Monolithic carbon aerogels within foam framework for high-temperature thermal insulation and organics absorption

Carbon aerogels exhibit high porosity, good electrical conductivity, and low thermal conductivity, but their practical applications are greatly hindered by their tedious preparation and inherent structure brittleness. Herein, monolithic carbon aerogels (MCAs) with low density and large size are prepared via a facile sol-gel polymerization of phenolic resin within melamine foam (MF), followed by ambient pressure drying and co-carbonization. During ambient pressure drying process, the MF matrix can deliver supporting force to counteract against the solvent evaporation surface tension, thus inhibiting volume shrinkage and shape deformation. Upon co-carbonization process, the MF matrix and organic aerogel could pyrolyze and shrink cooperatively, which could effectively prevent the brittle fracture of monolith. Therefore, large-sized MCAs (up to 250 × 250 × 20 mm) with low densities of 0.12-0.22 g·cm^-3 are obtained. The as-obtained MCAs possess high compressive strength (2.50 MPa), ultra-low thermal conductivity (0.051 W·m^-1·K^-1 at 25 °C and 0.111 W·m^-1·K^-1 at 800 °C), and high-volume organic absorption capability (77.3-88.0%, V/V). This facile and low-cost method for the fabrication of large-sized monolithic carbon aerogels with excellent properties could envision enormous potential for high-temperature thermal insulation and organics absorption.