Preparation of epoxy monoliths via chemically induced phase separation

Epoxy porous monoliths were prepared from a commercial epoxy resin, D.E.R. 331, that cured with a tertiary amine, 2,4,6-tris-(dimethylaminomethyl) phenol, in the presence of a solvent, diisobutyl ketone (DIBK). During the curing process, polymers were formed and a decrease in its solubility in DIBK; the solution thus phase-separated, usually referred to as chemically induced phase separation. The phase separation formed interconnected polymer-poor phase that then became interconnected pores after the removal of DIBK. By varying the content of DIBK from 32 to 40 vol.%, epoxy monoliths with interconnected pores were prepared, with surface pore size ranging from 0.20 to 2.33 mu m, overall porosity from 0.41 to 0.60, and ethanol permeability from 10 to 4,717 L/(m(2) h(-1) bar(-1)). The glass transition temperatures of the epoxy monoliths, measured with differential scanning calorimetry, were all higher than 100 A degrees C, and temperatures of 5 % weight loss, analyzed by thermal gravimetry, were higher than 350 A degrees C, evidencing the monoliths' high thermal stability. Also, the monolith morphology was found to be strongly related to the reaction mechanism of polymerization. The results indicate that the mechanism of chain initiation and propagation associated with the tertiary amine can effectively form monoliths with interconnected pores, which cannot be easily prepared with a stepwise polymerization mechanism associated with using primary amine as the curing agent.