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Research Article

Development of Carbon Coatings for Cordierite Foams: An Alternative to Cordierite Honeycombs

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Francisco José Maldonado-Hódar,*^† Sergio Morales-Torres,^† Filipa Ribeiro,^‡ Elisabete Ribeiro Silva,^‡ Agustín Francisco Pérez-Cadenas,^† Francisco Carrasco-Marín,^† and Fernando A. Costa Oliveira^§

Department of Inorganic Chemistry, Faculty of Sciences, University of Granada, Avda. Fuentenueva s/n, 18071 Granada, Spain, IBB-Institute for Biotechnology and Bioengineering, Instituto Superior Técnico, Av. Rovisco Pais, 1049-001 Lisboa, Portugal, Department of Materials and Production Technologies, INETI-I.P., Estrada do Paço do Lumiar, 1649-038 Lisboa, Portugal

Langmuir, 2008, 24 (7), pp 3267–3273

DOI: 10.1021/la703217t

Publication Date (Web): February 22, 2008

Abstract

Cordierite foams were prepared by replication of polyurethane foams and were coated with three types of carbon xerogels. The dip coating and synthesis conditions were optimized, and the coated foams were characterized exhaustively. The composition of the starting solution, coat loading, and carbonization temperature are the most important parameters determining both textural and mechanical properties. Carbon xerogel coatings obtained from aqueous solutions of resorcinol (R) and formaldehyde (F) are macro-, meso-, and microporous but present the greatest shrinkage, which causes a loss of adhesion between ceramic foams and carbon coatings. The coatings from polyfurfuryl alcohol (PFA) and RF−poly(vinyl butyral) (Butvar) resin are highly microporous and present very good adhesion even after carbonization. In all cases, coatings induce the improvement of the mechanical properties, which is related to the fact that the coating fills the defects present in the cordierite foams, thereby affecting both the rigidity and the way cracks propagate through the coated samples. These materials, due to the synergetic role of the highly porous coatings and the tortuous channels of the ceramic foams, are suitable materials for adsorption or catalytic treatments of fluids.

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This article has been cited by 1 ACS Journal articles (1 most recent appear below).

Synthesis and Properties of Phloroglucinol−Phenol−Formaldehyde Carbon Aerogels and Xerogels
Hana Jirglová, Agustín F. Pérez-Cadenas and Francisco J. Maldonado-Hódar
Langmuir2009 25 (4), 2461-2466
- Synthesis and Properties of Phloroglucinol−Phenol−Formaldehyde Carbon Aerogels and Xerogels
  Hana Jirglová, Agustín F. Pérez-Cadenas and Francisco J. Maldonado-Hódar
  Langmuir2009 25 (4), 2461-2466
  Carbon aerogels and xerogels were successfully prepared from phloroglucinol−phenol mixtures and characterized by different techniques to determine their potential. We examined the influence of the phloroglucinol/phenol ratio, reactant concentration, cure ...
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