This
paper discusses fabrication of polyimide aerogel foam sheets
with embedded micrometer size voids (macrovoids) introduced via oil-in-oil
(O/O) emulsion-templating of polyimide sol with silicone oil, followed
by casting, gelation, and supercritical drying. The aerogel foam sheets
contain significant fractions of mesopores (2–50 nm) inherent
to polyimide aerogels and macrovoids introduced in the form of silicone
oil droplets. An understanding is developed in this work to correlate
sol casting conditions, sol composition, and transient viscosity growth
with the macrovoid size distribution, mesopore content, and morphology
of aerogel foam sheets. The study finds that the flow of sol in a
doctor’s blade casting system induces coalescence of silicone
oil droplets. The study also determines that the properties of the
cast gel and aerogel sheet materials strongly depend on the time of
sol casting, measured in terms of lead time (t
lead) away from the gel point.