Foam Silica Films Synthesized by Calcium Chloride-Assisted Emulsification

The development of porous films with an accessible high specific surface area is important for designing new adsorbents, sensors, or catalyst supports. Here, we describe a simple method to prepare a silica foam coating using a calcium chloride-assisted evaporation-induced emulsification method. An alcoholic silica sol containing calcium chloride and a poly(ethylene oxide)-based polymer is deposited on a substrate by dipping. The evaporation of the alcohol induces a phase separation between the silica-rich phase and the calcium-rich one. The size of the droplets increases via a coalescence process until the gelation of the sol, which determines the final pore size between 100 nm and 3 μm. Thermal analysis and monitoring of droplet evaporation confirm that the departure of the solvent is delayed by the presence of calcium chloride in the sol. The influence of the nature of the polymer on the porosity is discussed. The use of a block copolymer such as the Pluronic F-127, which strongly stabilizes the emulsion, allows to reach a low pore size (400 nm), while on the contrary, we propose to use a short poly(ethylene glycol) (PEG) such as PEG-400, which weakly stabilizes it, leading to larger pores (2-3 μm). Furthermore, we show that the addition of a zirconium salt (ZrOCl₂·8H₂O) to the silica sol accelerates the condensation step of the silica and leads to the decrease in the pore size.