Pore structure control of mesoporous carbon monoliths derived from mixtures of phenolic resin and ethylene glycol

Mesoporous carbon monoliths derived from phenolic resin mixtures have been prepared in the process based on polymerization-induced phase separation. The effect of the composition of resin mixtures and the resin curing temperature on the pore structure of carbon monoliths has been systematically investigated, with emphasis on controlling the apparent porosity and pore size distribution. Fractal dimensions have been introduced to evaluate the morphologies of the carbon monoliths. The results showed that mesoporous carbon monoliths with narrow pore size distribution were obtained. The pore structure of carbon monoliths could be controlled by changing the resin curing temperature and the content of ethylene glycol, curing catalyst and water in the resin mixtures. The apparent porosity of carbon monoliths varied from 54.27% to 26.83%. Carbon monoliths had narrower pore size distribution when more ethylene glycol and higher resin curing temperature were employed. The pore structure of carbon monoliths would be changed radically when the initial resin samples were prepared with excess water (9.8 wt%), i.e. porous carbon foams with sponge structure were obtained. Carbon monoliths inherit their porosity from precursing cured resins where it was formed as a result of phase separation of resin-rich and glycol-rich phases. Volume contraction had certain effect on the pore structure of carbon monoliths.