Classifications

• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H13/00—Other non-woven fabrics
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
  • B01J20/02—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising inorganic material
  • B01J20/20—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising inorganic material comprising free carbon; comprising carbon obtained by carbonising processes
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
  • B01J20/28—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties
  • B01J20/28014—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties characterised by their form
  • B01J20/28033—Membrane, sheet, cloth, pad, lamellar or mat
  • B01J20/28038—Membranes or mats made from fibers or filaments
• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
  • D01F1/00—General methods for the manufacture of artificial filaments or the like
  • D01F1/02—Addition of substances to the spinning solution or to the melt
  • D01F1/10—Other agents for modifying properties
• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
  • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
  • D01F6/88—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from mixtures of polycondensation products as major constituent with other polymers or low-molecular-weight compounds
  • D01F6/94—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from mixtures of polycondensation products as major constituent with other polymers or low-molecular-weight compounds of other polycondensation products
• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
  • D01F9/00—Artificial filaments or the like of other substances; Manufacture thereof; Apparatus specially adapted for the manufacture of carbon filaments
  • D01F9/08—Artificial filaments or the like of other substances; Manufacture thereof; Apparatus specially adapted for the manufacture of carbon filaments of inorganic material
  • D01F9/12—Carbon filaments; Apparatus specially adapted for the manufacture thereof
  • D01F9/14—Carbon filaments; Apparatus specially adapted for the manufacture thereof by decomposition of organic filaments
  • D01F9/20—Carbon filaments; Apparatus specially adapted for the manufacture thereof by decomposition of organic filaments from polyaddition, polycondensation or polymerisation products
  • D01F9/24—Carbon filaments; Apparatus specially adapted for the manufacture thereof by decomposition of organic filaments from polyaddition, polycondensation or polymerisation products from macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
  • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
  • D04H1/4209—Inorganic fibres
  • D04H1/4242—Carbon fibres
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
  • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
  • D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather

Definitions

• the present invention relates to an activated carbon fiber nonwoven fabric and an element using the nonwoven fabric.
• an element constituted by wrapping an activated carbon fiber nonwoven fabric around a cylinder is suitably used because the adsorption / desorption speed is high and the size can be reduced.
• miniaturization of elements has been desired in order to reduce the installation space of the apparatus and to reduce manufacturing costs.
• An effective means for reducing the size of such elements is to increase the bulk density of the activated carbon fiber nonwoven fabric.
• the fibers constituting the activated carbon fiber nonwoven fabric if the bulk density of the nonwoven fabric is increased while maintaining the single fiber fineness as before (about 2 dtex to 3 dtex), the pressure loss of the element increases, and the element is treated. It is necessary to increase the capacity of the blower for blowing gas. As a result, there are cases where the benefits associated with the miniaturization of the elements cannot be fully enjoyed.
• Patent Document 1 a patent application for an activated carbon fiber nonwoven fabric using a fiber having a single fiber fineness of 5 dtex or more to suppress the pressure loss of the element, and have already obtained the right (Patent Document 1). ).
• the activated carbon fiber nonwoven fabric has a reduced tensile strength. For this reason, when the activated carbon fiber nonwoven fabric is strongly wound around the cylinder to obtain an element having a high bulk density, the activated carbon fiber nonwoven fabric may be damaged.
• the present invention has been made in order to solve the above-mentioned problems, and is composed of fibers having a fiber diameter that can reduce the pressure loss of the element, and has activated carbon having a tensile strength that does not break even when strongly wound around a cylinder. Providing a fiber nonwoven fabric was raised as an issue.
• the inventors of the present invention have not only been able to reduce the pressure loss of an element composed of the nonwoven fabric, but the activated carbon fiber nonwoven fabric having a predetermined fiber diameter obtained using phenolic fibers can not only reduce the pressure loss of the element. It has been found that it has sufficient tensile strength and can be strongly wound around a cylinder and the bulk density of the element can be increased, and the present invention has been completed.
• the activated carbon fiber nonwoven fabric of the present invention is obtained by spinning and curing a mixture in which a phenol resin is mixed with at least one compound selected from the group consisting of fatty acid amides, phosphate esters, and celluloses.
• the resulting activated carbon fiber is obtained by carbonizing and activating the non-woven fabric after processing the non-woven fabric, the fiber diameter is 21 ⁇ m to 40 ⁇ m, the toluene adsorption rate is 20% to 75%, and the tensile strength of the nonwoven fabric is 4 N / cm 2. It is the activated carbon fiber nonwoven fabric characterized by the above.
• the basis weight is 200 g / m 2 to 800 g / m 2 and the bulk density is 65 kg / m 3 to 100 kg / m 3 , both of which are preferable embodiments.
• the present invention includes an activated carbon fiber element comprising the above activated carbon fiber nonwoven fabric and having a bulk density of 90 kg / m 3 to 170 kg / m 3 .
• the pressure loss is 550 mmAq or less.
• the present invention provides a method for producing the activated carbon fiber nonwoven fabric, which comprises spinning a mixture in which at least one compound selected from the group consisting of fatty acid amides, phosphate esters, and celluloses is mixed with a phenol resin. And curing to produce phenolic fiber, processing the phenolic fiber into a nonwoven fabric to produce an activated carbon fiber nonwoven fabric precursor, and carbonizing and activating the precursor.
• the manufacturing method of the activated carbon fiber nonwoven fabric characterized by this is included.
• the activated carbon fiber nonwoven fabric of the present invention has a large fiber diameter of the fibers constituting the nonwoven fabric, an element with low pressure loss can be obtained. Moreover, since the activated carbon fiber nonwoven fabric of the present invention has a high tensile strength and is not easily damaged even when strongly wound around a cylinder, an element having a high bulk density can be obtained.
• the activated carbon fiber nonwoven fabric of the present invention is a nonwoven fabric composed of activated carbon fibers having a fiber diameter of 21 ⁇ m to 40 ⁇ m and a toluene adsorption rate of 20% to 75%, and has a tensile strength of 4 N / cm 2 or more.
• the activated carbon fiber nonwoven fabric of the present invention will be described in detail.
• the activated carbon fiber is simply referred to as ACF (Activated Carbon Fiber).
