WO2021033752A1 - 自動車キャニスタ用活性炭素繊維シート - Google Patents
自動車キャニスタ用活性炭素繊維シート Download PDFInfo
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- WO2021033752A1 WO2021033752A1 PCT/JP2020/031503 JP2020031503W WO2021033752A1 WO 2021033752 A1 WO2021033752 A1 WO 2021033752A1 JP 2020031503 W JP2020031503 W JP 2020031503W WO 2021033752 A1 WO2021033752 A1 WO 2021033752A1
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- activated carbon
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- carbon fiber
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- B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
- B01J20/30—Processes for preparing, regenerating, or reactivating
- B01J20/3078—Thermal treatment, e.g. calcining or pyrolizing
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- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
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- C—CHEMISTRY; METALLURGY
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- C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
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- C01B32/312—Preparation
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- 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
- D01F9/16—Carbon filaments; Apparatus specially adapted for the manufacture thereof by decomposition of organic filaments from products of vegetable origin or derivatives thereof, e.g. from cellulose acetate
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
- F02M25/00—Engine-pertinent apparatus for adding non-fuel substances or small quantities of secondary fuel to combustion-air, main fuel or fuel-air mixture
- F02M25/08—Engine-pertinent apparatus for adding non-fuel substances or small quantities of secondary fuel to combustion-air, main fuel or fuel-air mixture adding fuel vapours drawn from engine fuel reservoir
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B01D2257/70—Organic compounds not provided for in groups B01D2257/00 - B01D2257/602
- B01D2257/702—Hydrocarbons
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B01D2259/4516—Gas separation or purification devices adapted for specific applications for fuel vapour recovery systems
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B01D2259/4566—Gas separation or purification devices adapted for specific applications for use in transportation means
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B01D—SEPARATION
- B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
- B01D53/02—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by adsorption, e.g. preparative gas chromatography
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B01J2220/00—Aspects relating to sorbent materials
- B01J2220/50—Aspects relating to the use of sorbent or filter aid materials
- B01J2220/66—Other type of housings or containers not covered by B01J2220/58 - B01J2220/64
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- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06C—FINISHING, DRESSING, TENTERING OR STRETCHING TEXTILE FABRICS
- D06C7/00—Heating or cooling textile fabrics
- D06C7/04—Carbonising or oxidising
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- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
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- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
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- D10B2505/12—Vehicles
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
- F02M2200/00—Details of fuel-injection apparatus, not otherwise provided for
- F02M2200/90—Selection of particular materials
- F02M2200/9046—Multi-layered materials
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
- F02M25/00—Engine-pertinent apparatus for adding non-fuel substances or small quantities of secondary fuel to combustion-air, main fuel or fuel-air mixture
- F02M25/08—Engine-pertinent apparatus for adding non-fuel substances or small quantities of secondary fuel to combustion-air, main fuel or fuel-air mixture adding fuel vapours drawn from engine fuel reservoir
- F02M25/0854—Details of the absorption canister
Definitions
- the present invention relates to an activated carbon fiber sheet, and more particularly to an activated carbon fiber sheet suitable for use in an automobile canister and a method for producing the same.
- a canister equipped with an adsorbent such as activated carbon is provided. .. (Hereinafter, in the present specification, a canister mounted on an automobile may be abbreviated as “automobile canister” or simply “canister”.)
- the activated carbon fiber (or fibrous activated carbon) is sometimes called the third activated carbon, as opposed to the powdered, granular, or pellet-shaped activated carbon that has been around for a long time.
- activated carbons in a broad sense, activated carbon fibers are said to have a relatively high specific surface area, a large adsorption capacity, and a tendency to have a high adsorption / desorption rate.
- activated carbon fibers have not yet been put into practical use in canisters, and research and development have not yet been sufficiently advanced as to what characteristics of activated carbon fibers are suitable for practical use in canisters.
- the present inventors have conducted diligent research with the aim of putting activated carbon fiber into practical use as an adsorbent for automobile canisters, and found that it is necessary to fix the adsorbent so that it will not be worn by vibration during driving of the automobile. From the viewpoint of ease of handling and the like, it has been found that a sheet made of activated carbon fiber is practically suitable. However, when the activated carbon fiber sheet obtained by carbonizing and activating as in the conventional case is filled in the room for accommodating the adsorbent without providing a gap, the pressure loss of the canister becomes large. ..
- one of the problems to be solved by the present invention is an adsorbent using activated carbon fiber, which is suitable for an automobile canister and has an suppressed pressure loss. To provide.
- the present inventors have improved air permeability and can suppress pressure loss by producing an activated carbon fiber material using fibers having a larger fiber diameter than the conventional one, and can be used as an automobile canister.
- a suitable adsorbent can be obtained, and have completed the present invention based on such findings.
- the present invention includes, for example, the following as means for solving the problems, which can be grasped from various aspects.
- An activated carbon fiber sheet for automobile canisters The specific surface area of the sheet is 1100 to 2300 m 2 / g. The density of the sheet is 0.010 to 0.200 g / cm 3 or less. The thickness of the sheet is 0.10 to 100.00 mm. The fiber diameter of the sheet is 13.0 ⁇ m or more. The sheet.
- An adsorption laminate for storage in an adsorption material chamber of an automobile canister which is a laminate in which a plurality of activated carbon fiber sheets for an automobile canister according to any one of the above [1] to [5] are laminated.
- a laminate in which a plurality of the activated carbon fiber sheets are laminated is filled in the adsorbent chamber of the automobile canister, and the flow direction of the fluid passing through the laminate is the sheet.
- the automobile canister according to the above [7] which is arranged so as to be substantially parallel to the main surface.
- a method for manufacturing an activated carbon fiber sheet for an automobile canister Including carbonization and activation of a precursor fiber sheet retaining either one or both of a phosphoric acid-based catalyst and an organic sulfonic acid-based catalyst.
- the precursor fiber sheet contains cellulosic fibers, and the fiber diameter of the fibers is 4.0 dtex or more. The manufacturing method.
- an activated carbon fiber material suitable for an automobile canister which can suppress a pressure loss.
- an activated carbon fiber sheet that is easy to handle and has high adsorption / desorption performance at a low concentration can be obtained.
- an automobile canister having excellent adsorption / desorption performance at a low concentration can be provided.
- FIG. 1 is a diagram schematically showing an embodiment of an adsorption laminate in which a plurality of activated carbon fiber sheets are laminated, and an example of a flow direction of a fluid passing through the adsorption laminate.
- AA to BB indicates “AA or more and BB or less” (here, “AA” and “BB” indicate arbitrary numerical values).
- the unit of the lower limit and the upper limit is the same as the unit attached immediately after the latter (that is, “BB” here) unless otherwise specified.
- the activated carbon fiber sheet for automobile canisters of the present invention is a sheet-like molded product formed of activated carbon fibers, and serves as an adsorbent to be stored in a canister mounted on an automobile. It is preferably used.
- the activated carbon fiber sheet for an automobile canister of the present invention may be abbreviated as the activated carbon fiber sheet of the present invention.
- the activated carbon fiber sheet has a predetermined air permeability.
- Breathability can be defined using, for example, Frazier breathability.
- the Frazier air permeability can usually be measured at any thickness allowed by the measuring device, but in one embodiment of the present invention, for example, the thickness of the sheet used for measuring the Frazier air permeability is 1 to 4 mm. Can be shown as a numerical value in the case of.
- "when the thickness of the sheet is 1 to 4 mm” means that the thickness of the sheet used for measuring the Frazier air permeability is prepared so as to be within the range of 1 to 4 mm, and the measurement is performed using a test sample. It means when you go.
- the lower limit of the Frazier air permeability is preferably 100 cm 3 / cm 2 / s or more, more preferably 120 cm 3 / cm 2 / s or more, still more preferably 130, 140, in any of the above embodiments. It can be 150 cm 3 / cm 2 / s or more.
- the upper limit of the Frazier air permeability is preferably 300 cm 3 / cm 2 / s or less, more preferably 290 cm 3 / cm 2 / s or less, still more preferably 280 cm 3 / cm 2 / s. It can be less than or equal to s.
- the preferable Frazier air permeability in "when the thickness of the sheet is 1 to 4 mm" is not preferable unless the above lower limit or upper limit is satisfied in the entire range of the thickness of 1 to 4 mm. It means that it is preferable to satisfy the above lower limit or upper limit at at least one point within the range of 1 to 4 mm in thickness.
- the Frazier air permeability When the Frazier air permeability satisfies the above lower limit, pressure loss can be suppressed and it can be suitable as an adsorbent for automobile canisters. On the other hand, if the Frazier air permeability satisfies the above upper limit, the adsorbent can have a sufficiently large amount of adsorption / desorption.
- the activated carbon fiber sheet of the present invention can be made into a more preferable embodiment by further satisfying at least one of the following predetermined items or any two or more conditions.
- the lower limit of the specific surface area of the activated carbon fiber sheet of the present invention is preferably 1100 m 2 / g or more, more preferably 1200 m 2 / g or more, still more preferably 1300, 1400, 1500, 1600, 1700, or 1800 m 2 / g or more. Can be. Generally, a large specific surface area of the activated carbon fiber sheet of the present invention is preferable from the viewpoint of adsorption performance, but in the case of the activated carbon fiber sheet, the upper limit of the specific surface area is approximately 2400, 2300, 2200, or 2100 m 2 / g.
- the sheet can be made more excellent in the adsorption / desorption performance with respect to the evaporated fuel gas. Further, in one embodiment of the present invention, it is possible to achieve a reduction in pressure loss in the canister while maintaining a large specific surface area as the adsorption material used in the canister as described above.
