,183,854 (2001).

[8] Stiller AH, Stansberry PG, Zondlo JW, US Patent 5,888,469 (1999).

[9] Wan Y, Yang HF, Zhao DY, Acc. Chem. Res., 39, 423 (2006)

[10] Xu H, Gao Q, Guo H, Wang H, Microporous Mesoporous Mater., 133, 106 (2010)

[11] Ozaki J, Endo N, Carbon, 35, 1031 (1997)

[12] Sakintuna B, Akta Z, Yurum Y, Prepr. Pap.-Am. Chem. Soc. Div. Fuel Chem., 48, 614 (2003)

[13] Guo T, Zhu J, Chen X, J. Non-Cryst. Solids, 353, 2893 (2007)

[14] Lee J, Sohn K, Hyeon T, Chem. Commun., 2674 (2002)

[15] Inagaki M, Morishita T, Kuno A, Kito T, Hirano M, Carbon, 42, 497 (2004)

[16] Kyotani T, Nagai T, Inoue S, Tomita A, Chem. Mater., 9, 609 (1997)

[17] Costa L, di Montelera LR, Camino G, Weil ED, Pearce EM, Polym. Degrad. Stabil., 56, 23 (1997)

[18] Javni I, Petrovic ZS, Guo A, Fuller R, J. Appl. Polym. Sci., 77(8), 1723 (2000)

[19] Morterra C, Low MJDIR, Carbon, 23, 525 (1985)

[20] Camino G, Luda MP, Costa L, Trossarelli L, in Thermal Analysis, Miller B, Ed., Wiley, New York, 1982, Vol. 2, p 1137.

[21] Jha V, Banthia AK, Paul A, J. Therm. Anal., 35, 1229 (1989)

[22] Jackson WM, Conley RT, J. Appl. Polym. Sci., 8, 2163 (1964)

[23] Bark LS, Moran D, Percival SJ, Wear, 34, 131 (1975)

[24] Ozaki JI, Ohizumi W, Oya A, Carbon, 38, 1515 (2000)

[25] Fyfe CA, McKinnon MS, Rudin A, Tchir WJ, Macromolecules, 16, 1216 (1983)

[26] Morterra C, Low MJD, Langmuir, 1, 320 (1985)

[27] Lisperguer J, Drouguett C, Ruf B, Nunez M, J. Chil. Chem. Soc., 50, 451 (2005)