• ACF nonwoven fabric may be omitted and referred to as “ACF nonwoven fabric”.
• the fiber diameter of the fibers constituting the ACF nonwoven fabric of the present invention is 21 ⁇ m or more (preferably 22 ⁇ m or more, more preferably 23 ⁇ m or more, and further preferably 24 ⁇ m or more). By setting the fiber diameter to 21 ⁇ m or more, the pressure loss of the element obtained using the ACF nonwoven fabric of the present invention can be sufficiently suppressed.
• the upper limit of the fiber diameter is 40 ⁇ m (preferably 35 ⁇ m). In order to obtain an ACF nonwoven fabric having a fiber diameter exceeding 40 ⁇ m, it is necessary to process a raw yarn (fiber) having a single fiber fineness exceeding 22 dtex, and then to activate the raw yarn. Then, the raw yarn exceeding 22 dtex is processed into a nonwoven fabric. May be difficult.
• the activated carbon fiber constituting the ACF nonwoven fabric of the present invention has a toluene adsorption rate of 20% or more (preferably 30% or more, more preferably 40% or more), 75% or less, which is one of the indices representing the degree of activation. (Preferably 70% or less).
• a toluene adsorption rate of 20% or more (preferably 30% or more, more preferably 40% or more), 75% or less, which is one of the indices representing the degree of activation. (Preferably 70% or less).
• Tensile strength of the ACF nonwoven fabric of the present invention 4N / cm 2 or more (preferably 4.5 N / cm 2 or more, more preferably 5N / cm 2 or more). If the tensile strength is 4 N / cm 2 or more, even if the tension when the ACF nonwoven fabric is strongly wound around the cylinder is increased, the nonwoven fabric is not easily damaged, so that an element with a high bulk density can be obtained.
• the upper limit of the tensile strength is not particularly limited, but it is difficult to achieve a tensile strength exceeding 20 N / cm 2 in an ACF nonwoven fabric having a fiber diameter of 21 ⁇ m to 40 ⁇ m.
• the ACF nonwoven fabric of the present invention preferably has a basis weight of 200 g / m 2 or more (more preferably 250 g / m 2 or more, more preferably 300 g / m 2 or more).
• the upper limit of the basis weight is 800 g / m 2 (more preferably 750 g / m 2 , still more preferably 700 g / m 2 ).
• An ACF nonwoven fabric having a basis weight of more than 800 g / m 2 is difficult to produce, or even if the nonwoven fabric can be produced, the effect of improving the tensile strength has reached its peak and lacks flexibility.
• it tends to be difficult to wind the element around a cylinder.
• the ACF nonwoven fabric of the present invention preferably has a bulk density of 65 kg / m 3 or more (more preferably 67 kg / m 3 or more, and further preferably 70 kg / m 3 or more). If the bulk density is 65 kg / m 3 or more, an element with a high bulk density can be obtained even if the ACF nonwoven fabric winding tension around the cylinder when producing the element is lowered.
• the upper limit of the bulk density is 100 kg / m 3 (more preferably 95 kg / m 3 ).
• An ACF nonwoven fabric having a bulk density exceeding 100 kg / m 3 has a tendency to be difficult to wind around a cylinder due to lack of flexibility although tensile strength is increased.
• Pressure loss of ACF nonwoven fabric Since the ACF nonwoven fabric of the present invention having the above characteristics can have a pressure loss coefficient of 0.5 mmAq ⁇ s / cm 2 or less, an element having a low pressure loss can be produced.
• Pressure loss coefficient of the ACF nonwoven fabric of the present invention is preferably a 0.45mmAq ⁇ s / cm 2 or less (more preferably 0.40mmAq ⁇ s / cm 2 or less). When the pressure loss coefficient exceeds 0.5 mmAq ⁇ s / cm 2 , the resistance during gas passage is high, and the power loss of the ventilation blower may increase.
• the ACF nonwoven fabric of the present invention can be produced by processing a nonwoven fabric using phenolic fibers as a raw yarn to produce an ACF nonwoven fabric precursor, and then carbonizing and activating the precursor.
• the manufacturing method of the ACF nonwoven fabric of this invention is demonstrated in detail.
• the phenol fiber used in the present invention is obtained by spinning a mixture obtained by mixing a phenol resin with at least one compound (compound) selected from the group consisting of fatty acid amides, phosphate esters, and celluloses. Phenol fiber is preferably used.
• the compound By adding the compound to the phenolic resin, the phenolic fiber can be finished soft, so that the entanglement of the fiber can be enhanced when forming the nonwoven fabric. Thereby, since the entanglement property of the fiber in the ACF nonwoven fabric obtained by carbonization and activation is improved, desired tensile strength can be imparted to the ACF nonwoven fabric.
• phenol resin a novolac type phenol resin obtained by reacting phenols and aldehydes in the presence of an acidic catalyst, or a resol type phenol obtained by reacting phenols and aldehydes in the presence of a basic catalyst
• a resol type phenol obtained by reacting phenols and aldehydes in the presence of a basic catalyst
• examples thereof include resins, various modified phenolic resins, and mixtures thereof.
• the phenols are not particularly limited as long as they can be reacted with aldehydes in the presence of an acidic or basic catalyst to obtain each phenol resin.
• phenol, o-cresol, m-cresol, p-cresol, bisphenol A, 2,3-xylenol, 3,5-xylenol, m-butylphenol, p-butylphenol, o-butylphenol, 4- Phenylphenol and resorcinol are preferred, with phenol being most preferred.
• the said phenols may be used individually by 1 type, and may use 2 or more types together.
• aldehydes examples include formaldehyde, trioxane, furfural, paraformaldehyde, benzaldehyde, methyl hemiformal, ethyl hemiformal, propylhemiformal, salicylaldehyde, butylhemiformal, phenylhemiformal, acetaldehyde, propylaldehyde, phenylacetaldehyde, ⁇ - Phenylpropylaldehyde, ⁇ -phenylpropylaldehyde, o-hydroxybenzaldehyde, m-hydroxybenzaldehyde, p-hydroxybenzaldehyde, o-chlorobenzaldehyde, o-nitrobenzaldehyde, m-nitrobenzaldehyde, p-nitrobenzaldehyde, o-methylbenzaldehyde, m-methylbenzaldehyde, p-nitro
• formaldehyde, paraformaldehyde, furfural, benzaldehyde, and salicylaldehyde are preferable, and formaldehyde and paraformaldehyde are particularly preferable.