- the lower limit of the total pore volume of the activated carbon fiber sheet of the present invention is preferably 0.50 cm 3 / g or more, more preferably 0.60 cm 3 / g or more, still more preferably 0.70, 0.80, or 0. It can be 90 cm 3 / g or more.
- the upper limit of the total pore volume of the activated carbon fiber sheet of the present invention may be preferably 1.20 cm 3 / g or less, more preferably 1.10 cm 3 / g or less, and further preferably 1.00 cm 3 / g or less. ..
- pore diameter means the diameter or width of a pore, not the radius of the pore, unless otherwise specified.
- the lower limit of the average pore diameter of the activated carbon fiber sheet of the present invention is preferably 1.69 nm or more, more preferably 1.70 nm or more, still more preferably 1.72, 1.75, 1.78, or 1.80 nm or more. Can be.
- the upper limit of the average pore diameter of the activated carbon fiber sheet of the present invention may be arbitrary, but is preferably 4.00 nm or less, more preferably 3.50 nm or less, and further preferably 3.00 nm or less.
- the term "ultra micropore” means a pore having a pore diameter of 0.7 nm or less.
- the lower limit of ultra micro pore volume of activated carbon fiber sheet of the present invention is preferably 0.05 cm 3 / g or more, more preferably 0.10 cm 3 / g or more, more preferably 0.12 or 0.14 cm 3 / Can be greater than or equal to g.
- the upper limit of the ultramicro pore volume of the activated carbon fiber sheet of the present invention is preferably 0.30 cm 3 / g or less, more preferably 0.29 cm 3 / g or less, still more preferably 0.26, 0.24, 0. It can be 22 or 0.20 cm 3 / g or less.
- micropore means a pore having a pore diameter of 2.0 nm or less.
- the lower limit of the micropore volume of the activated carbon fiber sheet of the present invention is preferably 0.50 cm 3 / g or more, more preferably 0.60 cm 3 / g or more, still more preferably 0.65 or 0.70 cm 3 / g. That could be the end.
- the upper limit of the micropore volume of the activated carbon fiber sheet of the present invention can be preferably 1.00 cm 3 / g or less, more preferably 0.90 cm 3 / g or less, and further preferably 0.80 cm 3 / g or less.
- V 0.7-2.0 ⁇ Pore volume of pores with pore diameter larger than 0.7 nm and 2.0 nm or less.
- the pore volume V 0.7-2.0 of a pore having a pore diameter larger than 0.7 nm and 2.0 nm or less can be calculated by the following formula 1 using the value a of the ultramicro pore volume and the value b of the micropore volume. it can.
- V 0.7-2.0 ba ⁇ ⁇ ⁇ Equation 1
- the lower limit of the pore volume V 0.7-2.0 of pores having a pore diameter larger than 0.7 nm and 2.0 nm or less is preferably 0.20 cm 3 / g or more, more preferably 0. It can be .30 cm 3 / g or more, more preferably 0.36, 0.40, 0.45, or 0.50 cm 3 / g or more.
- the upper limit of the pore volume V 0.7-2.0 of the pores having a pore diameter larger than 0.7 nm and 2.0 nm or less is preferably 1.20 cm 3 / g or less.
- It can be preferably 1.00 cm 3 / g or less, more preferably 0.90, 0.80, 0.75, 0.70, 0.65, or 0.60 cm 3 / g or less.
- R 0.7 / 2.0 ⁇ Abundance ratio of ultramicro pore volume to micropore volume.
- the abundance ratio R 0.7 / 2.0 of the pore volume of the ultramicro pores having a pore diameter of 0.7 nm or less in the pore volume of the micropores having a pore diameter of 2.0 nm or less is the value a of the ultramicro pore volume.
- the value b of the micropore volume it can be obtained by the following equation 2.
- R 0.7 / 2.0 a / b x 100 (%) ⁇ ⁇ ⁇ Equation 2
- the lower limit of the abundance ratio R 0.7 / 2.0 of the ultramicro pore volume to the micropore volume is preferably 15.0% or more, more preferably 18% or more, still more preferably 19% or more. Can be.
- the upper limit of the abundance ratio R 0.7 / 2.0 of the ultramicro pore volume to the micropore volume is preferably 60% or less, more preferably 50% or less, still more preferably 40, 30, or more. It can be 25% or less.
- the lower limit of the activated carbon fiber sheet having a basis weight of the present invention is preferably 50.0 g / m 2 or more, more preferably 60.0 g / m 2 or more, more preferably 70.0 or 80.0 g / m 2 or more It is possible.
- the upper limit of the basis weight of the activated carbon fiber sheet of the present invention is preferably 2000.0 g / m 2 or less, more preferably 1900.0 g / m 2 or less, still more preferably 1800.0, 1700.0, 1600.0, Or it can be 1500.0 g / m 2 or less.
- the lower limit of the thickness of the activated carbon fiber sheet of the present invention is preferably 0.10 mm or more, more preferably 0.50 mm or more, still more preferably 1.00, 1.50, 2.00, or 2.50 mm or more. sell.
- the upper limit of the thickness of the activated carbon fiber sheet of the present invention is preferably 100.00 mm or less, more preferably 70.00 mm or less, still more preferably 50.00, 40.00, 30.00, 20.00, or 10. It can be 00 mm or less.
- the lower limit of the density of the activated carbon fiber sheet of the present invention is preferably 0.010 g / cm 3 or more, more preferably 0.015 g / cm 3 or more, more preferably it is a 0.020 g / cm 3 or more.
- the upper limit of the density of the activated carbon fiber sheet of the present invention is preferably 0.200 g / cm 3 or less, more preferably 0.100 g / cm 3 or less, more preferably 0.080, or 0.050 g / cm 3 or less It is possible.
- the sheet density By setting the sheet density in the above range, it is possible to obtain a sheet having better adsorption / desorption performance per volume required for the canister within the range of the capacity of the adsorbent that can be stored in the canister. Further, by setting it to the above lower limit or more, it is possible to avoid deterioration of the mechanical properties (for example, strength) of the sheet. Further, the sheet density can be adjusted in combination with other requirements such as the thickness of the sheet to suppress the pressure loss of the activated carbon fiber sheet.
- the thickness and density of the activated carbon fiber sheet can be adjusted by adjusting the type of precursor fiber, the thickness and density of the raw material sheet, and the like, or by pressing the activated carbon fiber sheet.
- the lower limit of the fiber diameter constituting the activated carbon fiber sheet of the present invention is preferably 13.0 ⁇ m or more, more preferably 14.0 or more, still more preferably 15.0, 16.0, 17.0, 18.0, and so on. It can be 19.0, or 20.0 or higher.
- the upper limit of the fiber diameter constituting the activated carbon fiber sheet of the present invention may be arbitrary, but for example, 60.0 ⁇ m or less, preferably 50.0 ⁇ m or less, more preferably 45.0, 40.0, or 35. It can be 0 ⁇ m. When the fiber diameter of the fibers constituting the activated carbon fiber sheet is in the above range, the activated carbon fiber sheet can further suppress the pressure loss.
- the lower limit of the tensile strength (MD) of the activated carbon fiber sheet of the present invention can be preferably 0.005 kN / m or more, more preferably 0.007 kN / m or more, and more preferably 0.009 kN / m or more.
- the upper limit of the tensile strength (MD) of the activated carbon fiber sheet of the present invention is not particularly limited and may be arbitrary, but is preferably 2.50 kN / m or less, more preferably 2.00 kN / m or less, still more preferably 1. It can be 0.25, 1.00, 0.75, or 0.50 kN / m or less.
- the lower limit of the tensile strength (CD) of the activated carbon fiber sheet of the present invention can be preferably 0.005 kN / m or more, more preferably 0.008 kN / m or more, still more preferably 0.009 kN / m or more.
- the upper limit of the tensile strength (CD) of the activated carbon fiber sheet of the present invention is not particularly limited and may be arbitrary, but is preferably 2.50 kN / m or less, more preferably 2.00 kN / m or less, still more preferably 1. It can be 0.25, 1.00, 0.75, or 0.50 kN / m or less.
- the activated carbon fiber sheet of the present invention preferably has a predetermined water content.
- the lower limit of the water content under the conditions of 23 ° C. and 50% relative humidity can be preferably 1.0% or more, more preferably 2.0% or more, still more preferably 3.0% or more.
- the upper limit of the water content under the conditions of 23 ° C. and 50% relative humidity is preferably 25.0% or less, more preferably 20.0% or less, still more preferably 10.0 or 8.0% or less. sell.
- the activated carbon fiber sheet of the present invention preferably has a predetermined methylene blue adsorption performance as an adsorbent.
- the methylene blue absorption performance can be shown as the amount of methylene blue adsorbed per weight of the activated carbon fiber sheet.
- the methylene blue adsorption performance of the activated carbon fiber sheet of the present invention is preferably 100 ml / g or more, more preferably 150 ml / g or more, still more preferably 200, 250, 280, or 300 ml / g or more.
- the activated carbon fiber sheet of the present invention preferably has a predetermined n-butane adsorption / desorption performance as an adsorbent. Since the n-butane adsorption / desorption performance is an index of the transpiration gas adsorption / desorption performance, those having excellent n-butane adsorption / desorption performance are suitable for automobile canister applications.
- the n-butane adsorption / desorption performance is based on the amount of adsorption when the n-butane is sufficiently absorbed and broken, then desorbed from the adsorbent when placed under predetermined desorption conditions, and then the adsorption is repeated. It can be shown as the effective adsorption amount of n-butane per weight of the carbon fiber sheet.
- the effective adsorption / desorption amount (first adsorption amount) of n-butane obtained according to the measurement method shown in the following examples is preferably 8.00 wt% or more. It can be preferably 10.00 wt% or more.
