Manufacture of cordierite foams by direct foaming

Open cell cordiereti fosms were prepared by a direct foaming two-component polyurethane (PUR)/ceramic system. Throught optimization of several experimental parameters such as contents of catalysts and ceramic cordiereti precursor, as well as plasticizer presence, foams with porosites 85-95&% and densities ranging from 130-410 kg/m3 were obtained. Thse foams characteristics make them attractive to be used as catalyst supports. The new two-component PUR/ceramics system developped allows the high solid's loading (higher than 40 wt. %). Finer ceramic particles in this system provide better particles packaged and cohesion upon sintering, favouring the cordiereti foam stability