• the aldehydes may be used alone or in combination of two or more.
• the acidic catalyst examples include hydrochloric acid, sulfuric acid, phosphoric acid, formic acid, acetic acid, succinic acid, butyric acid, lactic acid, benzenesulfonic acid, p-toluenesulfonic acid, boric acid, and salts with metals such as zinc chloride or zinc acetate. It is done.
• the said acidic catalyst may be used individually by 1 type, and may use 2 or more types together.
• Examples of the basic catalyst include alkali metal hydroxides such as sodium hydroxide and lithium hydroxide; alkaline earth metal hydroxides such as calcium hydroxide and barium hydroxide; ammonium hydroxide; diethylamine, triethylamine, Examples include amines such as ethanolamine, ethylenediamine, and hexamethylenetetramine.
• the said basic catalyst may be used individually by 1 type, and may use 2 or more types together.
• modified phenolic resins include those obtained by modifying novolac-type or resol-type phenolic resins by known techniques such as boron modification, silicon modification, heavy metal modification, nitrogen modification, sulfur modification, oil modification, and rosin modification.
• a novolac type phenol resin or a resol type phenol resin it is preferable to use a novolac type phenol resin or a resol type phenol resin.
• a phenol resin may be used individually by 1 type, and may use 2 or more types together.
• the fatty acid amides used as a blend in the present invention means a non-polymer having a structure in which one or more hydrogen atoms bonded to the nitrogen atom of ammonia or amine are substituted with an acyl group.
• a primary amide in which two atoms are bonded, a secondary amide in which one hydrogen atom is bonded to the nitrogen atom, a tertiary amide in which no hydrogen atom is bonded to the nitrogen atom, a lactam, and one molecule Includes those having two or more amine nitrogen atoms. Therefore, the “fatty acid amides” in the present invention are different from polymers such as so-called aliphatic polyamides typified by nylon-6 and nylon-6,6. “Fatty acid amides” are also referred to as fatty acid amides.
• Examples of the primary amide include compounds represented by the general formula “R 1 C ( ⁇ O) NH 2 ”.
• R 1 is a hydrocarbon group which may have a substituent.
• “may have a substituent” means that a part or all of the hydrogen atoms of the hydrocarbon group may be substituted with a substituent.
• the hydrocarbon group for R 1 may be saturated or unsaturated, and may be linear or branched, and preferably has 5 to 31 carbon atoms, more preferably 11 to 23 carbon atoms. However, the carbon number of the hydrocarbon group of R 1 does not include the carbon number in the substituent described later.
• Examples of the substituent that the hydrocarbon group may have include a hydroxy group and a hydroxyalkyl group.
• the hydroxyalkyl group preferably has 1 to 11 carbon atoms.
• primary amides include caproic acid amide, caprylic acid amide, pelargonic acid amide, lauric acid amide, myristylic acid amide, palmitic acid amide, stearic acid amide, arachidic acid amide, behenic acid amide, lignoceric acid amide, etc.
• Saturated fatty acid monoamides such as oleic acid amide, erucic acid amide, and ricinoleic acid amide.
• secondary amides include compounds represented by the general formula “R 1 C ( ⁇ O) NHR 2 ”.
• R 1 is the same as R 1 in the description of the primary amide.
• R 2 is a hydrocarbon group which may have a substituent, or —C ( ⁇ O) R 3 .
• the hydrocarbon group for R 2 may be saturated or unsaturated, and may be linear or branched, and the carbon number thereof is preferably 1 to 23, and more preferably 1 to 17.
• Examples of the substituent that the hydrocarbon group may have include a hydroxy group.
• R 3 may be the same as R 1 in the description of the primary amide, and R 1 and R 3 may be the same as or different from each other.
• a compound in which R 2 is —C ( ⁇ O) R 3 is also referred to as an imide.
• secondary amides include substituted amides such as stearyl stearic acid amide, oleyl oleic acid amide, stearyl oleic acid amide, oleyl stearic acid amide, stearyl erucic acid amide, oleyl palmitic acid amide; methylol stearic acid amide, methylol And methylolamide such as behenic acid amide.
• tertiary amide examples include compounds represented by the general formula “R 1 C ( ⁇ O) NR 4 R 5 ”.
• R 1 is the same as R 1 in the description of the primary amide.
• R 5 are each like can be mentioned as R 2 in the description of the secondary amide, may be different from one another identical R 4 and R 5.
• tertiary amide examples include N, N-dimethylformamide, N, N-diethylformamide, N, N-dimethylacetamide, N, N-diethylacetamide and the like.
• lactams include those having 3 to 12 carbon atoms. Specific examples include ⁇ -propiolactam, ⁇ -butyrolactam (2-pyrrolidone), ⁇ -valerolactam (2-piperidone), ⁇ -caprolactam, undecaractam, dodecaractam (lauro / laurylactam). It is done.
• Examples of compounds having two or more amine nitrogen atoms in one molecule include compounds represented by the general formula “R 11 C ( ⁇ O) NH—R 6 —NHC ( ⁇ O) R 12 ”, 11 NHC ( ⁇ O) —R 7 —C ( ⁇ O) NHR 12 ”.
• R 11 and R 12 are each a hydrocarbon group which may have a substituent, and examples thereof include those similar to R 1 described above.
• R 6 and R 7 are each a divalent hydrocarbon group, and the carbon number thereof is preferably 1 to 10, more preferably 1 to 8.
• Specific examples of compounds having two or more amine nitrogen atoms in one molecule include methylenebisstearic acid amide, ethylene bisstearic acid amide, ethylene biscaprylic acid amide, ethylene bislauric acid amide, and ethylene bisbehenic acid amide.
• primary amides and secondary amides are preferable, primary amides are more preferable, saturated fatty acid monoamides, non-volatile amides from the viewpoints of handleability, stability and spinnability of the raw material mixture. Saturated fatty acid monoamides are particularly preferred, with behenamide being most preferred.
