Hierarchical Carbon Foams with Independently Tunable Mesopore and Macropore Size Distributions

Hierarchical carbon foams with independently tunable mesopore and macropore size distributions were formed in a high internal phase emulsion (HIPE) template. The HIPE consists of an internal oil phase that controls the macropore dimensions and an aqueous resorcinol-formaldehyde precursor solution external phase that directs the mesopore size distribution. Once the emulsion is formed, the precursor solution is cured, fluid elements are extracted from the monolith via solvent exchange, and then the sample is pyrolyzed to create a hierarchical open-cell foam consisting of macropores with mesoporous carbon xerogel walls. Both mesopore and macropore size distributions may be independently tuned by changing the synthesis parameters. These samples have a peak in the mesopore size distribution that may be tuned to between 5 and 8 nm and macropore average diameters that may be tuned to between 0.7 and 2.1 mu m. Furthermore, the 0.7 and 2.1 mu m average diameter macropores have 0.18 and 0.53 mu m diameter macropore windows between adjacent pores, respectively. Pore volumes up to 5.26 cm(3)/g and electrical conductivities as high as 0.34 S/cm are observed after 1200 degrees C carbonization of the framework. These foams may have potential applications as 3-D current collectors in batteries and as fuel cell catalyst supports.