In the process of preparing porous epoxy materials using reaction-induced phase separation (RIPS), the introduction of an appropriate amount of SiO2 particles enables the control of the phase separation behavior of the system and its ultimate phase structure. This study examined the role of SiO2 particles in the preparation and size control of epoxy resin multilevel structures by analyzing the phase separation and reaction kinetics in an epoxy resin blend system and characterizing the ultimate phase structure. It was found that fumed SiO2 particles (0–3 wt%) added to the DGEBA/DDCM/PEG200 blends resulted in significant interfacial stabilization, delaying phase separation. With an increase in the fumed SiO2 particle content, the phase structure stopped evolving at an earlier stage of phase separation. In addition, the fumed SiO2 particles dispersed in the porogen-enriched phase helped to stabilize the system, i.e., preventing or slowing down the segregation and aggregation of the components in the system, which may inhibit secondary phase separation in the porogen-enriched phase. When 350 nm SiO2 particles were used, an increase in the particle size resulted in a larger phase structure. The SiO2 particles were dispersed within the pore-forming agent phase, increasing the proportion of the pore-forming agent and exerting an occupancy effect, which diminished with decreasing SiO2 particle size and increasing hydrophobicity. Notably, the surface of the epoxy porous material skeleton was decorated with small pits formed by the acid etching of the SiO2 particles, and this multilevel structure contributed to the specific surface area. The multilevel structure can be precisely controlled by adjusting the size, content, and wettability of the SiO2 particles. The results of this study are universal and instructive for the preparation of porous materials using a phase separation method in combination with solid particles.
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