Preparation of syntactic carbon foam

A pressure molding technique for preparing syntactic carbon foam having high compressive strength and low bulk density (> 500 lb/in² at 0·18 g/cm³) is described. The use of hollow phenolic resin and carbon microspheres of various types, particle size, and wall thickness, along with different carbonaceous binder materials, solvents, and molding pressures prior to coking at 900°C were some of the major variables investigated in relation to compressive strength and density characteristics of the syntactic carbon foams.