Fire-resistant polyphenylene ether molded body, fire-resistant polyphenylene ether fiber molded body, carbon molded body, activated carbon molded body and methods for producing the same

Abstract

The minimum value (% / °C) of the differential thermogravimetric curve of the flame-resistant polyphenylene ether molded article of the present invention in the range of 400°C to 550°C is greater than or equal to -0.40% / °C and less than or equal to -0.10% / °C.

Description

Technical Field

[0001] The present invention relates to a refractory polyphenylene ether formed body, a refractory polyphenylene ether fiber formed body, a carbon formed body, an activated carbon formed body and methods for producing the same. Background Art

[0002] Phenolic resins are excellent in heat resistance, flame retardancy, and chemical resistance, and molded articles formed from phenolic resins are used in a wide range of fields, including the field of industrial materials. In addition, phenolic carbon fibers obtained by carbonizing phenolic fibers formed from phenolic resins, and phenolic activated carbon fibers obtained by activating phenolic fibers are used as functional materials in specific fields.

[0003] In general, novolac fibers are produced by melt-spinning novolak-type phenolic resins, reacting the resins with aldehydes such as formaldehyde in the presence of an acid catalyst, and rendering them infusible by three-dimensional crosslinking.

[0004] In addition, Patent Document 1 proposes a method for producing phenolic carbon fibers, which is characterized in that the phenolic fibers produced by the phenolic fiber production method are reacted with aldehydes such as formaldehyde under an acidic catalyst to perform three-dimensional crosslinking to prevent them from melting and then carbonizing them. The phenolic fiber production method includes a raw material mixing step of mixing phenolic resins and fatty acid amines, and a spinning step of spinning the raw material mixture obtained in the above raw material mixing step to obtain filaments; and a method for producing phenolic activated carbon fibers, which is characterized in that the phenolic carbon fibers produced by the above method are activated.

[0005] In addition, Patent Document 2 proposes a method for producing carbonaceous fibers, characterized in that fibers obtained from polyphenylene oxide as a raw material are subjected to a non-melting treatment in a temperature range of 150°C to 300°C, and then further fired in an inert gas atmosphere at high temperature or in a vacuum.

[0006] [Prior art literature]

[0007] [Patent Literature]

[0008] [Patent Document 1] Japanese Patent Publication No. 2012-52283

[0009] [Patent Document 2] Japanese Patent Publication No. 49-013431 Summary of the invention

[0010] [Problems to be solved by the invention]

[0011] Phenolic fibers are useful materials that can be used as precursors of carbon fibers or activated carbon fibers. However, harmful aldehydes are used in the production of phenolic fibers. From the perspectives of respiratory sensitization, skin sensitization, carcinogenicity, and acute hazard to the aquatic environment, the use of aldehydes such as formaldehyde has the problem of adverse effects on the human body and the environment. Therefore, a new precursor that can replace phenolic fibers is sought to be developed.

[0012] In addition, when phenolic fibers are used for filters and the like, in order to reduce pressure loss, phenolic fibers with thick fiber diameters (thickened) are required. However, phenolic fibers cured with aldehydes (three-dimensionally crosslinked without melting) lack flexibility and are extremely brittle. Therefore, when phenolic fibers are thickened, there is a problem that the production and weaving of woven fabrics, non-woven fabrics, felts, etc. lack the necessary mechanical strength and the processability deteriorates.

[0013] In Patent Document 1, when thickening phenolic fibers, fatty acid amides are mixed with phenolic resins in order to improve mechanical strength.

[0014] However, phenolic fibers containing fatty acid amides have the problem of generating harmful decomposition gases such as HCN and NOx during combustion, carbonization or activation.

[0015] Furthermore, in the method for producing carbonaceous fibers described in Patent Document 2, when fibers obtained from polyphenylene ether as a raw material are subjected to an infusibility treatment, there are problems such as large dry heat shrinkage, poor processability, and the occurrence of fusion bonding between fibers.

[0016] In addition, no research has been conducted on activated carbon formed bodies, activated carbon fibers, and activated carbon fiber formed bodies obtained by activating polyphenylene ether formed bodies, polyphenylene ether fibers, and polyphenylene ether fiber formed bodies. In particular, the current situation is that there is no material that satisfies the adsorption performance and activation yield important for activated carbon formed bodies, activated carbon fibers, and activated carbon fiber formed bodies. In particular, when the activation yield is low, in the manufacture of activated carbon formed bodies, activated carbon fibers, and activated carbon fiber formed bodies, there is a problem of requiring a large amount of polyphenylene ether fiber formed bodies composed of polyphenylene ether formed bodies, polyphenylene ether fibers, and polyphenylene ether fibers, and a large amount of excess decomposition gas, carbon dioxide, etc. will be released into the atmosphere during the activation treatment.