• the fatty acid amides if the carbon number is too small, the heat resistance of the phenolic fiber may be reduced, and if the carbon number is too large, the compatibility with the phenol resin used as the raw material for the phenolic fiber is reduced. There is a fear. Therefore, the fatty acid amides preferably have 12 to 30 carbon atoms in the whole molecule, and more preferably 18 to 24 carbon atoms. Fatty acid amides may be used alone or in combination of two or more.
• Phosphoric acid of the phosphoric acid esters used as a blend in the present invention is a general term for various oxo acids generated by hydrolysis of tetraphosphorus decaoxide (P 4 O 10 ), and is represented by the following chemical formula.
• Orthophosphoric acid (a), pyrophosphoric acid (diphosphoric acid) (b), triphosphoric acid (c), tetraphosphoric acid (d), metaphosphoric acid (e) and the like.
• phosphate esters mean those in which one or more of —OH in phosphoric acid is substituted with a group represented by the following general formula (1) (phosphate esters) or salts thereof.
• R 13 is a hydrocarbon group having 4 or more carbon atoms which may have a hetero atom (atom other than carbon and hydrogen), AO is an oxyalkylene group having 2 to 4 carbon atoms, and n Is the average number of moles added and represents a number from 0 to 100. ]
• an alkyl group, an alkenyl group, an aryl group, a group in which a part of hydrogen atoms of the alkyl group is substituted with an aryl group, or a part of hydrogen atoms in an alkenyl group are groups substituted with an aryl group.
• R 13 When the hydrocarbon group for R 13 is an alkyl group or an alkenyl group, R 13 preferably has 4 to 22 carbon atoms, and more preferably 8 to 18 carbon atoms.
• R 13 When the hydrocarbon group for R 13 is an aryl group, R 13 preferably has 6 to 35 carbon atoms, and more preferably 6 to 27 carbon atoms. Specific examples include a phenyl group, a naphthyl group, a benzyl group, a tolyl group, and a xylyl group.
• examples of AO include an oxyethylene group, an oxypropylene group, and an oxybutylene group. Note that an oxygen atom in the oxyalkylene group is bonded to the phosphorus atom.
• n is preferably 0 to 50, more preferably 0 to 10.
• phosphate esters mechanical strength is likely to increase particularly when a large-diameter phenolic fiber is used, so that at least one of —OH in orthophosphoric acid is substituted with the group represented by the above formula (1). (Orthophosphoric acid ester) or a salt thereof is preferred.
• orthophosphoric acid ester examples include monoesters (f), diesters (g) and triesters (h) of orthophosphoric acid represented by the following general formula. Of these, monoesters and diesters of orthophosphoric acid are preferable.
• R 13 , AO and n are the same as defined above.
• a plurality of — (AO) n OR 13 may be the same or different from each other.
• phosphate ester salts examples include alkali metal salts, alkaline earth metal salts, ammonium salts, and amine salts of phosphate esters. Phosphate esters may be used alone or in combination of two or more.
• celluloses used as a blend in the present invention include methyl cellulose, ethyl cellulose, hydroxyethyl cellulose, carboxymethyl cellulose and the like.
• Cellulose may be used independently or may use 2 or more types together.
• the phenolic fiber used in the present invention is a raw material mixing step of mixing the phenol resin obtained by the above method and the above blend, and the raw material mixture obtained in the raw material mixing step is spun to obtain a yarn. It can be produced through a spinning process.
• melt-spinning which is the most common spinning method in the spinning process described later, is performed by melt-mixing a phenol resin and a blend
• either a novolak-type or resol-type phenol resin can be used as the phenol resin.
• the resol type is inferior in thermal stability to the novolak type, and the polymerization proceeds easily by heating during melting, so solidification in the melt spinning apparatus is inevitable, and continuous and stable spinning is performed. It ’s difficult. Therefore, it is particularly preferable to select a novolac type phenol resin in consideration of the ease of the process in industrial production and versatility.
• the amount of the phenol resin used is such that the proportion of the phenol resin in the obtained raw material mixture is 55% by mass to 99.9% by mass.
• the amount is preferably 70% by mass to 99% by mass, more preferably 85% by mass to 95% by mass.
• the amount of the compound used is such that the ratio of the compound in the obtained raw material mixture (the ratio of the total amount of the compound when a plurality of compounds are used) is 0.1% by mass to 45% by mass.
• the amount is preferably 1% by mass to 30% by mass, more preferably 5% by mass to 15% by mass. If the proportion of the blend is equal to or greater than the preferred lower limit, the effect of improving the mechanical strength when the phenolic fiber is increased in diameter is likely to be obtained. On the other hand, if the proportion of the blend is less than or equal to the preferable upper limit value, it is easy to maintain the characteristics such as heat resistance, flame retardancy, and chemical resistance of the phenol fiber.
• the amount of fatty acid amides used is preferably such that, for example, the proportion of fatty acid amides in the resulting raw material mixture is 0.1% by mass to 45% by mass, and 1% by mass to 30% by mass. %, More preferably 3% by mass to 10% by mass.
• the amount of the phosphate ester used is, for example, preferably such that the proportion of the phosphate ester in the obtained raw material mixture is 0.1% by mass to 45% by mass, and 1% by mass to 30% by mass.
• the amount is more preferably 5% by mass to 20% by mass.
• the amount of cellulose used is, for example, preferably such that the proportion of cellulose in the raw material mixture to be obtained is 0.1% by mass to 45% by mass, and an amount that provides 1% by mass to 30% by mass. It is more preferable that the amount is 5% by mass to 20% by mass.
• Examples of the method of mixing the phenol resin and the compound include a method of melting and mixing the two, a method of dissolving and mixing the two using a solvent, and the like. Among these, from the viewpoint of complexity of the process, environmental load, and economical efficiency, a method of melt-mixing both is preferable. An example of such melt mixing is a method of kneading both.
• the heat-kneading of the phenol resin and the compound can be performed using a known kneading apparatus, and examples of the kneading apparatus include an extruder-type kneader, a mixing roll, a Banbury mixer, and a high-speed biaxial continuous mixer. .
• the temperature of the heat kneading may be appropriately selected depending on the properties of the raw materials, and is preferably 200 ° C. or lower, more preferably 140 ° C. to 180 ° C.
• the temperature of the heat-kneading may be appropriately selected depending on the properties of the raw materials, and is preferably 200 ° C. or lower, more preferably 140 ° C. to 180 ° C.
