Ultralight Silica Foams with a Hierarchical Pore Structure via a Surfactant-Free High Internal Phase Emulsion Process

An ultralight silica aerogel is among the most versatile materials available for technical applications; however, it remains a huge challenge to reduce its manufacturing cost. Here, we report on a simple approach for the preparation of silica foam monoliths with ultrahigh porosity up to 99.5% and specific surface area as high as 755 m² g^-1, which are similar to those of an aerogel. Our strategy is based on the effective stabilization of water-in-oil high internal phase emulsions by a hydrophobic silica precursor polymer, hyperbranched polyethoxysiloxane because of its hydrolysis-induced amphiphilicity. After conversion of this precursor polymer to silica, the emulsions are solidified without significant volume shrinkage. Thus, mechanically strong macroporous silica monoliths are obtained after removal of its liquid components. According to nitrogen sorption data, the resulting silica foams exhibit a high specific surface area and a foam skeleton consisting of both micropores (<2 nm) and mesopores (2-50 nm). The pore size, porosity, and surface area can be regulated by varying pH as well as the concentration of the silica precursor in the oil phase. In addition, the pore size can be adjusted by controlling shear force during emulsification. This work opens a new avenue for producing ultralight porous materials amenable to numerous applications.