[0017] In view of the above problems, an object of the present invention is to provide a refractory polyphenylene ether molded body, a carbon molded body, an activated carbon molded body, and a method for producing the same, which have a high activation yield during activation treatment and can be produced safely.

[0018] The present inventors have conducted intensive studies and, as a result, have found a flame-resistant polyphenylene ether molded body that can solve the above-mentioned problems and have completed the present invention. The present invention is as follows.

[0019] The present invention provides a flame-resistant polyphenylene ether molded body, characterized in that the minimum value (% / °C) of the differential thermogravimetric curve in the range of 400°C to 550°C is -0.40% / °C or more and -0.10% / °C or less.

[0020] The flame-resistant polyphenylene ether molded article preferably has a wavelength of 1660 cm-1 derived from C═O stretching vibration in infrared spectrophotometry. -1 The absorbance height C is related to the wave number 1600cm of the skeleton vibration caused by the stretching between carbon and carbon in the benzene ring. -1 The absorbance height ratio (C / B) of the absorbance height B is greater than or equal to 0.40 and less than or equal to 0.75.

[0021] The flame-resistant polyphenylene ether molded article preferably has a moisture content of 3.5% or less.

[0022] The flame resistant polyphenylene ether molded article is preferably a flame resistant polyphenylene ether fiber.

[0023] The flame-resistant polyphenylene ether fiber preferably has a fiber diameter of 10 μm or more and 200 μm or less.

[0024] Furthermore, the present invention provides a flame resistant polyphenylene ether fiber formed body comprising the flame resistant polyphenylene ether fiber.

[0025] The flame resistant polyphenylene ether fiber formed body is preferably a flame resistant polyphenylene ether nonwoven fabric.

[0026] In addition, the present invention is a carbon formed body after the above-mentioned refractory polyphenylene ether formed body or the above-mentioned refractory polyphenylene ether fiber formed body is carbonized. Here, when the above-mentioned refractory polyphenylene ether formed body is the above-mentioned refractory polyphenylene ether fiber, the carbonized carbon formed body can also be called a carbon fiber. In addition, the carbon formed body after the above-mentioned refractory polyphenylene ether fiber formed body is carbonized can also be called a carbon fiber formed body.

[0027] In addition, the present invention is an activated carbon formed body after the above-mentioned refractory polyphenylene ether molded body, the above-mentioned refractory polyphenylene ether fiber molded body, or the above-mentioned carbon molded body is activated. In addition, the activated carbon formed body after the above-mentioned refractory polyphenylene ether fiber or the carbon fiber formed body after the above-mentioned refractory polyphenylene ether fiber is carbonized and activated can also be called activated carbon fiber. In addition, the activated carbon formed body after the above-mentioned refractory polyphenylene ether fiber molded body or the carbon fiber molded body formed body after the above-mentioned refractory polyphenylene ether fiber molded body is carbonized and activated can also be called activated carbon fiber molded body.

[0028] In addition, the present invention is a method for producing a flame-resistant polyphenylene ether molded body, characterized in that it includes a step of heat treating the polyphenylene ether molded body in air at 120°C to 220°C for 1 to 30 hours without melting it, and a step of heat treating it in air at 220°C to 250°C for 0.1 to 20 hours to render it flame-resistant.

[0029] In addition, the present invention relates to a method for producing a carbon molded body, which includes the step of carbonizing the refractory polyphenylene ether molded body produced by the above-mentioned manufacturing method. In addition, the present invention relates to a method for producing a carbon molded body, which includes the step of carbonizing the above-mentioned refractory polyphenylene ether molded body and the above-mentioned refractory polyphenylene ether fiber molded body. Here, in the case of refractory polyphenylene ether fibers, it is also possible to make a method for producing carbon fibers including the step of carbonizing the above-mentioned refractory polyphenylene ether fibers. In addition, in the case of refractory polyphenylene ether fiber molded bodies, it is also possible to make a method for producing a carbon fiber molded body including the step of carbonizing the above-mentioned refractory polyphenylene ether fiber molded bodies.

