Structure-Controlled Porous Cordierite Ceramics with High Solid Content Prepared by Pickering Emulsion Technique Using Sucrose as a Porogen

Porous cordierite ceramics (PCCs) with stable 3D microstructures were prepared by Pickering emulsion technique using sucrose as a porogen. The microstructural and mechanical properties could be adjusted by varying O/S ratios, sintering temperature, and sucrose content. The formation of the spherical structure was due to the broken oil bubbles. The appearance of cordierite and the concurrent consumption of sucrose were responsible for the observation of gradient pore structure. When the O/S ratio was 2, the pore-structure-controlled PCCs with cordierite as the main phase was obtained after sintering at 1300 °C. With the addition of 30 wt.% of sucrose, the obtained PCCs possessed high solid content of 45 vol.%, the porosity of 90.83%, the compressive strength of 6.09 MPa, and the optimized thermal conductivity of 0.4794 W/m.K. Compared with the predecessors’ research results, the as-prepared precursor of PCCs with sucrose content had the lowest initial Zeta potential without adjusting the pH to ensure the stable suspension. Our results showed that the addition of sucrose not only acts as a solvent to increase the solid content, but also acts as a pH modifier to maintain precursor stability, which enables the increase in compressive strength. In this work, via the scenario of “oil droplet” 3D accumulation, the stable and orderly spatial arrangement of the micro-emulsion system was successfully realized to obtain the structure-controlled PCCs by controlling the precursor conditions.