Organic, open cell foam materials, their carbonized derivatives, and methods for producing same
View Patent ↗Organic, small pore area materials (“SPMs”) are provided comprising open cell foams in unlimited sizes and shapes. These SPMs exhibit minimal shrinkage and cracking. Processes for preparing SPMs are also provided that do not require supercritical extraction. These processes comprise sol-gel polymerization of a hydroxylated aromatic in the presence of at least one suitable electrophilic linking agent and at least one suitable solvent capable of strengthening the sol-gel. Also disclosed are the carbonized derivatives of the organic SPMs.
1. An organic low density microcellular material comprising acetic acid, wherein the acetic acid is attached to the solid network of the low density microcellular material.
2. The organic low density microcellular material of claim 1 , wherein the material is prepared using a non-critical drying process.
3. The organic low density microcellular material of claim 1 , wherein the material has a monolithic form.
4. The organic low density microcellular material of claim 1 , wherein the material is produced in a method that uses a surfactant.
5. The organic low density microcellular material of claim 1 , wherein the material comprises greater than about 80% open pores.
6. The organic low density microcellular material of claim 1 , wherein the material comprises a density less than about 300 kg/m 3 .
7. The organic low density microcellular material of claim 6 , wherein the density is less than about 275 kg/m 3 .
8. The organic low density microcellular material of claim 7 , wherein the density is less than about 250 kg/m 3 .
9. The organic low density microcellular material of claim 8 , wherein the density is less than about 150 kg/m 3 .
10. The organic low density microcellular material of claim 9 , wherein the density is less than about 100 kg/m 3 .
11. The organic low density microcellular material of claim 1 having a thermal conductivity less than about 0.0135 W/(m·K) at a pressure of up to about 10 Torr.
12. The organic low density microcellular material of claim 11 , wherein the thermal conductivity is less than about 0.008 W/(m·K) at a pressure of up to about 10 Torr.
13. The organic low density microcellular material of claim 1 having a thermal conductivity less than about 0.009 W/(m·K) at a pressure of up to about 1 Torr.
14. The organic low density microcellular material of claim 13 , wherein the thermal conductivity is less than about 0.007 W/(m·K) at a pressure of up to about 1 Torr.
15. The organic low density microcellular material of claim 1 having a thermal conductivity less than about 0.005 W/(m·K) at a pressure of up to about 0.1 Torr.
16. The organic low density microcellular material of claim 15 , wherein the thermal conductivity is less than about 0.0035 W/(m·K) at a pressure of up to about 0.1 Torr.
17. The organic low density microcellular material of claim 1 , wherein the material is a carbonized form.
18. The organic low density microcellular material of claim 1 , further comprising a hydroxylated aromatic and an electrophilic linking agent.
19. The organic low density microcellular material of claim 18 , wherein the hydroxylated aromatic is selected from phenol, resorcinol, catechol, hydroquinone, phloroglucinol, and liquid phenolic resins.
20. The organic low density microcellular material of claim 18 , wherein the hydroxylated aromatic is a hydroxylated benzene compound.
21. The organic low density microcellular material of claim 18 , wherein the hydroxylated aromatic comprises a phenolic-novolak resin.
22. The organic low density microcellular material of claim 18 , wherein the electrophilic linking agent comprises an aldehyde.
23. The organic low density microcellular material of claim 22 , wherein the electrophilic linking agent comprises furfural.
24. The organic low density microcellular material of claim 22 , wherein said electrophilic linking agent comprises formaldehyde.
25. The organic low density microcellular material of claim 18 , wherein the electrophilic linking agent comprises alcohol.
26. The organic low density microcellular material of claim 25 , wherein said alcohol is furfuryl alcohol.
27. The organic low density microcellular material of claim 18 , wherein the material is in the form of a complex prepared during a sol-gel polymerization process.
28. The organic low density microcellular material of claim 18 , further comprising an agent selected from the group metal powders, metal oxides, metal salts, silica, alumina, aluminosilicates, carbon black, novoloid fibers, and fire resistant additives.
29. The organic low density microcellular material of claim 1 , wherein the acetic acid is attached to the solid network of the low density microcellular material through hydrogen bonding.
30. The organic low density microcellular material of claim 1 , wherein the acetic acid is attached to the solid network of the low density microcellular material through covalent modifications.