[0030] In addition, the present invention relates to a method for producing an activated carbon molded body, which includes the step of activating a refractory polyphenylene ether molded body produced by the above-mentioned production method or a carbon molded body produced by the above-mentioned production method. In addition, the present invention relates to a method for producing an activated carbon molded body, which includes the step of activating the above-mentioned refractory polyphenylene ether molded body, the above-mentioned refractory polyphenylene ether fiber molded body or the above-mentioned carbon molded body.

[0031] Here, in the case of the above-mentioned refractory polyphenylene ether fiber or the above-mentioned carbon fiber, it is also possible to make a method for producing an activated carbon fiber including a step of activating the above-mentioned refractory polyphenylene ether fiber or the above-mentioned carbon fiber. In addition, in the case of the above-mentioned refractory polyphenylene ether fiber formed body or the above-mentioned carbon fiber formed body, it is also possible to make a method for producing an activated carbon fiber formed body including a step of activating the above-mentioned refractory polyphenylene ether fiber formed body or the above-mentioned carbon fiber formed body.

[0032] [Effects of the Invention]

[0033] In the thermogravimetric measurement of the refractory polyphenylene ether molded body of the present invention in a nitrogen atmosphere, the minimum value (% / °C) of the differential thermogravimetric curve in the range of 400°C to 550°C is -0.40% / °C or more and -0.10% / °C or less. Since the refractory polyphenylene ether molded body of the present invention has the above-mentioned characteristics, the activation yield during the activation treatment becomes high. Furthermore, the refractory polyphenylene ether molded body of the present invention has the advantage that no harmful decomposition gas is generated during combustion. In addition, the refractory polyphenylene ether molded body of the present invention has the advantage that no harmful substances such as aldehydes that have adverse effects on the human body and the environment are required in its manufacture. The refractory polyphenylene ether molded body of the present invention can be suitably used as a new precursor of a carbon molded body or an activated carbon molded body with excellent adsorption performance to replace phenolic resins and phenolic fibers. In addition, since the activation yield of the activated carbon molded body of the present invention is sufficiently high during the activation treatment, it can be manufactured from a small amount of refractory polyphenylene ether molded body, and has the advantage that the emission of decomposition gas, carbon dioxide, etc. is small. BRIEF DESCRIPTION OF THE DRAWINGS

[0034]

Figure 1

[0035] Reference numerals

[0036] 1: Hopper

[0037] 2: Extruder

[0038] 3: Gear pump

[0039] 4: Filter

[0040] 5: Spinning nozzle

[0041] 6: Filter material

[0042] 7: Insulation space

[0043] 8: Introduction of inert gas

[0044] 9: Heating torch. DETAILED DESCRIPTION

[0045] 1. Fire-resistant polyphenylene ether molded body

[0046] The flame-resistant polyphenylene ether molded article of the present invention has a minimum value (% / °C) of a differential thermogravimetric curve in the range of 400°C to 550°C of -0.40% / °C to -0.10% / °C.

[0047] The minimum value of the differential thermogravimetric curve in the range of 400°C to 550°C shows a larger value by subjecting the polyphenylene ether molded body to flame retardant treatment. In the present invention, thermogravimetric measurement is performed in a nitrogen atmosphere, and the peak with the smallest value of the differential thermogravimetric curve in the range of 400°C to 550°C is taken as the minimum value.

[0048] From the viewpoint of improving the carbonization yield and activation yield, the lower limit of the minimum value of the differential thermogravimetric curve is preferably -0.35% / °C or more, and more preferably -0.30% / °C or more. In addition, when the lower limit of the minimum value of the differential thermogravimetric curve is less than -0.40% / °C, when the flame-resistant polyphenylene ether molded body is activated, tar-like decomposition gas is easily generated. The decomposition gas will hinder the activation and reduce the activation yield.

[0049] From the viewpoint of improving the mechanical strength of the molded body and the fiber, the carbonization yield, and the activation yield, the upper limit of the minimum value of the differential thermogravimetric curve is preferably -0.12% / °C or less, and more preferably -0.13% / °C or less. In addition, when the upper limit of the minimum value of the differential thermogravimetric curve is greater than -0.10% / °C, crosslinking of the refractory polyphenylene ether molded body further proceeds, and when the refractory polyphenylene ether molded body is activated, activation inside the pores is difficult to proceed, and the activation yield becomes low.

