BioResources, Vol 3, No 4 (2008)

Carbonized Starch Microcellular Foam-Cellulose Fiber Composite Structures

Andrew R Rutledge, Richard A. Venditti, Joel J Pawlak, Sameer Patel, Janderson L Cibils

Abstract


Carbon foams are porous low density materials typically in the range of 0.3 to 0.5 g/cm3 that contain high percentages of carbon. The foams are used in applications such as thermal insulation, battery electrodes, filters, fuel cells, and medical devices. In this study, the production of microporous carbon foams from starch microcellular foam-fiber (SMCF-Fiber) composites is described. SMCF-Fiber composites are created by microwave heating of a starch fiber solution forming an aquagel. The aquagel is then cooled, solvent exchanged, air dried, and carbonized. The use of higher amylose content starches as well as up to a 4% fiber suspension content of the precursor aquagel improved the uniformity and the preservation of the foam structure upon solvent exchange and drying. Increased amylopectin content improved compression strength of the starch microcellular-fiber foams but caused defects during the drying process. At a 10°C/min carbonization ramp the materials expanded in an irreproducible manner resulting in a fragile, non-uniform structure. At a slower 0.5ºC/min heating ramp the materials did not expand and formed uniform foams with well developed structure and higher compression strengths. The micro porous structure observed in the non-carbonized materials was converted to a larger plate like structure at treatment temperatures above 350˚C. The carbonized structures relative to the non-carbonized material had lower compression strength at the 350°C to 450°C range but higher compression strength at temperatures of 700˚C. The carbon foam products from these precursors are promising carbon structures with moderate strength and low density.

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