Aerosol assisted synthesis of silica/phenolic resin composite mesoporous hollow spheres

Hollow spheres of phenolic resin/silica composite are synthesized by macroscopic phase separation of a sorbitan monooleate surfactant Span 80 during aerosol-assisted spraying. The cavity can be evolved from multiple compartments to single hollow cavity with the increase of Span 80 content. The composite shell becomes mesoporous due to the release of small molecules after thermal treatment above 350 degrees C. After further thermal treatment at a higher temperature for example 900 degrees C in nitrogen or 1,450 degrees C in argon, the carbon/silica composite hollow spheres or crystalline silicon carbide hollow spheres are derived, respectively. Compared to the pure phenolic resin-based carbon spheres, thermal stability of the carbon-based composite spheres in air is essentially improved by the introduction of inorganic component silica. The carbon-based composite hollow spheres combine both performances of easy mass transportation through macropores and high specific surface area of mesopores, which will be promising to support catalysts for fuel cells.