• the raw material mixture is obtained by dissolving and mixing both in a solvent that can dissolve both, and then evaporating and removing the solvent.
• Examples of the solvent capable of dissolving both include a solvent obtained by mixing one or two or more selected from ketone solvents, ether solvents, nitrogen-containing solvents, hydrocarbon solvents, ester solvents, alcohol solvents, and the like. It is done.
• the dissolution and mixing of the phenol resin and the compound it is preferable to gradually add the phenol resin and the compound while stirring the solvent. At that time, heating is effective if the phenol resin or the compound is hardly dissolved in the solvent. Further, by applying pressure, it is possible to heat the solvent at a temperature higher than the boiling point of the solvent at normal pressure, which is further effective. However, since exposure to the raw material at a high temperature may cause thermal denaturation and deterioration, it is preferable to perform the heating limitedly until the raw material is completely dissolved.
• the concentration of the phenol resin and the compound dissolved in the solvent is not particularly limited, and may be set as appropriate in consideration of the properties of the raw material and the spinning method in the subsequent spinning process. In addition, from the point that it takes a lot of time and energy to recover the solvent to be removed by evaporation, it is preferable to set the concentrations of the phenol resin and the compound as high as possible in consideration of their respective solubilities.
• the method of mixing the phenol resin and the compound may be a method other than the melt mixing and dissolution mixing described above.
• a raw material mixture solution obtained by dissolving and mixing both in a solvent capable of dissolving both the phenol resin and the compound is used. It may be prepared.
• the raw material mixture solution can be used directly as a stock solution for spinning.
• the raw material mixing step even if any method is used to obtain the raw material mixture, known additives, plasticizers, compatibilizers, antioxidants, ultraviolet absorbers, penetrants, if necessary. Thickeners, antifungal agents, dyes, pigments, fillers and the like may be used.
• the phenol resin and the fatty acid amide are melt-mixed and the melt viscosity of the fatty acid amide is extremely different from that of the phenol resin, it is preferable to use a compatibilizing agent. This can prevent separation during spinning.
• melt spinning is preferred because of the simplicity of the apparatus and economic advantages.
• melt spinning is used as a spinning method, a general melt spinning apparatus can be used.
• a grid melter type As a melting apparatus of the melt spinning apparatus, a grid melter type, a single screw extruder method, a twin screw extruder method, a tandem extruder method, or the like can be used.
• nitrogen substitution in the melt spinning apparatus may be performed, or an operation of removing a trace amount of residual solvent or monomers is performed using an extruder equipped with a vent. May be.
• the temperature condition is preferably 120 ° C. to 200 ° C., more preferably 140 ° C. to 170 ° C.
• the temperature condition is preferably 120 ° C. to 200 ° C., more preferably 140 ° C. to 170 ° C.
• the hole diameter is preferably 0.05 mm or more and 1 mm or less, more preferably 0.07 mm or more and 0.5 mm or less, and the L / D (length / diameter) of the capillary part is 0.5 or more and 10 or less are preferable, and 1 or more and 5 or less are more preferable.
• a conjugate base that combines a side-by-side type or seascore type or a third component polymer. Can also be used.
• the spinning speed is preferably 15 m / min or more and 3000 m / min or less, more preferably 30 m / min or more and 2000 m / min or less, and further preferably 50 m / min or more and 1600 m / min or less.
• the spinning speed is preferably 15 m / min or more and 3000 m / min or less, more preferably 30 m / min or more and 2000 m / min or less, and further preferably 50 m / min or more and 1600 m / min or less.
• the step of producing the phenol fiber includes a curing step of curing the yarn obtained in the spinning step.
• the phenol resin portion is mainly cross-linked, so that the mechanical strength of the thickened phenol fiber increases.
• a method of curing the yarn obtained in the spinning step is to immerse the yarn processed into a staple shape or a tow shape in the treatment liquid in the reaction vessel.
• the treatment liquid is composed of a catalyst and aldehydes.
• the catalyst examples include acidic catalysts and basic catalysts exemplified as those that can be used when producing a phenol resin.
• the aldehydes the aldehydes illustrated as what can be used when manufacturing a phenol resin are mentioned.
• Curing is preferably performed in the liquid phase by heating at a temperature of 60 ° C. to 110 ° C. for 3 hours to 30 hours. Moreover, in this invention, you may harden
• the yarn when a resol type phenol resin is used as a raw material phenol resin, the yarn can be cured by heat treatment by a wet heat method or a dry heat method.
• the temperature is preferably 100 to 220 ° C, more preferably 120 to 180 ° C, and the treatment time is preferably 5 to 120 minutes, more preferably 20 to 60 minutes.
• the single fiber fineness of the phenolic fiber used in the present invention is preferably 7 dtex or more (more preferably 8 dtex or more), and preferably 22 dtex or less (more preferably 17 dtex or less).
• the pressure loss of the element may increase.
• the single fiber fineness of the phenol fiber exceeds 22 dtex, it may be difficult to process the nonwoven fabric using the fiber.
• the phenolic fiber used in the present invention has a tensile modulus of 370 to 410 kgf / mm 2 (more preferably 380 to 400 kgf / mm 2 ) and an elongation of 10 to 20% (more preferably 15 to 19%). Preferably there is.
• phenolic fibers having a tensile elastic modulus and elongation in this range the nonwoven fabric can be easily processed even if the single fiber fineness is 7 dtex or more.
• the fiber length of the phenolic fiber is preferably 35 mm or more (more preferably 50 mm or more), and is preferably 130 mm or less (more preferably 100 mm or less, further preferably 80 mm or less). If the fiber length is less than 35 mm, the fibers cannot be sufficiently entangled, and the resulting ACF nonwoven fabric may have a low tensile strength. When the fiber length exceeds 130 mm, for example, fiber cutting or damage during needle punching becomes severe, and the tensile strength may also be lowered.
• the presence or absence of crimping of phenolic fibers is not particularly limited.
• the phenolic fiber may have a crimp.
• the phenolic fiber containing the blend is soft even if it has a large diameter, and is excellent in confounding property. Therefore, in the present invention, a phenolic fiber having no crimp can be used.
