Abstract: A method of forming a carbon foam material comprises forming an emulsion may include a phenol formaldehyde and hexamine in monoethylene glycol and water, curing the emulsion to yield a cured resin, and carbonizing the cured resin to form the carbon foam material. Forming the emulsion may include dispersing the phenol formaldehyde and hexamine in the monoethylene glycol to form an initial solution, contacting the initial solution with the water to form an initial emulsion, and agitating the initial emulsion to form an agitated emulsion. The method may further comprise contacting the agitated emulsion with an oil. Also, a carbon foam material that may be characterized as exhibiting a density of less than about 0.500 g/cc, as exhibiting a compressive strength equal to or greater than about 200 psi, or both.

Abstract: A porous carbon material suitable for incorporation in smoke filters for cigarettes has a BET surface area of at least 800 m2/g and a pore structure that includes mesopores and micropores. The pore volume (as measured by nitrogen adsorption) is at least 0.9 cm3/g and from 15 to 65% of the pore volume is in mesopores. The pore structure of the material provides a bulk density generally less than 0.5 g/cc. The material may be produced by carbonizing and activating organic resins and may be in the form of beads for ease of handling.

Abstract: A process is provided for producing discrete solid beads of polymeric material e.g. phenolic resin having a mesoporous structure, which process may produce resin beads on an industrial scale without aggregates of resin building up speedily and interrupting production. The process comprises the steps of: (a) combining a stream of a polymerizable liquid precursor e.g. a novolac and hexamine as cross-linking agent dissolved in a first polar organic liquid e.g. ethylene glycol with a stream of a liquid suspension medium which is a second non-polar organic liquid with which the liquid precursor is substantially or completely immiscible e.g. transformer oil containing a drying oil; (b) mixing the combined stream to disperse the polymerizable liquid precursor as droplets in the suspension medium e.g.

Abstract: A process is provided for producing discrete solid beads of polymeric material e.g. phenolic resin having a mesoporous structure, which process may produce resin beads on an industrial scale without aggregates of resin building up speedily and interrupting production. The process comprises the steps of: (a) combining a stream of a polymerizable liquid precursor e.g. a novolac and hexamine as cross-linking agent dissolved in a first polar organic liquid e.g. ethylene glycol with a stream of a liquid suspension medium which is a second non-polar organic liquid with which the liquid precursor is substantially or completely immiscible e.g. transformer oil containing a drying oil; (b) mixing the combined stream to disperse the polymerizable liquid precursor as droplets in the suspension medium e.g.

Abstract: A porous carbon material suitable for incorporation in smoke filters for cigarettes has a BET surface area of at least 800 m2/g and a pore structure that includes mesopores and micropores. The pore volume (as measured by nitrogen adsorption) is at least 0.9 cm3/g and from 15 to 65% of the pore volume is in mesopores. The pore structure of the material provides a bulk density generally less than 0.5 g/cc. The material may be produced by carbonising and activating organic resins and may be in the form of beads for ease of handling.