Preparation of porous carbon template with controllable channels by phenolic resin pyrolyzing

Porous carbon templates were prepared by pyrolysis of samples. The samples were fabricated by filling mixture of phenolic resin and corn starch into negative molds with network structure manufactured by stereolithography. The network structure generated the channels in pyrolysis process. Thermo-gravimetric analysis (TGA) was applied to reveal the pyrolysis behaviors of photo-curable resin, phenolic resin and corn starch. X-ray diffraction (XRD), Fourier transform infrared spectroscope (FTIR) and scanning electron microscope (SEM) were employed to characterize and analyze the phase identification and microstructures of the carbon templates. Open porosity and density of the carbon templates were measured by Archimedes principle. The results show that the carbon template is noncrystalline materials. It is in partly graphitized amorphous state, and has a turbostratic structure, and contains minim C-H bonds. With increasing carbonization temperature, the graphitization advances. The pore phase includes channels, macro-pores (d = 10-50 μm) and micro-pores (d = l-3 μm). The channels could prevent the carbon templates from breaking and cracking.