Template-assisted production of porous materials
The present disclosure provides composites comprising an open cell foam and a small pore area material, methods for their preparation, articles of manufacture comprising them and methods for preparing the same.
1. An evacuated composite comprising:
(a) an open cell foam, wherein the open cell foam is floral foam; and
(b) a small pore area material, wherein the small pore area material comprises the reaction product of a hydroxylated aromatic; a carboxylic acid; and an electrophilic linking agent;
wherein the hydroxylated aromatic is a phenolic-novolak resin or phenolic-resole resin;
the carboxylic acid is acetic acid; and
the electrophilic linking is furfural or furfuryl alcohol.
2. The evacuated composite according to claim 1 , wherein the open cell foam further comprises an opacifier.
3. The evacuated composite according to claim 1 , further comprising an agent selected from the group consisting of metal powders, metal oxides, metal salts, silica, alumina, aluminosilicates, carbon black, novoloid fibers and fire resistant additives.
4. A method for preparing an article of manufacture, wherein the method comprises the step:
(a) placing the evacuated composite of claim 1 inside a bag.
5. The method of claim 4 , further comprising the steps:
(b) evacuating the bag; and
(c) sealing the bag.
6. The evacuated composite according to claim 1 , wherein the hydroxylated aromatic is a phenolic-novolak resin.
7. The evacuated composite according to claim 1 , wherein the electrophilic linking agent comprises furfural.
8. The evacuated composite according to claim 1 , wherein the electrophilic linking agent comprises furfuryl alcohol.
9. The evacuated composite according to claim 1 , wherein the composite comprises substantially no air.
10. The evacuated composite according to claim 1 , wherein the composite comprises air at a concentration of less than about 100 mtorr.
11. The evacuated composite according to claim 1 , wherein the composite comprises air at a concentration of less than about 50 mtorr.
12. An evacuated composite comprising (a) floral foam; and (b) a small pore area material comprising the reaction product of novolak resin, furfural and acetic acid.
13. The evacuated composite according to claim 1 , wherein the hydroxylated aromatic is a phenolic-resole resin.
14. A method for preparing an evacuated composite comprising an open cell foam and a small pore area material, the method comprising:
(a) providing an open cell foam, wherein the open cell foam is floral foam;
(b) forming a solution comprising a hydroxylated aromatic, an electrophilic linking agent, and a carboxylic acid;
(c) combining the solution from step (b) with the open cell foam;
(d) allowing the solution to form a sol-gel;
(e) removing substantially all of the fluid portion of the sol-gel; and
(f) evacuating the composite.
15. The method according to claim 14 , wherein the solution formed in step (b) further comprises a catalyzing agent.
16. The method according to claim 14 , wherein step (d) includes the substep of subjecting said solution to either: (i) a temperature or a pressure higher than ambient; or (ii) a temperature and a pressure higher than ambient.