Hierarchical Ceramic Foams with 3D Interconnected Network Architecture for Superior High-Temperature Particulate Matter Capture

Developing new filters for the effective removal of high-temperature particulate matter is of great importance but still remains a challenge. Herein, we demonstrate a novel and facile strategy for producing hierarchical ceramic foams with three-dimensional interconnected porous architecture via the combination of chemical grafting of pore-forming agent and polyurethane foaming technique. Carbamate groups are directly grafted onto carbon black surface to enhance its dispersion. Abundant micrometer-sized pores are generated on the cell walls of porous frameworks to form three-dimensional interconnected porous architectures, resulting in the mullite foam with high particulate matter removal efficiency and relatively low pressure drop. The optimized mullite foam exhibits integrated properties of high particulate matter removal efficiency (96.7%), ultralow pressure drop (35 Pa), and outstanding recyclability. Our results open new opportunities for fabricating efficient particulate matter filters used in high-temperature environmental fields.