[0050] The flame-resistant polyphenylene ether molded article of the present invention has a wave number of 1660 cm-1 derived from C=O stretching vibration in the measurement based on infrared spectrophotometry. -1 The absorbance height C is related to the wave number 1600cm of the skeleton vibration caused by the stretching between carbon and carbon in the benzene ring. -1 The absorbance height ratio (C / B) of the absorbance height B is greater than or equal to 0.40 and less than or equal to 0.75.

[0051] The wave number from the second C=O stretching vibration is 1660 cm -1 The peak of is formed by subjecting the polyphenylene ether molded body to flame retardant treatment. In the present invention, in consideration of the measurement error based on infrared spectrophotometry, the peak derived from C=O stretching vibration is set to a wavelength of 1660±10 cm -1 The peak of the range.

[0052] From the viewpoint of improving heat resistance, carbonization yield, and activation yield, the lower limit of the absorbance height ratio (C / B) is preferably 0.45 or more, and more preferably 0.50 or more. From the viewpoint of improving the mechanical strength of the molded body and fiber, the carbonization yield, and activation yield, the upper limit of the absorbance height ratio (C / B) is preferably 0.73 or less, and more preferably 0.70 or less.

[0053] From the viewpoint of reducing the excess heating energy during carbonization and activation, the fire-resistant polyphenylene ether molded article of the present invention preferably has a moisture content of 3.5% or less, more preferably 3.0% or less. The lower limit of the moisture content is not particularly limited, but is preferably 0% or more.

[0054] 2. Fire-resistant polyphenylene ether fiber

[0055] As the above-mentioned refractory polyphenylene ether molded body, representative examples include refractory polyphenylene ether fibers and refractory polyphenylene ether films. The above-mentioned refractory polyphenylene ether fibers may be long fibers or short fibers. Hereinafter, as an example of the refractory polyphenylene ether molded body of the present invention, refractory polyphenylene ether fibers are described.

[0056] When the flame-resistant polyphenylene ether formed body of the present invention is a flame-resistant polyphenylene ether fiber, its fiber diameter is preferably 200 μm or less, more preferably 140 μm or less, further preferably 100 μm or less, and further preferably 80 μm or less. By having a fiber diameter within the above range, fabrics, knitted fabrics, nonwoven fabrics, etc. can be processed into various shapes. In addition, the lower limit of the fiber diameter is not particularly limited, but from the viewpoint of coarsening, it is preferably 10 μm or more, more preferably 15 μm or more, and further preferably 25 μm or more.

[0057] The tensile strength of the flame-resistant polyphenylene ether fiber of the present invention is not particularly limited, but is preferably 0.3 cN / dtex or more, more preferably 0.6 cN / dtex or more, and preferably 50 cN / dtex or less, more preferably 30 cN / dtex or less, from the viewpoint of improving mechanical strength and processability.

[0058] The elongation at break of the flame-resistant polyphenylene ether fiber of the present invention is not particularly limited, but is preferably 5% or more, more preferably 10% or more, and is preferably 160% or less, more preferably 130% or less, from the viewpoint of improving mechanical strength and processability.

[0059] 3. Fire-resistant polyphenylene ether fiber forming body

[0060] The flame-resistant polyphenylene ether fiber formed body of the present invention is a formed body containing the flame-resistant polyphenylene ether fiber. As the flame-resistant polyphenylene ether fiber formed body, for example, flame-resistant polyphenylene ether fabric, flame-resistant polyphenylene ether knitted fabric and flame-resistant polyphenylene ether non-woven fabric can be listed. The flame-resistant polyphenylene ether non-woven fabric can be a long fiber non-woven fabric or a short fiber non-woven fabric.

[0061] The weight of the flame-resistant polyphenylene ether fiber forming body (such as nonwoven fabric) is not particularly limited and can be appropriately determined according to the application. However, from the viewpoint of processability, adsorption characteristics and physical properties of the manufactured carbon fiber forming body or activated carbon fiber forming body, it is preferably 20 g / m 2 More preferably 50g / m 2 More preferably, 100 g / m 2 Above, preferably 1200g / m 2 Below, more preferably 900g / m 2 Below, more preferably 600g / m 2 the following.