- the effective adsorption / desorption amount of n-butane (the average of the second adsorption amount and the desorption amount) obtained according to the measurement method shown in the following Examples is preferably 6. It can be 00 wt% or more, more preferably 6.25 wt% or more, still more preferably 6.50, 6.75, or 7.00 wt% or more.
- the effective adsorption / desorption rate of n-butane obtained according to the measurement method shown in the following examples is preferably 25.0% or more, more preferably 30.0. % Or more, more preferably 35.0, 40.0, or 45.0%.
- the activated carbon fiber sheet of the present invention can suppress pressure loss, and as one embodiment, it may have a predetermined air permeability (for example, Frazier air permeability).
- Preferred embodiments of the present invention include embodiments that further satisfy one or any two or more of the above items related to physical properties or performance. Examples of preferred embodiments are shown below.
- the activated carbon fiber sheet of the present invention is not limited to the following combinations.
- An activated carbon fiber sheet for an automobile canister that meets the following requirements (1) to (4).
- the specific surface area of the activated carbon fiber sheet is 1100 to 2300 m 2 / g.
- the density of the activated carbon fiber sheet is 0.010 to 0.200 g / cm 3 .
- the thickness of the activated carbon fiber sheet is 0.10 to 100.00 mm.
- the fiber diameter of the sheet is 13.0 ⁇ m or more.
- an adsorption laminate for storage may be provided in the adsorption material chamber of an automobile canister.
- the adsorption laminate is a laminate in which a plurality of the above-mentioned activated carbon fiber sheets are laminated.
- the adsorption laminate of the present invention preferably has a suppressed pressure loss.
- the upper limit of the pressure loss can be preferably 1.50 kPa or less, more preferably 1.20 kPa or less, still more preferably 1.10, 1.00, 0.90, 0.80, or 0.70 kPa or less.
- the lower limit of the pressure loss is preferably 0.05 kPa or more, more preferably 0.10 kPa or more, still more preferably 0. It can be 15 kPa or more.
- FIG. 1 shows an embodiment of the adsorption laminate of the present invention.
- the dimensions such as the length and thickness of the sheet are schematically expressed, and the present invention is not limited to this.
- the number of sheets is set to 4 as an example, but the number is not limited to this.
- the adsorption laminate 1 shown in FIG. 1 is a laminate formed by stacking four activated carbon fiber sheets 10.
- the activated carbon fiber sheet 10 is formed by superimposing the main surfaces 10a of the sheets on each other.
- the sheet has a strong tensile strength and is arranged along the gas flow.
- the side end surfaces 10b of the plurality of activated carbon fiber sheets face each other with respect to the flow direction of the fluid F. Have been placed. By arranging in this way, the pressure loss can be reduced.
- the short side end surface 10b faces the flow direction of the fluid F, but the present invention is not limited to this, and the long side end surface 10c may face the flow direction of the fluid F.
- the adsorption laminate may have a rectangular parallelepiped shape or a cubic shape as a whole.
- the shape of the adsorbent chamber for accommodating the activated carbon fiber sheet may be matched, or the activated carbon fiber sheet may be rolled into a cylindrical shape.
- the activated carbon fiber sheet of the present invention can be easily processed or molded into various shapes, and is a material having excellent handleability.
- the activated carbon fiber sheet of the present invention is suitable as an adsorbent to be housed in an automobile canister. That is, the present invention can also provide an automobile canister as another embodiment.
- the automobile canister of the present invention is equipped with an activated carbon fiber sheet as an adsorbent.
- the structure of the automobile canister is not particularly limited, and a general structure can be adopted.
- examples of automobile canisters include those having the following structures.
- An adsorbent chamber for storing the adsorbent in the housing and A first opening for movably communicating gas between the adsorbent chamber and the engine, A second opening for movably communicating gas between the adsorbent chamber and the fuel tank, A third opening that opens when a predetermined pressure is applied from the adsorbent chamber or the outside air and allows gas to move between the adsorbent chamber and the outside air.
- the activated carbon fiber sheet of the present invention can be used as an absorbent in the canister of the present invention. As described above, since the activated carbon fiber sheet of the present invention can reduce the pressure loss, even if it is filled without gaps, the pressure loss can be suppressed as compared with the case of the conventional activated carbon fiber sheet.
- Each of the first, second, and third openings is a delivery port through which gas enters and exits.
- the arrangement of each opening which is the gas delivery port is not particularly limited, but the gas moves between the first and / or the second opening in the third opening which is the outside air delivery port. At that time, it is preferable that the gas is arranged at a position where the gas sufficiently passes through the adsorbent.
- the first and second openings are provided on the first side surface portion of the housing, and the third opening portion is provided on the second side surface portion located opposite to the first side surface portion. Can be taken.
- the adsorbent chamber may be divided into a plurality of chambers.
- the adsorbent chamber may be divided into two or more sections by a partition wall.
- a partition wall As the partition wall, a breathable perforated plate or the like can be used.
- an external second housing is provided separately from the first housing, and the first housing and the second housing are communicated with each other via a gas passage, and an adsorbent chamber is additionally equipped. You may.
- a third partition or housing unit is provided from the first or second opening through which gas flows from the engine or the fuel tank.
- the adsorbent or the adsorbent chamber may be arranged so that the adsorbent capacity gradually decreases toward the opening side.
- a composite canister including a main body canister (first housing) and a second canister (second housing) added to the outside air intake side can be exemplified.
- the compartment or housing in which the transpiration gas first flows from the engine or fuel tank is designated as the main body (first compartment or first housing) having the largest storage volume.
- the conventional inexpensive activated carbon is stored in the main body, the activated carbon fiber sheet having a relatively small storage volume and having excellent adsorption / desorption performance at a low concentration is stored in the second compartment or the second housing or later. As a result, it is possible to make a high-performance canister while keeping costs down.
- the adsorbent chamber located later than the engine or fuel tank that is, the adsorbent chamber located closer to the outside air inlet / outlet
- the concentration of transpiration fuel gas becomes thinner. Therefore, the activated carbon fiber sheet of the present invention having a high n-butane adsorption capacity at a low concentration of about 0.2% is located in the second section or the second housing or the second housing located later than the engine or the fuel tank. Further, it is suitable as an adsorbent to be stored in the adsorbent chamber in the subsequent stage.
- the activated carbon fiber sheet of the present invention when used in an adsorbent chamber closer to the intake port of the outside air, the activated carbon fiber sheet of the present invention has a high effective adsorption / desorption amount by purging, so that when the vehicle is stopped for a long time. It is also suitable as an adsorbent used in automobile canisters in that the amount of leakage of vaporized fuel gas can be reduced.
- An automobile canister having two or more adsorbent chambers.
- the activated carbon fiber sheet of the present invention is housed in a second or subsequent adsorbent chamber arranged later than the first adsorbent chamber in which gas first flows from the engine or fuel tank.
- the number of adsorbent chambers may be two or more.
- the activated carbon fiber sheet of the present invention may be housed in at least one adsorbent chamber after the second adsorbent chamber.
- the activated carbon fiber sheet of the present invention can be produced by carbonizing and activating fibers having a predetermined fiber diameter.
- the fiber before carbonization and activation is called a precursor fiber, and the sheet formed of the precursor fiber is called a precursor fiber sheet.
- the term "fiber diameter” means the diameter or width of a fiber, not the radius of the fiber, unless otherwise specified. Further, the term “fiber diameter” is mainly used for fibers of an activated carbon sheet after carbonization and activation.
- the following method can be mentioned. Including carbonization and activation of a precursor fiber sheet retaining either one or both of a phosphoric acid-based catalyst and an organic sulfonic acid-based catalyst.
- the precursor fiber sheet contains cellulosic fibers, and the fiber diameter of the fibers is 4.0 to 60.0 dtex. Method.
- the lower limit of the fiber diameter (as fineness) of the precursor fiber is preferably 4.0 dtex or more, more preferably 5.0 dtex or more, still more preferably 8.0, 10.0, 12.0, or 15.0 dtex. That could be the end.
- the upper limit of the fiber diameter (as fineness) of the fiber serving as the precursor may be preferably 60.0 dtex or less, more preferably 50.0 dtex or less, still more preferably 40.0 or 30.0 dtex or less.
- the method for producing the activated carbon fiber sheet of the present invention can be carried out with reference to the following information.
- raw material sheet preparation of raw material sheet (precursor fiber sheet) ⁇ Type of fiber>
- fiber constituting the raw material sheet include cellulosic fiber, pitch fiber, PAN fiber, phenol resin fiber and the like, and cellulosic fiber is preferable.
- Cellulose-based fibers are fibers composed mainly of cellulose and / or its derivatives.
- the cellulose and the cellulose derivative may be derived from any of chemical synthetic products, plant-derived cellulose, regenerated cellulose, cellulose produced by bacteria, and the like.
- the cellulosic fiber for example, a fiber formed of a plant-based cellulose substance obtained from a tree or the like, or a long fibrous form obtained by dissolving a plant-based cellulosic substance (cotton, pulp, etc.) by chemically treating the fiber. Fibers composed of the regenerated cellulose-based material of the above can be used.
- the fiber may contain components such as lignin and hemicellulose.
- cellulose fibers for example, cotton (short fiber cotton, medium fiber cotton, rayon cotton, rayon, rayon, rayon, etc.), linen, bamboo, etc.
- Vegetable cellulose fibers such as kozo, mitsumata, banana, and capsules; regenerated cellulose fibers such as copper-ammonia rayon, biscous rayon, polynosic rayon, and bamboo-based cellulose; organic solvent (N-methylmorpholin) N oxide) purified cellulose fibers spun; and acetate fibers such as diacetate and triacetate.
