Hierarchical Macroporous PolyDCPD Composites from Surface-Modified Calcite-Stabilized High Internal Phase Emulsions

High Internal Phase Emulsions (HIPEs) of dicyclopentadiene (DCPD) were prepared using mixtures of surface-modified calcite (mCalcite) and a non-ionic surfactant. Twelve different emulsion formulations were created using an experimental design methodology. Three distinctive levels of the internal phase ratio, the amount of mCalcite loading, and the surfactant were used to prepare the HIPEs. Accordingly, macroporous polyDCPD composites were synthesized by performing ring-opening metathesis polymerization (ROMP) on the HIPEs. The variations in the morphological and physical properties of the composites were investigated in terms of experimental parameters. In the end, five different model equations were derived with a confidence level of 95%. The main and binary interaction effects of the experimental parameters on the responses, such as the average cavity size, interconnecting pore size, specific surface area, foam density, and compression modulus, were demonstrated. The synergistic interaction between the amount of surfactant, the amount of mCalcite loading, and the internal phase ratio appeared to have a dominant role in the average cavity diameter. The solo effect of the internal phase ratio on the interconnecting pore size, foam density, and compression modulus was confirmed. In addition, it was demonstrated that the specific surface area of the composites was mainly changed depending on the amount of mCalcite loading.