Pore development of thermosetting phenol resin derived mesoporous carbon through a commercially nanosized template

Mesoporous carbons (MCs) with high specific surface area and pore volume were synthesized from thermosetting phenol resin (TPR) by using commercial nanosized silica particles as template. Based on the results of thermogravimetric analysis, nitrogen adsorption, mercury adsorption and high-resolution transmission electron microscopy (HRTEM), mechanism of the pore formation of MCs was proposed. Silica particles not only participated in the pore formation of MCs but also influenced the thermosetting process of the carbon precursor. The mechanism of pore formation in the MCs may be described as follows: mesopores were introduced by the removal of silica particles; small mesopores were created by the combination of aperture between TPR and silica particles and opened pores in the matrix generated by the release of small molecules in the carbon during carbonization process; macropores were produced by the aggregation of silica particles and the collapse of carbon wall.