• the method for processing a phenol-based fiber into a nonwoven fabric is not particularly limited as long as it can prevent fiber breakage at the time of processing and can sufficiently entangle between fibers, and examples thereof include a needle punch method and a water punch method. It is done.
• the needle punch method is preferable because the density of the nonwoven fabric obtained can be adjusted by adjusting the needle density and the needle depth according to the change in the fiber diameter.
• the needle density is 370 / inch 2 or more (more preferably 450 / inch 2 or more), the needle depth is 5 mm or more (more preferably 7 mm or more), 30 mm or less (more Preferably it is 20 mm or less.
• the needle density is 370 / inch 2 or more, the entanglement between the fibers increases, and the bulk density of the ACF nonwoven fabric precursor increases accordingly. If the needle density is too high, fiber breakage may occur, and the resulting ACF nonwoven fabric may have a lower bulk density and tensile strength. Therefore, the upper limit of the needle density is preferably 700 / inch 2 .
• the needle depth is less than 5 mm, the ACF nonwoven fabric precursor may be bulky. When the needle depth exceeds 30 mm, needle breakage is likely to occur. Further, the ACF nonwoven fabric precursor tends to have more stripes.
• Carbonization and activation treatment of the ACF nonwoven fabric precursor is, for example, carbonized at 400 ° C. to 1000 ° C. for 10 minutes to 120 minutes in an inert atmosphere such as nitrogen or argon in a carbonization furnace, and then in an activation furnace, The activation can be carried out in an activation gas atmosphere such as water vapor at 800 ° C. or higher for 30 minutes to 180 minutes.
• an activation gas atmosphere such as water vapor at 800 ° C. or higher for 30 minutes to 180 minutes.
• the element of the present invention can be produced by winding the ACF nonwoven fabric obtained through the above steps around a cylinder.
• the winding tension of the nonwoven fabric is preferably about 1/3 or less of the tensile strength so that the ACF nonwoven fabric is not damaged.
• the element of the present invention since the element of the present invention has a large bulk density, an element having the same adsorption ability as that of a conventional element can be produced with a smaller size.
• the volume of the element of the present invention is made equal to the volume of the conventional element, an element with even more excellent adsorbability can be produced.
• the element of the present invention since the element of the present invention has a large bulk density, it is not necessary to adjust the bulk density by further compressing the element after the element is manufactured. Therefore, the ACF can be prevented from dropping or scattering due to the compression.
• the bulk density of the element of the present invention is preferably 100 kg / m 3 to 150 kg / m 3 .
• the element of this invention is comprised using the ACF nonwoven fabric comprised from a fiber with a large fiber diameter, a pressure loss is small, specifically, it can be set to 550 mmAq or less. Therefore, even if the bulk density of the ACF nonwoven fabric is increased to reduce the size of the element, it is not necessary to increase the capacity of the blower for blowing the gas to be processed to the element, so that the benefits associated with the downsizing of the element can be fully enjoyed. .
• the pressure loss of the element of the present invention is preferably 500 mmAq or less (more preferably 400 mmAq or less).
• the lower limit of the pressure loss is not particularly limited, but is preferably 100 mmAq or more (more preferably 110 mmAq or more).
• the single fiber fineness, tensile elastic modulus, elongation, fiber diameter of “activated carbon fiber constituting ACF nonwoven fabric”, toluene adsorption rate, “ACF nonwoven fabric” The tensile strength, basis weight, bulk density, pressure loss (pressure loss) coefficient, and the bulk density and pressure loss measurement method of the “element” will be described below.
• Fiber diameter of activated carbon fiber constituting ACF nonwoven fabric The fiber diameter (fiber diameter) was measured using a high-definition digital microscope VH-6300 (manufactured by KEYENCE) in accordance with JIS K1477 5.1 (fiber diameter test method).
• Toluene adsorption rate of activated carbon fiber constituting ACF nonwoven fabric The toluene adsorption rate was measured according to JIS K1477 “7.8 Toluene adsorption performance”.
• Test strength of ACF nonwoven fabric Five test pieces (25 mm in width and 100 mm in length) were cut from the width direction and the length direction of the ACF nonwoven fabric, respectively, and an Instron type tensile tester (for example, “STM-T-200BP” manufactured by Toyo Baldwin Co., Ltd.) ), Grip both ends of the test piece with a chuck, measure the breaking strength with a chuck interval of 50 mm and a tensile speed of 20 mm / min (elongation rate 40% / min), and the value is the cross-sectional area of the test piece (width ⁇ thickness). ) (Unit N / cm 2 ).
• the thickness was measured using a disk with an area of 4 cm 2 and a load applied to the ACF nonwoven fabric of 9 gf / cm 2 .
• the smaller value was taken as the tensile strength of the ACF nonwoven fabric of the present invention.
• ACF nonwoven fabric weight The mass per unit area of the ACF nonwoven fabric was measured and determined in units of g / m 2 . The mass was measured in a completely dry state at 100 ° C.
• the bulk density was determined in units of kg / m 3 by dividing the basis weight by the thickness. The thickness was measured using a disk with an area of 4 cm 2 and a load applied to the ACF nonwoven fabric of 9 gf / cm 2 .
• the ACF nonwoven fabric is cut out into a perfect circle with a diameter of 72 mm and set in a ventilation pressure loss measuring jig. Between the true circle with a diameter of 50.5 mm and the perfect circle with a diameter of 72 mm is 0.1 MPa.
• the pressure loss was measured by pressing with compressed air and flowing air with a wind speed of 30 cm / sec, and the value was determined by dividing the value by the wind speed and thickness (unit: mmAq ⁇ s / cm 2 ). The measurement was performed at a temperature of 25 ° C. and a humidity of 50%. The thickness was measured in the same manner as that used when measuring the bulk density.
• the obtained yarn was cut into a length of 70 mm, placed in a container, immersed in an aqueous solution of 14% by mass hydrochloric acid and 8% by mass formaldehyde for 30 minutes at room temperature, heated to 98 ° C. in 2 hours, and further 98 Curing was performed by holding at 2 ° C. for 2 hours.
• phenol fiber 1 having a single fiber fineness of 11 dtex, a fiber length of 70 mm, and no fiber crimp.
• the phenolic fiber 1 obtained had a tensile modulus of 395 kgf / mm 2 and an elongation of 12%.
