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Porous carbon ablators offer cost-effective thermal protection for aerospacevehicles during re-entry into planetary atmospheres. However, the explorationof more distant planets requires the development of ablators that are able towithstand stronger thermal radiation conditions. Here, we report thedevelopment of bio-inspired porous carbon insulators with pore sizes that aredeliberately tuned to enhance heat-shielding performance by increasingscattering of high-temperature thermal radiation. Pore size intervals thatpromote scattering are first estimated using an established model for theradiative contribution to the thermal conductivity of porous insulators. On thebasis of this theoretical analysis, we identify a polymer additive that enablesthe formation of pores in the desired size range through thepolymerization-induced phase separation of a mixture of phenolic resin andethylene glycol. Optical and electron microscopy, porosimetry and mechanicaltests are used to characterize the structure and properties of porousinsulators prepared with different resin formulations. Insulators with poresizes in the optimal scattering range reduce laser-induced damage of the porousstructures by up to 42%, thus offering a promising and simple route for thefabrication of carbon ablators for enhanced thermal protection at hightemperatures.

Carbon ablators with porosity designed for enhanced aerospace thermal protection