- at least one selected from cupraammonium rayon, viscose rayon, and purified cellulose fiber is preferable because of its availability.
- the form of the cellulosic fiber is not particularly limited, and a yarn prepared into a raw yarn (unprocessed yarn), a false twisted yarn, a dyed yarn, a single yarn, a combined twisted yarn, a covering yarn, etc. is used according to the purpose. Can be done.
- the cellulosic fiber contains two or more kinds of raw materials, it may be a blended yarn, a blended yarn or the like.
- the above-mentioned raw materials of various forms may be used alone or in combination of two or more.
- non-twisted yarn is preferable from the viewpoint of achieving both moldability and mechanical strength of the composite material.
- a fiber sheet is a sheet obtained by processing a large number of fibers into a thin and wide sheet, and includes woven fabrics, knitted fabrics, and non-woven fabrics.
- the method of weaving the cellulosic fiber there is no particular limitation on the method of weaving the cellulosic fiber, and a general method can be used, and the weaving structure of the woven fabric is not particularly limited, and a plain weave, a twill weave, and a satin weave can be used.
- the gap between the warp and weft of the cellulosic fiber is preferably 0.1 to 0.8 mm, more preferably 0.2 to 0.6 mm, still more preferably 0.25 to 0.25. It can be 0.5 mm.
- the basis weight of the woven fabric made of cellulosic fibers may be preferably 50 to 500 g / m 2 , and more preferably 100 to 400 g / m 2 .
- the carbon fiber woven fabric obtained by heat-treating the woven fabric can be made excellent in strength.
- the method for producing the non-woven fabric is also not particularly limited, but for example, a method of obtaining a fiber sheet by using the above-mentioned fibers cut to an appropriate length as a raw material by a dry method or a wet method, an electrospinning method, or the like is used. Examples include a method of obtaining a fiber sheet directly from a solution. Further, after obtaining the non-woven fabric, a treatment such as a resin bond, a thermal bond, a spunlace, or a needle punch may be added for the purpose of bonding the fibers to each other.
- a treatment such as a resin bond, a thermal bond, a spunlace, or a needle punch may be added for the purpose of bonding the fibers to each other.
- the catalyst is held on the raw material sheet prepared as described above.
- a porous activated carbon fiber sheet can be obtained by holding a catalyst on a raw material sheet, performing carbonization treatment, and further activating it with water vapor, carbon dioxide, air gas, or the like.
- the catalyst for example, a phosphoric acid-based catalyst, an organic sulfonic acid-based catalyst, or the like can be used.
- phosphoric acid-based catalyst examples include phosphoric acid, metaphosphoric acid, pyrophosphoric acid, phosphite, phosphonic acid, phosphonic acid, phosphinic acid and other phosphorus oxy acids, ammonium dihydrogen phosphate, diammonium hydrogen phosphate, and the like.
- One type of phosphoric acid catalyst may be used alone, or two or more types may be used in combination. When the phosphoric acid-based catalyst is used as an aqueous solution, its concentration can be preferably 0.05 to 2.0 mol / L, more preferably 0.1 to 1.0 mol / L.
- Organic sulfonic acid an organic compound having one or a plurality of sulfo groups can be used, and for example, compounds in which a sulfo group is bonded to various carbon skeletons such as an aliphatic type and an aromatic type can be used.
- organic sulfonic acid-based catalyst a catalyst having a low molecular weight is preferable from the viewpoint of handling.
- organic sulfonic acid-based catalyst examples include R-SO 3 H (in the formula, R is a linear / branched alkyl group having 1 to 20 carbon atoms, a cycloalkyl group having 3 to 20 carbon atoms, or carbon.
- Examples thereof include compounds represented by an aryl group having 6 to 20 atoms, and the alkyl group, cycloalkyl group, and aryl group may be substituted with an alkyl group, a hydroxyl group, and a halogen group, respectively.
- the organic sulfonic acid-based catalyst include methanesulfonic acid, ethanesulfonic acid, propanesulfonic acid, 1-hexanesulfonic acid, vinylsulfonic acid, cyclohexanesulfonic acid, p-toluenesulfonic acid, p-phenolsulfonic acid and naphthalenesulfone.
- Acids benzene sulfonic acids, camphor sulfonic acids and the like can be mentioned. Of these, methanesulfonic acid can be preferably used. In addition, one type of organic sulfonic acid catalyst may be used alone, or two or more types may be used in combination.
- the organic sulfonic acid when used as an aqueous solution, its concentration can be preferably 0.05 to 2.0 mol / L, more preferably 0.1 to 1.0 mol / L.
- ⁇ Mixed catalyst> The above-mentioned phosphoric acid-based catalyst and organic sulfonic acid-based catalyst may be mixed and used as a mixing catalyst. The mixing ratio may be adjusted as appropriate.
- retention means that the catalyst is kept in contact with the raw material sheet, and may be in various forms such as adhesion, adsorption, and impregnation.
- the method for retaining the catalyst is not particularly limited, and includes, for example, a method of immersing the catalyst in an aqueous solution containing the catalyst, a method of sprinkling the aqueous solution containing the catalyst on the raw material sheet, a method of contacting the vaporized catalyst vapor, and a catalyst. Examples thereof include a method of mixing the fibers of the raw material sheet with an aqueous solution to make a paper.
- a method of immersing the raw material sheet in an aqueous solution containing a catalyst and impregnating the inside of the fiber with the catalyst can be preferably used.
- the temperature at the time of immersion in the aqueous solution containing the catalyst is not particularly limited, but room temperature is preferable.
- the immersion time is preferably 10 seconds to 120 minutes, more preferably 20 seconds to 30 minutes.
- immersion for example, 1 to 150% by mass, preferably 5 to 60% by mass of a catalyst is adsorbed on the fibers constituting the raw material sheet.
- the drying method may be any method such as leaving at room temperature or introducing into a dryer.
- Drying may be carried out after removing the sample from the aqueous solution containing the catalyst until the excess water evaporates and the sample weight does not change.
- the drying time may be 0.5 days or more. After the mass change is almost eliminated by drying, the process proceeds to the step of carbonizing the raw material sheet holding the catalyst.
- Carbonization treatment After preparing a raw material sheet holding the catalyst, it is carbonized.
- the carbonization treatment for obtaining the activated carbon fiber sheet can be carried out according to a general carbonization method for activated carbon, but as a preferred embodiment, it can be carried out as follows.
- the inert gas atmosphere means an oxygen-free or low-oxygen atmosphere in which carbon is hard to undergo a combustion reaction and is carbonized, and is preferably a gas atmosphere such as argon or nitrogen.
- the raw material sheet holding the catalyst is heat-treated and carbonized in the above-mentioned predetermined gas atmosphere.
- the lower limit of the heating temperature can be preferably 300 ° C. or higher, more preferably 350 ° C. or higher, still more preferably 400 ° C. or higher or 750 ° C. or higher.
- the upper limit of the heating temperature can be preferably 1400 ° C. or lower, more preferably 1300 ° C. or lower, still more preferably 1200 ° C. or lower or 1000 ° C. or lower.
- the lower limit of the heat treatment time can be preferably 10 minutes or more, more preferably 11 minutes or more, still more preferably 12 minutes or more, and even more preferably 30 minutes or more.
- the upper limit of the heat treatment time can be arbitrary, but is preferably 180 minutes or less, more preferably 160 minutes, and even more preferably 140 minutes or less.
- further reheat treatment can be performed in a predetermined gas atmosphere. That is, in the carbonization treatment, the heat treatment having different conditions such as temperature may be performed in a plurality of stages. When the physical properties can be adjusted, carbonization and subsequent activation can proceed more satisfactorily, and an activated carbon fiber sheet having excellent absorbency and desorption can be obtained by performing the primary heat treatment and the reheat treatment under predetermined conditions. There is.
- Activation treatment The activation treatment in the present invention can be carried out, for example, by continuously supplying steam after the above heat treatment and holding it at an appropriate activation temperature for a predetermined time, and an activated carbon fiber sheet can be obtained. ..
- the lower limit of the activation temperature can be preferably 300 ° C. or higher, more preferably 350 ° C. or higher, and even more preferably 400 or 750 ° C. or higher.
- the upper limit of the activation temperature can be preferably 1400 ° C. or lower, more preferably 1300 ° C. or lower, still more preferably 1200 or 1000 ° C. or lower.
- the lower limit of the activation time can be preferably 1 minute or more, more preferably 5 minutes or more.
- the upper limit of the activation time can be arbitrary, but is preferably 180 minutes or less, more preferably 160 minutes or less, still more preferably 140 minutes or less, 100 minutes or less, 50 minutes or less, and 30 minutes or less.
- the fiber diameter was determined from the average value after randomly extracting 10 fibers from a 500-fold image using a scanning electron microscope JSM-IT300 InTouchScop (manufactured by JEOL Ltd.).
- Total pore volume (unit: cm 3 / g) by the one-point method was calculated from the results of the isotherm adsorption line obtained in the above specific surface area section at a relative pressure of 0.990.
- Average pore diameter (unit: nm) 4 ⁇ total pore volume ⁇ 10 3 ⁇ specific surface area ⁇ ⁇ ⁇ Equation 3
- ⁇ Sheet basis weight> The activated carbon fiber sheet was allowed to stand for 12 hours or more in an environment of a temperature of 23 ⁇ 2 ° C. and a relative humidity of 50 ⁇ 5%, and the sheet basis weight (unit: g / m 2 ) was determined from the weight and the vertical and horizontal dimensions.