• the obtained phenol fiber 5 had a tensile modulus of 427 kgf / mm 2 and an elongation of 10%.
• Production Example 6 Production of phenolic fiber 6
• the mixing amount of the novolak-type phenol resin was 450 kg, and the same procedure as in Production Example 1 except that 50 kg of cellulose diacetate was used instead of 25 kg of behenamide, the single fiber fineness 11 dtex, the fiber length 70 mm, the fiber A phenolic fiber 6 without crimp was obtained.
• the obtained phenol fiber 6 had a tensile modulus of 380 kgf / mm 2 and an elongation of 11%.
• Production Example 7 Production of phenol fiber 7
• a single fiber fineness of 11 dtex, a fiber length of 70 mm, and no fiber crimping were performed in the same manner as in Production Example 1 except that 450 kg of novolak type phenol resin and 25 kg of behenamide were used instead of 500 kg of novolak type phenol resin.
• a phenol fiber 7 was obtained.
• the obtained phenol fiber 7 had a tensile modulus of 469 kgf / mm 2 and an elongation of 4%.
• Example 1 Using the phenolic fiber 1 produced in Production Example 1, the back and front treatment was performed with a needle punch machine under the conditions of a needle density of 500 / inch 2 , a needle depth of 12 mm (back) and 7 mm (front), and a dry basis weight of 540 g / An ACF nonwoven fabric precursor with m 2 and a bulk density of 82.4 kg / m 3 was obtained.
• the obtained ACF nonwoven fabric precursor was carbonized by heating from normal temperature to 890 ° C. over 30 minutes in an inert atmosphere (nitrogen atmosphere), and then at a temperature of 890 ° C. in an atmosphere containing 12% by mass of water vapor. Activation for a minute gave an ACF nonwoven fabric.
• the obtained ACF nonwoven fabric was wound around a cylindrical structure having an inner diameter of 200 mm and a length of 1100 mm with a tension of 1.47 N / cm 2 until the element mass reached 100 kg, and had a diameter of 1.09 m and a bulk density of 100 kg / m 3 .
• Table 1 shows the characteristics of the activated carbon fiber, the ACF nonwoven fabric and the elements constituting the obtained ACF nonwoven fabric.
• Example 2 Using the phenolic fiber 1 produced in Production Example 1, the back and front treatment was performed with a needle punch machine under the conditions of a needle density of 500 / inch 2 , a needle depth of 12 mm (back), and 7 mm (front), and a dry basis weight of 520 g / An ACF nonwoven fabric precursor with m 2 and bulk density of 82.0 kg / m 3 was obtained.
• the obtained ACF nonwoven fabric precursor was heated from normal temperature to 890 ° C. over 36 minutes in an inert atmosphere to be carbonized, and then activated for 120 minutes at a temperature of 890 ° C. in an atmosphere containing 12% by mass of water vapor.
• ACF nonwoven fabric was obtained.
• Table 1 shows the characteristics of the activated carbon fiber and the ACF nonwoven fabric constituting the obtained ACF nonwoven fabric.
• the element of the present invention was obtained in the same manner as in Example 1 except that the obtained ACF nonwoven fabric was used.
• the characteristics of the obtained element are shown in Table 1.
• Example 3 Using the phenolic fiber 1 produced in Production Example 1, the back and front treatment was performed with a needle punch machine under the conditions of a needle density of 500 / inch 2 , a needle depth of 12 mm (back), and 7 mm (front), and a dry basis weight of 1254 g / An ACF nonwoven fabric precursor with m 2 and a bulk density of 99.6 kg / m 3 was obtained.
• the ACF nonwoven fabric and element of the present invention were obtained in the same manner as in Example 1 except that the obtained ACF nonwoven fabric precursor was used.
• Table 1 shows the characteristics of the activated carbon fiber, the ACF nonwoven fabric, and the elements constituting the obtained ACF nonwoven fabric.
• Example 4 The ACF nonwoven fabric produced in Example 1 was wound around a cylindrical structure having an inner diameter of 200 mm and a length of 1100 mm with a tension of 2.2 N / cm 2 until the element mass reached 100 kg.
• the characteristics of the obtained element are shown in Table 1.
• Example 5 Using the phenolic fiber 1 produced in Production Example 1, the back and front treatment was performed with a needle punch machine under the conditions of a needle density of 650 needles / inch 2 , a needle depth of 15 mm (back) and 10 mm (front), and a dry basis weight of 540 g / An ACF nonwoven fabric precursor with m 2 and bulk density of 129 kg / m 3 was obtained.
• the ACF nonwoven fabric and element of the present invention were obtained in the same manner as in Example 1 except that the obtained ACF nonwoven fabric precursor was used.
• Table 1 shows the characteristics of the activated carbon fiber, the ACF nonwoven fabric, and the elements constituting the obtained ACF nonwoven fabric.
• Example 6 The ACF nonwoven fabric obtained in Example 5 was wound around a cylindrical structure having an inner diameter of 200 mm and a length of 1100 mm with a tension of 2.2 N / cm 2 until the element mass reached 150 kg.
• the characteristics of the obtained element are shown in Table 1.
• Example 7 In Example 1, in place of the phenolic fiber 1 produced in Production Example 1, the phenolic fiber 2 produced in Production Example 2 was used and heated from room temperature to 870 ° C. over 12 minutes in an inert atmosphere. ACF non-woven fabric precursor, ACF non-woven fabric, and element were obtained in the same manner as in Example 1 except that carbonization was performed and then activated for 40 minutes at 870 ° C. in an atmosphere containing 12% by mass of water vapor. Table 1 shows the characteristics of the activated carbon fiber, the ACF nonwoven fabric, and the elements constituting the obtained ACF nonwoven fabric.
• Example 8 In Example 2, instead of the phenolic fiber 1 produced in Production Example 1, the phenolic fiber 3 produced in Production Example 3 was used, and the needle density was 600 needles / inch 2 and the needle depth was measured with a needle punch machine. Except that the ACF nonwoven fabric precursor having a dry basis weight of 778 g / m 2 and a bulk density of 98.3 kg / m 3 was obtained by performing the back and front treatment under the conditions of 13 mm (back) and 9 mm (front), except that the ACF nonwoven fabric precursor was used. In the same manner as in Example 2, an ACF nonwoven fabric and elements were obtained. Table 1 shows the characteristics of the activated carbon fiber, the ACF nonwoven fabric, and the elements constituting the obtained ACF nonwoven fabric.
