Thermoset porous composites and methods thereof

A method of producing a density-graded porous polymer composite, comprising:

• preparing a mixture comprising a resin, a curing agent, dry ice and optionally a filler;
• casting the mixture;
• curing the casted mixture to obtain the porous composite;
• and
• controlling the reaction rate of the casted mixture to obtain a density gradient in the porous composite.

A method of producing a density-graded porous polymer composite, comprising:

• preparing a mixture comprising a resin, a curing agent, dry ice and optionally a filler;
• forming a first polymer composite layer having a first average density and/or a first average pore size;
• and
• varying one or more parameters to obtain a second polymer composite layer having a second average density and/or a second average pore size, wherein the parameters are chosen from amount of dry ice, time of exposure to dry ice, pressure of the mixture, temperature of the mixture, and viscosity of the mixture;
• and wherein the first and second polymer composite layers are formed by a single unitary continuous material.

A method of producing a layered porous polymer composite, comprising:

• preparing a mixture comprising a resin, a curing agent, dry ice and optionally a filler;
• adding additional dry ice to the mixture;
• casting the mixture;
• curing the mixture to obtain the porous composite;
• and
• exposing top and bottom portions of the casted mixture to a decreased temperature so as to form density gradients in the polymer composite.