[0062] The thickness of the flame-resistant polyphenylene ether fiber forming body (such as nonwoven fabric, etc.) is not particularly limited and can be appropriately determined according to the application, but from the viewpoint of processability, adsorption characteristics and physical properties of the manufactured carbon fiber forming body or activated carbon fiber forming body, it is preferably 0.1 to 12.0 mm, and more preferably 0.2 to 6.0 mm.

[0063] The dry heat shrinkage of the flame-resistant polyphenylene ether fiber forming body (such as nonwoven fabric) at 900°C is not particularly limited, but is preferably 60% or less, more preferably 50% or less from the viewpoint of shape stability. In addition, the lower limit of the dry heat shrinkage is not particularly limited, but is usually 0% or more, and there are also cases of 5% or more, 10% or more, or 20% or more.

[0064] The flame-resistant polyphenylene ether molded body or flame-resistant polyphenylene ether fiber molded body of the present invention is a molded body subjected to flame-resistant treatment on a polyphenylene ether molded body or a polyphenylene ether fiber molded body (e.g., a fabric, a knitted fabric, a nonwoven fabric, etc.). The polyphenylene ether fiber molded body is a molded body containing polyphenylene ether fibers. The flame-resistant polyphenylene ether molded body is described below.

[0065] 4. Polyphenylene ether molded body

[0066] <Polyphenylene ether component>

[0067] The polyphenylene ether molded article used in the present invention is a molded article containing a polyphenylene ether component.

[0068] The polyphenylene ether component is not particularly limited, and examples thereof include those commonly used in the art. Specifically, examples thereof include homopolymers having repeating units represented by the following general formula (1), copolymers containing two or more different repeating units of the general formula (1), or copolymers having repeating units of the general formula (1) and repeating units other than the general formula (1).

[0069]

Chemical formula 1

[0070]

[0071] As R in the above general formula (1) 1 , R 2 , for example, a hydrogen atom, an alkyl group having 1 to 10 carbon atoms, such as a methyl group, an ethyl group, a propyl group, an isopropyl group, a n-butyl group, an isobutyl group, a tert-butyl group, a pentyl group, a cyclopentyl group, a hexyl group, a cyclohexyl group, an octyl group, a decyl group, an aryl group having 6 to 10 carbon atoms, such as a phenyl group, a 4-methylphenyl group, a 1-naphthyl group, a 2-naphthyl group, an aralkyl group having 7 to 10 carbon atoms, such as a benzyl group, a 2-phenylethyl group, a 1-phenylethyl group, and the like.

[0072] When the hydrocarbon group has a substituent, examples of the substituent include a halogen atom such as a fluorine atom, an alkoxy group such as a methoxy group, etc. Specific examples of the hydrocarbon group having a substituent include a trifluoromethyl group, etc.

[0073] Among them, as R 1 , R 2 , preferably a hydrogen atom or a methyl group, more preferably a hydrogen atom.

[0074] As R in the above general formula (1) 3 , for example, there can be mentioned a hydrogen atom, an alkyl group having 1 to 10 carbon atoms, such as a methyl group, an ethyl group, a propyl group, an isopropyl group, a n-butyl group, an isobutyl group, a tert-butyl group, a pentyl group, a cyclopentyl group, a hexyl group, a cyclohexyl group, an octyl group, a decyl group, an aryl group having 6 to 10 carbon atoms, such as a phenyl group, a 4-methylphenyl group, a 1-naphthyl group, a 2-naphthyl group, and an aralkyl group having 7 to 10 carbon atoms, such as a benzyl group, a 2-phenylethyl group, a 1-phenylethyl group, and the like.

[0075] When the hydrocarbon group has a substituent, examples of the substituent include halogen atoms such as a fluorine atom and alkoxy groups such as a methoxy group. Specific examples of the hydrocarbon group having a substituent include a trifluoromethyl group.

[0076] Among them, as R 3 , preferably methyl.

[0077] Specific examples of the repeating unit of the general formula (1) include repeating units derived from 2,6-dimethyl-1,4-phenylene ether, 2,6-diethyl-1,4-phenylene ether, 2-methyl-6-ethyl-1,4-phenylene ether, and 2,6-dipropyl-1,4-phenylene ether. Among them, repeating units derived from 2,6-dimethyl-1,4-phenylene ether are preferred.

[0078] In addition, the polyphenylene ether may contain repeating units other than the general formula (1) as long as the effect of the present invention is not impaired. The content of repeating units other than the general formula (1) is not particularly limited as long as the effect of the present invention is not impaired. For example, the content of the repeating units in the copolymer is preferably 5 mol% or less, and more preferably not contained.

