Uniformly Porous Composites with 3‐D Network Structure (UPC‐3D) for High‐Temperature Filter Applications

Abstract

Uniformly porous composites with 3‐D network structure (UPC‐3D) have been recently developed via a pyrolytic reactive sintering process, which takes advantage of the evolved CO2 gas from a decomposing carbonate source (e.g., dolomite, CaMg(CO3)2) and does not require any additional pore‐forming agent nor long‐time burning‐out process. Through liquid formation via LiF doping, strong necks are formed between constituent particles before completion of the pyrolysis of carbonate, resulting in the formation of a strong 3‐D network structure. The pore size distribution is very narrow (with typical pore size: ∼1 μm), and the porosity was controllable (∼30–60%) by changing the sintering temperature. This article presents the development details of UPC‐3D, and reports the recent findings in CaZrO3/MgAl2O4 system, which will be one of the more promising systems for practical applications.