- the activated carbon fiber sheet is allowed to stand for 12 hours or more in an environment of a temperature of 23 ⁇ 2 ° C. and a relative humidity of 50 ⁇ 5%, and is 0 using a digital compact side thicker FS-60DS (Daei Kagaku Seiki Seisakusho Co., Ltd.).
- the sheet thickness (unit: mm) when a load of 3 kPa was applied was measured.
- Sheet density (unit: g / cm 3 ) sheet basis weight ⁇ sheet thickness ⁇ 10 3 ⁇ ⁇ ⁇ Equation 4
- ⁇ Tensile strength (MD), tensile strength (CD)> The sample is allowed to stand for 12 hours or more in an environment of a temperature of 23 ⁇ 2 ° C. and a relative humidity of 50 ⁇ 5%, and a test piece (width) is obtained from the Machine Direction (MD) direction and the Cross Direction (CD) direction perpendicular to the direction. Cut out 15 mm, length 50-60 mm) so that each direction has a length, and use a Tensilon universal tester RTG-1210 (A & D) to pull at a grip interval of 40 mm and a pulling speed of 100 mm / min. The tensile strength was calculated by the following formula 5.
- Frazier is the result of measurement using the Frazier Permiyameter model FP2 (Toyo Seiki Seisakusho Co., Ltd.) according to the breathability A method (Frazil type method) of the Japanese Industrial Standards woven fabric and knitted fabric test method (JIS L1096: 2010). The air permeability (cm 3 / cm 2 / s) was used.
- the adsorbent sample was dried in a dryer at 115 ⁇ 5 ° C. for 3 hours or more, and the dry weight was measured after cooling. After measuring the mass of an empty test tube (inner diameter 1.47 cm, cross-sectional area 1.67 cm 2 , sample filling length 10 cm, sample filling volume 16.7 ml glass tube), transfer the adsorbent sample to the suction tube 16. 7 ml was filled.
- test tube is placed in a distribution device, and at a test temperature of 25 ° C., 500 ml / min of n-butane gas diluted to a concentration of 0.2% with air is passed through the test tube to adsorb n-butane. Remove the test tube from the distribution device and measure the mass. The flow of this 0.2% concentration n-butane gas was repeated until a constant mass was achieved, that is, until the adsorption amount was saturated. The test tube was re-installed in the distribution device, and 4.0 L / min of air was flowed through the test tube for 3 minutes and 48 seconds at a test temperature of 25 ° C. to desorb n-butane. The test tube was removed from the distribution device and the mass was measured.
- each numerical value is as follows. Effective adsorption / desorption amount (unit: wt%) Second n-butane adsorption amount (unit: g) Second n-butane desorption amount (unit: g) Adsorbent sample dry weight (unit: g)
- Effective adsorption / desorption rate Effective adsorption / desorption amount / First adsorption amount x 100 The unit of each numerical value is as follows. Effective adsorption / desorption rate (unit:%) Effective adsorption / desorption amount (unit: wt%) First adsorption amount (unit: wt%)
- Example 1 A needle punched non-woven fabric having a basis weight of 300 g / m 2 made of rayon fiber (17.0 dtex, fiber length 76 mm) is impregnated with a 6 to 10% diammonium hydrogen phosphate aqueous solution, squeezed, dried, and 8 to 10 weight by weight. % was attached.
- the obtained pretreated non-woven fabric was heated to 900 ° C. in a nitrogen atmosphere in 50 minutes and kept at this temperature for 4 minutes. Subsequently, the activation treatment was carried out for 18 minutes in a nitrogen stream containing water vapor at a dew point of 71 ° C. at that temperature.
- Example 2 The activated carbon fiber sheet of Example 2 was prepared by the same method as in Example 1 except that a needle-punched non-woven fabric having a basis weight of 300 g / m 2 made of rayon fiber (7.8 dtex, fiber length 51 mm) was used.
- Example 3 A needle punched non-woven fabric having a basis weight of 300 g / m 2 made of rayon fiber (17.0 dtex, fiber length 76 mm) is impregnated with a 4 to 8% methanesulfonic acid aqueous solution, squeezed, dried, and adhered to 6 to 8% by weight. I let you.
- the obtained pretreated non-woven fabric was heated to 900 ° C. in a nitrogen atmosphere in 40 minutes and kept at this temperature for 3 minutes. Subsequently, the activation treatment was carried out for 16 minutes in a nitrogen stream containing water vapor at a dew point of 71 ° C. at that temperature.
- the obtained pretreated non-woven fabric was heated to 900 ° C. in 50 minutes in a nitrogen atmosphere, and subsequently activated at that temperature in a nitrogen stream containing water vapor at a dew point of 60 ° C. for 13 minutes.
- Comparative example 2 The activated carbon fiber sheet of Comparative Example 2 was prepared by the same method as in Comparative Example 1 except that a needle-punched non-woven fabric having a basis weight of 300 g / m 2 made of rayon fiber (1.7 dtex, fiber length 40 mm) was used.
- Table 1 shows the results of measuring the physical properties and performance of Examples 1 and 2 and Comparative Examples 1 to 3.
- a frame which is a cubic container and one surface and the opposite surface are open so as to allow ventilation was prepared.
