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This report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof.

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ABSTRACT:Resorcinol-formaldehyde (RF) aerogel chemistry has been used with encapsulation techniques to fabricate low-density, transparent, foam shells. To accomplish this, the gelation time was reduced from several hours to several minutes by the addition of acid following base-catalyzed RF particle growth. However, additional ''annealing'' of the gel for at least 20 h was needed to maximize crosslinking and minimize swelling in exchange solvents. Increasing the molar ratio of formaldehyde to resorcinol from 2 to 3 also helped to increase crosslinking. Densification of the foam shells due to dehydration during curing was greatly reduced by judicious choice of immiscible oil phases and by saturating the exterior oil phase during the annealing stage. Shells have been produced with diameters of about 2 mm, wall thicknesses ranging from 100 to 200 mm and foam densities approaching 50 mg/cc.

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