[0079] The molecular weight of the polyphenylene ether is not particularly limited, but the weight average molecular weight (Mw) is preferably 40,000 to 100,000, and more preferably 50,000 to 80,000. In addition, the number average molecular weight (Mn) is preferably 7,000 to 30,000, and more preferably 8,000 to 20,000. In addition, the molecular weight distribution (Mw / Mn) is preferably 3.5 to 8.0, and more preferably 4.0 to 6.0.

[0080] Examples of methods for obtaining a polyphenylene ether molded body include a method comprising a step of melting the polyphenylene ether (when the molded body is a fiber, for example, melt spinning, etc.), and a method comprising a step of dissolving the polyphenylene ether in an organic solvent (when the molded body is a fiber, for example, dry spinning, wet spinning, etc.).

[0081] <Components other than polyphenylene ether component>

[0082] The polyphenylene ether molded article used in the present invention may contain resin components other than the above-mentioned polyphenylene ether components. Examples of resin components other than polyphenylene ether include polyolefins such as polystyrene, polyethylene, and polypropylene; polyamides such as polyamide 4, polyamide 6, polyamide 10, polyamide 11, polyamide 66, polyamide 6T, and polyamide 6T / 11; polyesters such as polyethylene terephthalate and polybutylene terephthalate; and polycarbonate. Among them, the content is preferably 5% by mass or less, more preferably 2% by mass or less, and even more preferably not contained (0% by mass).

[0083] Furthermore, additives such as lubricants, plasticizers, antioxidants, ultraviolet absorbers, matting agents, and antistatic agents may be added to the polyphenylene ether molded article used in the present invention within a range that does not impair the effects of the present invention.

[0084] <Polyphenylene ether content>

[0085] In addition, in the polyphenylene ether molded article used in the present invention, the content of polyphenylene ether in all the components forming the molded article is preferably 95 mass % or more, more preferably 98 mass % or more, and further preferably substantially only polyphenylene ether (100 mass %). When the content of the polyphenylene ether in the molded article is within the above range, excellent mechanical strength and processability can be obtained.

[0086] <Method for producing polyphenylene ether fiber>

[0087] Hereinafter, a method for producing polyphenylene ether fibers will be described as an example of a polyphenylene ether molded article.

[0088] Polyphenylene ether fibers can be produced by various production methods such as melt spinning, dry spinning, wet spinning, etc. Among them, melt spinning is preferred because productivity can be improved.

[0089] Display spinning device Figure 1 An example of producing polyphenylene ether fibers by melt spinning is described below. Figure 1 The hopper 1 is put into an extruder 2 having a barrel and a screw, and the molten polyphenylene ether is discharged at a metered discharge rate by a gear pump 3, and is discharged from a spinning nozzle 5 through a filter 4 composed of a metal nonwoven fabric, etc., to obtain fibers. In addition, it is preferred to set a filter material 6 composed of fine sand, etc. on the filter 4. By setting the filter material 6, foreign matter can be removed in advance, and clogging of the filter 4 can be prevented, etc., which is preferred.

[0090] The hole diameter of the spinning nozzle, the discharge rate per hole of the spinning nozzle, and the spinning speed are not particularly limited and may be appropriately set according to the required fineness and the like.

[0091] The polyphenylene ether as a raw material may be a homopolymer having a repeating unit of the general formula (1) or a copolymer containing two or more different repeating units of the general formula (1), or a copolymer having a repeating unit of the general formula (1) and a repeating unit other than the general formula (1). The content of the repeating unit other than the general formula (1) in the copolymer may be the above-mentioned content. Among them, a homopolymer having a repeating unit of the general formula (1) is preferred.

[0092] Specific examples of the homopolymer having a repeating unit of the general formula (1) include poly(2,6-dimethyl-1,4-phenylene ether), poly(2,6-diethyl-1,4-phenylene ether), poly(2-methyl-6-ethyl-1,4-phenylene ether), and poly(2,6-dipropyl-1,4-phenylene ether). Among them, poly(2,6-dimethyl-1,4-phenylene ether) is preferred.

[0093] As the poly(2,6-dimethyl-1,4-phenylene ether), commercially available products can be used as appropriate, and specific examples thereof include PPO640, PPO646, and PPOSA120 manufactured by SABIC Innovative Plastics, and Xyron (registered trademark) S201A and Xyron (registered trademark) S202A manufactured by Asahi Kasei Chemicals Corporation.