- the frame container was prepared with a length and width of 3.8 x 3.8 cm on one side.
- the prepared laminate or granular activated carbon was filled inside the frame container according to the size of the frame container, and used as a test sample for measuring the pressure loss.
- the dimensions of each frame container are as shown in Table 2.
- the pressure loss was measured as follows. 60 L / min of air was circulated through the test sample prepared as described above, and the result of measuring the differential pressure at the entrance and exit of the test sample using a testo 510 differential pressure gauge (Testo Co., Ltd.) was defined as a pressure loss (kPa). The measurement results of pressure loss are shown in Table 2.
- Adsorption laminate 10 Activated carbon fiber sheet, 10a Main surface of activated carbon fiber sheet, 10b Side end face of activated carbon fiber sheet, 10c Side end face of activated carbon fiber sheet, F gas flow direction
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Abstract
Description
前記シートの比表面積が1100~2300m2/gであり、
前記シートの密度が0.010~0.200g/cm3以下であり、
前記シートの厚みが0.10~100.00mmであり、
前記シートの繊維径が、13.0μm以上である、
前記シート。
〔2〕 前記活性炭素繊維シートのフラジール通気度が、150.0cm3/cm2/s以上である、上記〔1〕に記載の自動車キャニスタ用活性炭素繊維シート。
〔3〕 全細孔容積が0.50~1.20cm3/gである、上記〔1〕または〔2〕に記載の自動車キャニスタ用活性炭素繊維シート。
〔4〕 細孔径が0.7nmより大きく2.0nm以下である細孔の細孔容積が、0.20~1.20cm3/gである、上記〔1〕~〔3〕のいずれか一項に記載の自動車キャニスタ用活性炭素繊維シート。
〔5〕 細孔径が2.0nm以下である細孔の細孔容積に占める、細孔径が0.7nm以下である細孔の細孔容積の存在比率R0.7/2.0が、15%以上、25%未満である、上記〔1〕~〔4〕のいずれか一項に記載の自動車キャニスタ用活性炭素繊維シート。
〔6〕 上記〔1〕~〔5〕のいずれか一項に記載の自動車キャニスタ用活性炭素繊維シートを複数重ね合わされた積層体である、自動車キャニスタの吸着材室に収納用の吸着積層体。
〔7〕 上記〔1〕~〔5〕のいずれか一項に記載の自動車キャニスタ用活性炭素繊維シートを備えた自動車キャニスタ。
〔8〕 複数の前記活性炭素繊維シートが重ね合わされた積層体が、前記自動車キャニスタの吸着材室内に充填されており、前記積層体は、前記積層体を通過する流体の流通方向が前記シートの主面に対して略平行になるように配置される、上記〔7〕に記載の自動車キャニスタ。
〔9〕 自動車キャニスタ用活性炭素繊維シートの製造方法であって、
リン酸系触媒若しくは有機スルホン酸系触媒のいずれか一方または双方を保持させた前駆体繊維シートを、炭化及び賦活化することを含み、
前記前駆体繊維シートはセルロース系繊維を含み、前記繊維の繊維径が4.0dtex以上である、
前記製造方法。
また、本発明の一態様において、取扱いが容易で、低濃度での吸脱着性能が高い活性炭素繊維シートとすることができる。さらに、本発明の一態様において、低濃度での吸脱着性能に優れた自動車キャニスタを提供することができる。
本発明の自動車キャニスタ用活性炭素繊維シートは、賦活化された炭素繊維で形成されているシート状の成形物であり、自動車に搭載されるキャニスタに収納する吸着材として好適に用いられる。(なお、以下、本発明の自動車キャニスタ用活性炭素繊維シートを、本発明の活性炭素繊維シートと略称する場合がある。)
フラジール通気度は、通常、測定機器が許容する任意の厚みにて測定しうるが、本発明の一実施形態においては、例えば、フラジール通気度を測定するために用いられるシートの厚みが1~4mmの場合における数値として示しうる。ここで「シートの厚みが1~4mmの場合」とは、フラジール通気度を測定するために用いられるシートの厚みを1~4mmの範囲内になるように調製した物を試験用サンプルとして測定を行った場合という意味である。
フラジール通気度の上限は、上記のようないずれの実施形態においても、好ましくは300cm3/cm2/s以下、より好ましくは290cm3/cm2/s以下、さらに好ましくは280cm3/cm2/s以下でありうる。
なお、「シートの厚みが1~4mmの場合」の好ましいフラジール通気度については、厚さ1~4mmの範囲内すべてにおいて上記の下限または上限を満たしていなければ好ましいとは言えないというわけではなく、厚さ1~4mmの範囲内における少なくとも1点で上記の下限または上限を満たすことが好ましいとの意味である。
本発明の活性炭素繊維シートの比表面積の下限は、好ましくは1100m2/g以上、より好ましくは1200m2/g以上、更に好ましくは1300、1400、1500、1600、1700、又は1800m2/g以上でありうる。
本発明の活性炭素繊維シートの比表面積は、一般に広い方が吸着性能の観点からは好ましいが、活性炭素繊維シートの場合、比表面積の上限は、概ね2400、2300、2200、又は2100m2/g以下でありうる。
比表面積を上記のような範囲とすることによって、蒸散燃料ガスに対する吸脱着性能について、より優れたシートとすることができる。また、本発明の一形態において、上記のようなキャニスタに用いられる吸着材料としては広めの比表面積を維持しつつ、キャニスタでの圧力損失の低減を達成しうる。
本発明の活性炭素繊維シートの全細孔容積の下限は、好ましくは0.50cm3/g以上、より好ましくは0.60cm3/g以上、更に好ましくは0.70、0.80、又は0.90cm3/g以上でありうる。
本発明の活性炭素繊維シートの全細孔容積の上限は、好ましくは1.20cm3/g以下、より好ましくは1.10cm3/g以下、更に好ましくは1.00cm3/g以下でありうる。
全細孔容積を上記のような範囲とすることによって、蒸散燃料ガスに対する吸脱着性能についてより優れたシートとすることができる。
本発明に関し、「細孔径」との用語は、特に明示しない限り、細孔の半径ではなく、細孔の直径又は幅のことを意味する。
本発明の活性炭素繊維シートの平均細孔径の下限は、好ましくは1.69nm以上、より好ましくは1.70nm以上、更に好ましくは1.72、1.75、1.78、又は1.80nm以上でありうる。
本発明の活性炭素繊維シートの平均細孔径の上限は任意でありうるが、好ましくは4.00nm以下、より好ましくは3.50nm以下、更に好ましくは3.00nm以下でありうる。
平均細孔径を上記のような範囲とすることによって、蒸散燃料ガスに対する吸脱着性能についてより優れたシートとすることができる。
本発明において「ウルトラマイクロ孔」との用語は、細孔径が0.7nm以下の細孔を意味する。
本発明の活性炭素繊維シートのウルトラマイクロ孔容積の下限は、好ましくは0.05cm3/g以上、より好ましくは0.10cm3/g以上、更に好ましくは0.12、又は0.14cm3/g以上でありうる。
本発明の活性炭素繊維シートのウルトラマイクロ孔容積の上限は、好ましくは0.30cm3/g以下、より好ましくは0.29cm3/g以下、更に好ましくは0.26、0.24、0.22、又は0.20cm3/g以下でありうる。
ウルトラマイクロ孔容積を上記のような範囲とすることによって、蒸散燃料ガスに対する吸脱着性能についてより優れたシートとすることができる。
本発明において「マイクロ孔」との用語は、細孔径が2.0nm以下の細孔を意味する。
本発明の活性炭素繊維シートのマイクロ孔容積の下限は、好ましくは0.50cm3/g以上、より好ましくは0.60cm3/g以上、更に好ましくは0.65、又は0.70cm3/g以上でありうる。
本発明の活性炭素繊維シートのマイクロ孔容積の上限は、好ましくは1.00cm3/g以下、より好ましくは0.90cm3/g以下、更に好ましくは0.80cm3/g以下でありうる。
マイクロ孔容積を上記のような範囲とすることによって、蒸散燃料ガスに対する吸脱着性能についてより優れたシートとすることができる。
細孔径が0.7nmより大きく2.0nm以下の細孔の細孔容積V0.7-2.0は、ウルトラマイクロ孔容積の値aとマイクロ孔容積の値bとを用い、下記式1によって求めることができる。
V0.7-2.0=b-a ・・・式1
本発明の本発明の活性炭素繊維シートにおいて、細孔径が0.7nmより大きく2.0nm以下の細孔の細孔容積V0.7-2.0の上限は、好ましくは1.20cm3/g以下、より好ましくは1.00cm3/g以下、更に好ましくは、0.90、0.80、0.75、0.70、0.65、又は0.60cm3/g以下でありうる。
当該細孔容積V0.7-2.0を上記のような範囲とすることによって、蒸散燃料ガスに対する吸脱着性能についてより優れたシートとすることができる。
細孔径が2.0nm以下であるマイクロ孔の細孔容積に占める、細孔径が0.7nm以下であるウルトラマイクロ孔の細孔容積の存在比率R0.7/2.0は、ウルトラマイクロ孔容積の値aとマイクロ孔容積の値bとを用い、下記式2によって求めることができる。
R0.7/2.0=a/b×100(%) ・・・式2
本発明の活性炭素繊維シートにおいて、マイクロ孔容積に占めるウルトラマイクロ孔容積の存在比率R0.7/2.0の上限は、好ましくは60%以下、より好ましくは50%以下、更に好ましくは40、30、又は25%以下でありうる。
当該ウルトラマイクロ孔容積の存在比率R0.7/2.0を上記のような範囲とすることによって、蒸散燃料ガスに対する吸脱着性能についてより優れたシートとすることができる。
本発明の活性炭素繊維シートの坪量の下限は、好ましくは50.0g/m2以上、より好ましくは60.0g/m2以上、更に好ましくは70.0又は80.0g/m2以上でありうる。
本発明の活性炭素繊維シートの坪量の上限は、好ましくは2000.0g/m2以下、より好ましくは1900.0g/m2以下、更に好ましくは1800.0、1700.0、1600.0、又は1500.0g/m2以下でありうる。
坪量を上記のような範囲とすることによって、キャニスタ内に収納できる吸着材の容量の範囲内において、キャニスタ用に要求される吸脱着性能についてより優れたシートとすることができる。
