Low-density microcellular carbon foams

A method has been developed to produce vitreous carbon foams having both low densities (0.03 to 0.10gcm^–3) and small cell sizes ( 20 m). This process involves the replication of a porous sacrificial substrate, i.e. sodium chloride. The salt is pressed initially into bars and sintered to give a structure with continuous porosity. The pores are infused with a phenolic solution, the solvent is evaporated, and the resin is pyrolysed within the salt substrate. Extraction of the salt and freeze drying lead to the final carbon foam. The substrate serves two purposes in this process: (1) it prevents shrinkage of the foam during pyrolysis, and (2) it dictates the cell size of the foam.