• Example 9 In Example 1, in place of the phenolic fiber 1 produced in Production Example 1, the phenolic fiber 4 produced in Production Example 4 was used, and the needle density was 450 needles / inch 2 and the needle depth by a needle punching machine. Except that the ACF nonwoven fabric precursor having a dry basis weight of 535 g / m 2 and a bulk density of 80.3 kg / m 3 was obtained by performing the back and front treatment under the conditions of 12 mm (back) and 7 mm (front), and the ACF nonwoven fabric precursor was used. In the same manner as in Example 1, an ACF nonwoven fabric and an element were obtained. Table 1 shows the characteristics of the activated carbon fiber, the ACF nonwoven fabric, and the elements constituting the obtained ACF nonwoven fabric.
• Example 10 the obtained ACF nonwoven fabric precursor was carbonized by heating from normal temperature to 870 ° C. over 18 minutes in an inert atmosphere, and then at a temperature of 870 ° C. in an atmosphere containing 12% by mass of water vapor.
• An ACF nonwoven fabric and an element were obtained in the same manner as in Example 8 except that activation was performed for 60 minutes.
• Table 1 shows the characteristics of the activated carbon fiber, the ACF nonwoven fabric, and the elements constituting the obtained ACF nonwoven fabric.
• Example 11 In Example 1, the phenolic fiber 1 produced in Production Example 1 was used, and the back and front treatment was performed with a needle punch machine under the conditions of a needle density of 600 / cm 2 , a needle depth of 13 mm (back), and 9 mm (front). An ACF nonwoven fabric and an element were obtained in the same manner as in Example 1 except that an ACF nonwoven fabric precursor having a dry basis weight of 420 g / m 2 and a bulk density of 81.7 kg / m 3 was obtained. Table 1 shows the characteristics of the activated carbon fiber, the ACF nonwoven fabric, and the elements constituting the obtained ACF nonwoven fabric.
• Example 12 An ACF nonwoven fabric precursor, an ACF nonwoven fabric, and an element were obtained in the same manner as in Example 1 except that the phenolic fiber 5 obtained in Production Example 5 was used instead of the phenolic fiber 1 used in Example 1. .
• Table 1 shows the characteristics of the activated carbon fiber, the ACF nonwoven fabric, and the elements constituting the obtained ACF nonwoven fabric.
• Example 13 An ACF nonwoven fabric precursor, an ACF nonwoven fabric, and an element were obtained in the same manner as in Example 1 except that the phenolic fiber 6 obtained in Production Example 6 was used instead of the phenolic fiber 1 used in Example 1. .
• Table 1 shows the characteristics of the activated carbon fiber, the ACF nonwoven fabric, and the elements constituting the obtained ACF nonwoven fabric.
• a monofilament fineness of 5.6 dtex, fiber length of 70 mm, phenolic fiber without fiber crimp (Kinei Chemical Industry Co., Ltd., Kynol KF-0570) is used, and the needle density is 500 / inch 2 by a needle punch machine.
• the back and front treatment was performed under the conditions of needle depth 12 mm (back) and 7 mm (front) to obtain an ACF nonwoven fabric precursor having a dry basis weight of 385 g / m 2 and a bulk density of 83.7 kg / m 3 .
• ACF nonwoven fabric precursor was heated from normal temperature to 890 ° C. for 18 minutes in an inert atmosphere to be carbonized, and then activated for 60 minutes at a temperature of 890 ° C. in an atmosphere containing 12% by mass of water vapor.
• ACF nonwoven fabric was obtained.
• the obtained ACF nonwoven fabric was wound around a cylindrical structure having an inner diameter of 200 mm and a length of 1100 mm with a tension of 1.1 N / cm 2 until the element mass reached 100 kg, and had a diameter of 1.26 m and a bulk density of 75 kg / m 3 . Got the element.
• Table 1 shows the characteristics of the activated carbon fiber, the ACF nonwoven fabric, and the elements constituting the obtained ACF nonwoven fabric.
• Comparative Example 2 The ACF nonwoven fabric obtained in Comparative Example 1 was wound around a cylindrical structure having an inner diameter of 200 mm and a length of 1100 mm with a tension of 1.47 N / cm 2 until the element mass reached 100 kg, and had a diameter of 1.09 m and a bulk density of 100 kg. An element of / m 3 was obtained. Table 1 shows the characteristics of the activated carbon fiber, the ACF nonwoven fabric, and the elements constituting the obtained ACF nonwoven fabric.
• the obtained ACF nonwoven fabric precursor was heated from normal temperature to 890 ° C. for 30 minutes in an inert atmosphere to be carbonized, and then activated for 100 minutes at a temperature of 890 ° C. in an atmosphere containing 12% by mass of water vapor.
• ACF nonwoven fabric was obtained.
• Table 1 shows the characteristics of the activated carbon fiber and the ACF nonwoven fabric constituting the obtained ACF nonwoven fabric.
• the obtained ACF nonwoven fabric was tried to be wound around a cylindrical structure having an inner diameter of 200 mm and a length of 1100 mm with a tension of 1.1 N / cm 2 , but the tensile strength of the ACF nonwoven fabric was low, and it was broken and wound. I wouldn't.
• Comparative Example 4 In Comparative Example 1, the back and front treatment was performed with a needle punch machine under the conditions of a needle density of 600 / inch 2 , a needle depth of 13 mm (back), and 9 mm (front), a dry basis weight of 575 g / m 2 , a bulk density of 105.1 kg / An ACF nonwoven fabric was obtained in the same manner as in Comparative Example 1 except that an m 3 ACF nonwoven fabric precursor was obtained.
• the obtained ACF nonwoven fabric was wound around a cylindrical structure having an inner diameter of 200 mm and a length of 1100 mm with a tension of 1.47 N / cm 2 until the element mass reached 100 kg, and had a diameter of 1.09 m and a bulk density of 100 kg / m 3 .
• Table 1 shows the characteristics of the activated carbon fiber, the ACF nonwoven fabric, and the elements constituting the obtained ACF nonwoven fabric.

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