本発明の活性炭素繊維シートの厚みの下限は、好ましくは0.10mm以上、より好ましくは0.50mm以上、さらに好ましくは1.00、1.50、2.00、又は2.50mm以上でありうる。
本発明の活性炭素繊維シートの厚みの上限は、好ましくは100.00mm以下、より好ましくは70.00mm以下、さらに好ましくは50.00、40.00、30.00、20.00、又は10.00mm以下でありうる。
シート厚みを上記のような範囲とすることによって、キャニスタ内に収納できる吸着材の容量の範囲内において、キャニスタ用に要求される吸脱着性能についてより優れたシートとすることができる。
本発明の活性炭素繊維シートの密度の下限は、好ましくは0.010g/cm3以上、より好ましくは0.015g/cm3以上、更に好ましくは0.020g/cm3以上でありうる。
本発明の活性炭素繊維シートの密度の上限は、好ましくは0.200g/cm3以下、より好ましくは0.100g/cm3以下、更に好ましくは0.080、又は0.050g/cm3以下でありうる。
本発明の活性炭素繊維シートを構成する繊維径の下限は、好ましくは13.0μm以上、より好ましくは14.0以上、更に好ましくは15.0、16.0、17.0、18.0、19.0、又は20.0以上でありうる。
本発明の活性炭素繊維シートを構成する繊維径の上限は、任意でありうるが、例えば、60.0μm以下、好ましくは50.0μm以下、より好ましくは45.0、40.0、又は35.0μmでありうる。
活性炭素繊維シートを構成する繊維の繊維径が上記の範囲であると、より圧力損失を抑制できる活性炭素繊維シートとすることができる。
本発明の活性炭素繊維シートの引張強度(MD)の下限は、好ましくは0.005kN/m以上、より好ましくは0.007kN/m以上、より好ましくは0.009kN/m以上でありうる。
本発明の活性炭素繊維シートの引張強度(MD)の上限は、特に制限はなく任意でありうるが、好ましくは2.50kN/m以下、より好ましくは2.00kN/m以下、さらに好ましくは1.25、1.00、0.75、又は0.50kN/m以下でありうる。
引張強度(MD)を上記のような範囲とすることによって、フレキシブル性を有するシートとすることができる。そのため、加工性に優れ、破損しにくく、キャニスタへの収納作業などにおける取扱いが容易な吸収材とすることができる。
本発明の活性炭素繊維シートの引張強度(CD)の下限は、好ましくは0.005kN/m以上、より好ましくは0.008kN/m以上、更に好ましくは0.009kN/m以上でありうる。
本発明の活性炭素繊維シートの引張強度(CD)の上限は、特に制限はなく任意でありうるが、好ましくは2.50kN/m以下、より好ましくは2.00kN/m以下、さらに好ましくは1.25、1.00、0.75、又は0.50kN/m以下でありうる。
引張強度(CD)を上記のような範囲とすることによって、フレキシブル性を有するシートとすることができる。そのため、加工性に優れ、破損しにくく、キャニスタへの収納作業などにおける取扱いが容易な吸収材とすることができる。
本発明の活性炭素繊維シートは、所定の水分含有量を有するものが好適である。例えば、23℃、相対湿度50%の条件下における水分含有量の下限は、好ましくは1.0%以上、より好ましくは2.0%以上、更に好ましくは3.0%以上でありうる。
また23℃、相対湿度50%の条件下における水分含有量の上限は、好ましくは25.0%以下、より好ましくは20.0%以下、さらに好ましくは10.0又は8.0%以下でありうる。
上記の条件下における水分含有量を上記のような範囲とすることによって、自動車キャニスタ用の吸着材としてより優れたシートとすることができる。
本発明の活性炭素繊維シートは、吸着材として、所定のメチレンブルー吸着性能を有することが好ましい。メチレンブルー吸収性能は、活性炭素繊維シート重量当たりのメチレンブルー吸着量として示すことができる。本発明の活性炭素繊維シートが有するメチレンブルー吸着性能は、好ましくは100ml/g以上であり、より好ましくは150ml/g以上、さらに好ましくは200、250、280、又は300ml/g以上でありうる。
本発明の活性炭素繊維シートは、吸着材として、所定のn-ブタン吸脱着性能を有することが好ましい。n-ブタン吸脱着性能は、蒸散ガスの吸脱着性能の指標となるため、n-ブタンの吸脱着性能が優れるものは、自動車キャニスタ用途に好適である。n-ブタン吸脱着性能は、n-ブタンを十分に吸収破過させた後、所定の脱着条件下に置いたときに吸着材から脱離させた後、吸着を繰り返す際の吸着量を、活性炭素繊維シート重量当たりのn-ブタンの有効吸着量として示すことができる。
本発明の活性炭素繊維シートは、圧力損失を抑制することができるものであり、一実施形態として、所定の通気度(例えば、フラジール通気度)を有するものでありうる。本発明の好ましい実施形態としては、上記の物性又は性能に係る項目のうちの1つ又は任意の2つ以上を条件をさらに満たす実施形態を挙げることができる。好ましい実施形態の例を以下に示す。なお、本発明の活性炭素繊維シートは下記の組合せの例に限定されるものではない。
以下の(1)~(4)の要件を満たす自動車キャニスタ用活性炭素繊維シート。
(1)活性炭素繊維シートの比表面積が1100~2300m2/gである。
(2)活性炭素繊維シートの密度が0.010~0.200g/cm3である。
(3)活性炭素繊維シートの厚みが0.10~100.00mmである。
(4)前記シートの繊維径が、13.0μm以上である。
本発明の他の実施形態として、自動車キャニスタの吸着材室に収納用の吸着積層体が提供されうる。当該吸着積層体は、上記の活性炭素繊維シートが複数重ね合わされた積層体である。
本発明の活性炭素繊維シートは、自動車キャニスタに収納される吸着材として好適である。すなわち、本発明は、他の一実施形態として、自動車キャニスタも提供することができる。
筐体内において吸着材を収納する吸着材室と、
吸着材室とエンジンとの間をガスが移動可能に連通するための第1の開口部と、
吸着材室と燃料タンクとの間をガスが移動可能に連通するための第2の開口部と、
吸着材室または外気から所定の圧力が負荷されたときに開口し、吸着材室と外気との間をガスが移動可能に連通するための第3の開口部と、
を備えるキャニスタ。
吸着材室を2つ又はそれ以上有する自動車用キャニスタであって、
エンジン又は燃料タンクから最初にガスが流入する第1の吸着材室よりも、より後段に配置された第2又はそれ以降の吸着材室に、本発明の活性炭素繊維シートが収納されている自動車用キャニスタ。
上記本発明の活性炭素繊維シートは、所定の繊維径を有する繊維を炭化、賦活化して製造することができる。なお、炭化、賦活化する前の繊維のことを、前駆体繊維といい、前駆体繊維で形成されているシートのことを、前駆体繊維シートという。本発明に関し、「繊維径」との用語は、特に明示しない限り、繊維の半径ではなく、繊維の直径又は幅のことを意味する。また、「繊維径」との用語は、炭化、賦活化後の活性炭素シートの繊維に対して主に用いる。
リン酸系触媒若しくは有機スルホン酸系触媒のいずれか一方または双方を保持させた前駆体繊維シートを、炭化及び賦活化することを含み、
前記前駆体繊維シートはセルロース系繊維を含み、前記繊維の繊維径が4.0~60.0dtexである、
方法。
前駆体となる繊維の繊維径(繊度として)の上限は、好ましく60.0dtex以下、より好ましくは50.0dtex以下、さらに好ましくは40.0、又は30.0dtex以下でありうる。
前駆体となる繊維の繊維径が上記の範囲であると、より圧力損失を抑制できる活性炭素繊維シートとすることができる。
<繊維の種類>
原料シートを構成する繊維としては、例えば、セルロース系繊維、ピッチ系繊維、PAN系繊維、フェノール樹脂系繊維などが挙げられ、好ましくはセルロース系繊維が挙げられる。
セルロース系繊維とは、セルロース及び/又はその誘導体を主成分として構成される繊維である。セルロース、セルロース誘導体は、化学合成品、植物由来、再生セルロース、バクテリアが産生したセルロースなど、その由来はいずれであってもよい。セルロース系繊維として好ましくは、例えば、樹木などから得られる植物系セルロース物質で形成された繊維、および、植物系セルロース物質(綿、パルプなど)に化学処理を施して溶解させて得られる長い繊維状の再生セルロース系物質から構成された繊維などを用いうる。また、この繊維には、リグニンやヘミセルロースなどの成分が含まれていても構わない。
繊維シートは、多数の繊維を薄く広いシート状に加工したもののことをいい、織物、編み物、および不織布などが含まれる。
製法実施形態1では、上記のようにして用意された原料シートに、触媒を保持させる。原料シートに触媒を保持させて炭化処理を行い、さらに水蒸気や二酸化炭素、空気ガス等を用いて賦活化し、多孔質の活性炭素繊維シートを得ることができる。触媒としては、例えば、リン酸系触媒、有機スルホン酸系触媒などを用いうる。
リン酸系触媒としては、例えば、リン酸、メタリン酸、ピロリン酸、亜リン酸、ホスホン酸、亜ホスホン酸、ホスフィン酸等のリンのオキシ酸、リン酸二水素アンモニウム、リン酸水素二アンモニウム、リン酸三アンモニウム、ジメチルホスホノプロパンアミド、ポリリン酸アンモニウム、ポリホスホニトリルクロライド、およびリン酸、テトラキス(ヒドロキシメチル)ホスホニウム塩またはトリス(1-アジリジニル)ホスフィンオキサイドと尿素、チオ尿素、メラミン、グアニン、シアナミツド、ヒドラジン、ジシアンジアミドまたはこれらのメチロール誘導体との縮合物などが挙げられ、好ましくはリン酸水素二アンモニウムが挙げられる。リン酸系触媒は、1種を単独で用いてもよく、2種以上を併用してもよい。リン酸系触媒を水溶液として用いる場合、その濃度は、好ましくは0.05~2.0mol/L、より好ましくは0.1~1.0mol/Lでありうる。
有機スルホン酸としては、1又は複数のスルホ基を有する有機化合物を用いることができ、例えば脂肪族系、芳香族系など種々の炭素骨格にスルホ基が結合した化合物が利用可能である。有機スルホン酸系触媒としては、取扱いの観点から、低分子量のものが好ましい。
上記、リン酸系触媒および有機スルホン酸系触媒は、混合して、混合触媒として用いてもよい。混合比は適宜調整してよい。
原料シートに対し触媒を保持させる。ここで「保持」とは、触媒が原料シートに接触した状態を保つことを意味し、付着、吸着、含浸などの諸形態でありうる。触媒を、保持させる方法には特に制限はないが、例えば、触媒を含む水溶液に浸漬する方法、触媒を含む水溶液を原料シートに対して振りかける方法、気化した触媒蒸気に接触させる方法、触媒を含む水溶液に原料シートの繊維を混ぜて抄紙する方法などが挙げられる。
触媒を保持させた原料シートを用意した後、それを炭化処理する。活性炭素繊維シートを得るための炭化処理は、一般的な活性炭の炭化方法に沿って行うことができるが、好ましい実施形態として、以下のようにして行うことができる。
加熱温度の上限は、好ましくは1400℃以下、より好ましくは1300℃以下、さらに好ましくは1200℃以下又は1000℃以下でありうる。
このような加熱温度設定とすることにより、繊維形態が維持された炭素繊維シートを得ることができる。加熱温度が上記の下限以下であると、炭素繊維の炭素含有量が80%以下で炭化が不十分となりやすい。
加熱処理時間の上限は任意でありうるが、好ましくは180分以下、より好ましくは160分、さらに好ましくは140分以下でありうる。
原料シートに十分に触媒を含浸させ、上記の好適な加熱温度に設定し、加熱処理時間を調整することにより、細孔形成の進行程度を調整することができ、比表面積、各種細孔の容積、平均細孔直径などの多孔体としての物性を調整することができる。
加熱処理時間が上記の下限より少ないと、炭化が不十分となりやすい。
本発明における賦活化処理としては、例えば上記加熱処理後に連続して、水蒸気を供給し適切な賦活温度で所定時間保持することで行うことができ、活性炭素繊維シートを得ることができる。
他方、賦活温度の上限は、好ましくは1400℃以下、より好ましくは1300℃以下、さらに好ましくは1200又は1000℃以下でありうる。
なお、加熱処理後に連続して賦活処理を行う場合、加熱処理温度と同等程度に調整することが望ましい。
賦活時間の上限は任意でありうるが、好ましくは180分以下、より好ましくは160分以下、さらに好ましくは140分以下、100分以下、50分以下、30分以下でありうる。
繊維径は走査電子顕微鏡JSM-IT300 InTouchScope(日本電子株式会社製)を用い、500倍の画像から10本の繊維を無作為に抽出し測定の上、平均値より求めた。
活性炭素繊維シートを約30mg採取し、200℃で20時間真空乾燥して秤量し、高精度ガス/蒸気吸着量測定装置BELSORP-maxII(マイクロトラック・ベル社)を使用して測定した。液体窒素の沸点(77K)における窒素ガスの吸着量を相対圧が10-8オーダー~0.990の範囲で測定し、試料の吸着等温線を作成した。この吸着等温線を、解析相対圧範囲を吸着等温線I型(ISO9277)の条件で自動的に決定したBET法により解析し、重量当たりのBET比表面積(単位:m2/g)を求め、これを比表面積(単位:m2/g)とした。
上記比表面積の項で得られた等温吸着線の、相対圧0.990での結果より1点法での全細孔容積(単位:cm3/g)を算出した。
次式3により算出した。
平均細孔直径(単位:nm)=4×全細孔容積×103÷比表面積 ・・・式3
上記比表面積の項で得られた等温吸着線を、高精度ガス/蒸気吸着量測定装置BELSORP-maxII(マイクロトラック・ベル社)付属の解析ソフトBELMasterを用いて、解析設定を「スムージング(細孔分布の解析全点で前後1点を使用した移動平均処理)」、「分布関数:No-assumption」、「細孔径の定義:Solid and Fluid Def. Pore Size」、「Kernel:Slit-C-Adsorption」としたGCMC法によって解析し、得られた吸着時の細孔分布曲線の結果から、0.7nmの積算細孔容積を読み取り、ウルトラマイクロ孔容積(単位:cm3/g)とした。
上記比表面積の項で得られた等温吸着線を、高精度ガス/蒸気吸着量測定装置BELSORP-maxII(マイクロトラック・ベル社)付属の解析ソフトBELMasterを用いて、解析設定を「スムージング(細孔分布の解析全点で前後1点を使用した移動平均処理)」、「分布関数:No-assumption」、「細孔径の定義:Solid and Fluid Def. Pore Size」、「Kernel:Slit-C-Adsorption」としたGCMC法によって解析し、得られた吸着時の細孔分布曲線の結果から、2.0nmの積算細孔容積を読み取り、マイクロ孔容積(単位:cm3/g)とした。
活性炭素繊維シートを、温度23±2℃、相対湿度50±5%の環境下で12時間以上静置し、重量と縦横の寸法からシート坪量(単位:g/m2)を求めた。
活性炭素繊維シートを、温度23±2℃、相対湿度50±5%の環境下で12時間以上静置し、デジタル小型側厚器FS-60DS(大栄科学精器製作所社)を用いて、0.3kPaの荷重をかけた際のシート厚さ(単位:mm)を測定した。
次式4により算出した。
シート密度(単位:g/cm3)=シート坪量÷シート厚み÷103 ・・・式4
試料を、温度23±2℃、相対湿度50±5%の環境下で12時間以上静置し、Machine Direction(MD)方向及びこれと直行するCross Direction(CD)方向から、それぞれ試験片(幅15mm、長さ50~60mm)を各方向が長さとなるように切り取り、テンシロン万能試験機RTG-1210(エー・アンド・デイ社)を用いて、つかみ間隔40mm、引っ張り速度100mm/分で引っ張り、次式5により引張強度を算出した。
引張強度(単位:kN/m)=試験中に加わった最大荷重(単位:N)÷15mm
活性炭素繊維シートを、温度23±2℃、相対湿度50±5%の環境下で12時間以上静置後、試料を0.5~1.0g採取し、乾燥機で115±5℃3時間以上乾燥させた際の重量変化から、水分(単位:%)を求めた。
日本水道協会規格水道用粉末活性炭(JWWA K113)のメチレンブルー脱色力(単位:ml/g)に従って測定した結果を、メチレンブルー吸着性能(単位:ml/g)とした。
日本工業規格織物及び編物の生地試験方法(JIS L1096:2010)の通気性A法(フラジール形法)に従って、フラジール・パーミヤメータ型式FP2(株式会社東洋精機製作所社)を使用し測定した結果を、フラジール通気度(cm3/cm2/s)とした。
米国試験材料協会規格Standard Test Method for Determination of Butane Working Capacity of Activated Carbon(ASTM D5228-16)を参考に、n-ブタンガスの濃度、流量、脱着させる空気の流量を独自に設定し、試験した。
試験管を流通装置に再設置し、試験温度25℃で空気4.0L/分を3分48秒間試験管に流し、n-ブタンを脱着させた。試験管を流通装置から取り外し、質量を測定した。
1回目吸着量=1回目n-ブタン吸着量÷吸着体試料乾燥重量×100
なお、各数値の単位は次のとおりである。
1回目吸着量(単位:wt%)
1回目n-ブタン吸着量(単位:g)
吸着体試料乾燥重量(単位:g)
有効吸脱着量(単位:wt%)
2回目n-ブタン吸着量(単位:g)
2回目n-ブタン脱着量(単位:g)
吸着体試料乾燥重量(単位:g)
有効吸脱着率=有効吸脱着量÷1回目吸着量×100
なお、各数値の単位は次のとおりである。
有効吸脱着率(単位:%)
有効吸脱着量(単位:wt%)
1回目吸着量(単位:wt%)
レーヨン繊維(17.0dtex、繊維長76mm)からなる坪量300g/m2のニードルパンチ不織布に6~10%リン酸水素二アンモニウム水溶液を含浸し、絞液後、乾燥して、8~10重量%付着させた。得られた前処理不織布を窒素雰囲気中、900℃まで50分で昇温し、この温度で4分保持した。引き続きその温度で露点71℃の水蒸気を含有する窒素気流中で18分間賦活処理を行った。
レーヨン繊維(7.8dtex、繊維長51mm)からなる坪量300g/m2のニードルパンチ不織布を用いたこと以外は、実施例1と同じ方法で、実施例2の活性炭素繊維シートを作製した。
レーヨン繊維(17.0dtex、繊維長76mm)からなる坪量300g/m2のニードルパンチ不織布に4~8%メタンスルホン酸水溶液を含浸し、絞液後、乾燥して、6~8重量%付着させた。得られた前処理不織布を窒素雰囲気中、900℃まで40分で昇温し、この温度で3分保持した。引き続きその温度で露点71℃の水蒸気を含有する窒素気流中で16分間賦活処理を行った。
レーヨン繊維(3.3dtex、繊維長76mm)からなる坪量300g/m2のニードルパンチ不織布に6~10%リン酸水素二アンモニウム水溶液を含浸し、絞液後、乾燥して、8~10重量%付着させた。得られた前処理不織布を窒素雰囲気中、900℃まで50分で昇温し、引き続きその温度で露点60℃の水蒸気を含有する窒素気流中で13分間賦活処理を行った。
レーヨン繊維(1.7dtex、繊維長40mm)からなる坪量300g/m2のニードルパンチ不織布を用いたこと以外は、比較例1と同じ方法で、比較例2の活性炭素繊維シートを作製した。
市販のキャニスタに充填された粒状活性炭を取り出し、比較例2の吸着材として用いた。市販のキャニスタとして、品番:14950-01FOA(日産自動車)のキャニスタを用いた。
実施例1、2、比較例1、2の活性炭素繊維シートを重ね合わせて、それぞれ積層体を用意した。比較例3の粒状活性炭はそのまま用いた。
圧力損失の測定結果を、表2に示す。
10b 活性炭素繊維シートの側端面、10c 活性炭素繊維シートの側端面、F ガスの流れ方向
Claims (9)
- 自動車キャニスタ用活性炭素繊維シートであって、
前記シートの比表面積が1100~2300m2/gであり、
前記シートの密度が0.010~0.200g/cm3以下であり、
前記シートの厚みが0.10~100.00mmであり、
前記シートの繊維径が、13.0μm以上である、
前記シート。 - 前記活性炭素繊維シートのフラジール通気度が、150.0cm3/cm2/s以上である、請求項1に記載の自動車キャニスタ用活性炭素繊維シート。
- 全細孔容積が0.50~1.20cm3/gである、請求項1または2に記載の自動車キャニスタ用活性炭素繊維シート。
- 細孔径が0.7nmより大きく2.0nm以下である細孔の細孔容積が、0.20~1.20cm3/gである、請求項1~3のいずれか一項に記載の自動車キャニスタ用活性炭素繊維シート。
- 細孔径が2.0nm以下である細孔の細孔容積に占める、細孔径が0.7nm以下である細孔の細孔容積の存在比率R0.7/2.0が、15%以上、25%未満である、請求項1~4のいずれか一項に記載の自動車キャニスタ用活性炭素繊維シート。
- 請求項1~5のいずれか一項に記載の自動車キャニスタ用活性炭素繊維シートを複数重ね合わされた積層体である、自動車キャニスタの吸着材室に収納用の吸着積層体。
- 請求項1~5のいずれか一項に記載の自動車キャニスタ用活性炭素繊維シートを備えた自動車キャニスタ。
- 複数の前記活性炭素繊維シートが重ね合わされた積層体が、前記自動車キャニスタの吸着材室内に充填されており、前記積層体は、前記積層体を通過する流体の流通方向が前記シートの主面に対して略平行になるように配置される、請求項7に記載の自動車キャニスタ。
- 自動車キャニスタ用活性炭素繊維シートの製造方法であって、
リン酸系触媒若しくは有機スルホン酸系触媒のいずれか一方または双方を保持させた前駆体繊維シートを、炭化及び賦活化することを含み、
前記前駆体繊維シートはセルロース系繊維を含み、前記繊維の繊維径が4.0dtex以上である、
前記製造方法。
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CA3151900A CA3151900C (en) | 2019-08-21 | 2020-08-20 | Activated carbon fiber sheet for motor vehicle canister |
MX2022002128A MX2022002128A (es) | 2019-08-21 | 2020-08-20 | Hoja de fibra de carbon activado para cartucho de vehiculo de motor. |
KR1020227009124A KR20220047374A (ko) | 2019-08-21 | 2020-08-20 | 자동차 캐니스터용 활성 탄소 섬유 시트 |
CN202080058141.2A CN114270026B (zh) | 2019-08-21 | 2020-08-20 | 汽车吸附罐用活性碳纤维片材 |
EP20855575.5A EP4019675A4 (en) | 2019-08-21 | 2020-08-20 | ACTIVATED CARBON FIBER SHEET FOR AUTOMOBILE CANISTER |
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