[0094] The glass transition temperature of the polyphenylene ether component having a high glass transition temperature is preferably 170° C. or higher, more preferably 200° C. or higher, and further preferably 210° C. or higher. In addition, the upper limit of the glass transition temperature is not particularly limited, but is preferably 230° C. or lower. By making the glass transition temperature of the polyphenylene ether as a raw material within the above range, a polyphenylene ether fiber and a molded body having high heat resistance can be obtained.

[0095] In the polyphenylene ether component as a raw material, the content of the polyphenylene ether having a glass transition temperature of 170°C or higher is preferably 70% by mass or higher, more preferably 80% by mass or higher, and further preferably 90% by mass or higher. In addition, the upper limit of the content of the polyphenylene ether having a glass transition temperature of 170°C or higher is not particularly limited, but is preferably 100% by mass or lower. In the present invention, since the obtained polyphenylene ether melt-extrusion molded product has excellent mechanical strength, heat resistance, chemical resistance, flame retardancy, etc., it is preferred that the polyphenylene ether having a high glass transition temperature (i.e., high molecular weight) is contained within the above range.

[0096] In addition, the resin component and additive other than the polyphenylene ether component can also be contained together with the polyphenylene ether as the raw material. The resin component and additive other than the polyphenylene ether component are as described above. In addition, the content of the resin component other than the polyphenylene ether component is preferably less than 5% by mass in the raw material, more preferably less than 2% by mass, and further preferably does not contain (0% by mass).

[0097] As the extruder having the barrel and the screw, a single-screw extruder or a twin-screw extruder commonly used in the art can be used. In the present invention, it is preferable to use a twin-screw extruder.

[0098] If the temperature in the cylinder is too low, the fluidity of the resin will be poor, while if it is too high, the fluidity will be improved but foaming will occur due to thermal decomposition of the resin. Therefore, it is necessary to select a balanced processing temperature.

[0099] <Polyphenylene ether nonwoven fabric>

[0100] As an example of a polyphenylene ether fiber formed body, a polyphenylene ether nonwoven fabric is described. The polyphenylene ether nonwoven fabric is a nonwoven fabric containing the above-mentioned polyphenylene ether fiber. For the raw materials used for the polyphenylene ether nonwoven fabric, the same raw materials as those mentioned above can be used for the polyphenylene ether fiber. The method for manufacturing the polyphenylene ether nonwoven fabric is not particularly limited, and a method commonly used in the art can be appropriately adopted. As a method for manufacturing the nonwoven fabric, for example, a spunbond method, a meltblown method, a spunlace method, a needle punch method, a thermal bonding method, a chemical bonding method, etc. can be cited. Among them, the needle punch method is preferred.

[0101] 5. Method for producing a fire-resistant polyphenylene ether formed body (or a fire-resistant polyphenylene ether fiber formed body)

[0102] The flame-resistant polyphenylene ether molded body (or flame-resistant polyphenylene ether fiber molded body) of the present invention can be produced by heat-treating the polyphenylene ether molded body (or polyphenylene ether fiber molded body) in air at 120 to 220° C. for 1 to 30 hours to render it infusible (infusible treatment), and further heat-treating it in air at 220 to 250° C. for 0.1 to 20 hours to render it flame-resistant (flame-resistant treatment). Here, in air refers to an environment that is not particularly adjusted.

[0103] The treatment temperature of the non-melting treatment is 120 to 220° C., preferably 140 to 220° C., and more preferably 150 to 210° C. In addition, the treatment time is 1 to 30 hours, preferably 5 to 28 hours, and more preferably 10 to 25 hours. By setting the above treatment temperature and treatment time, a non-melting structure is formed in the polyphenylene ether molded body (or polyphenylene ether fiber molded body).

[0104] The treatment temperature of the refractory treatment is 220 to 250° C., preferably 225 to 245° C. In addition, the treatment time is 0.1 to 20 hours, preferably 0.2 to 10 hours. In addition, the heating rate before reaching the treatment temperature is preferably 0.01 to 2° C. / minute, more preferably 0.1 to 1° C. / minute. By setting the above-mentioned treatment temperature, treatment time and heating rate, a refractory structure is formed in the polyphenylene ether molded body (or polyphenylene ether fiber molded body).

[0105] 6. Method for producing carbon compact

[0106] The carbon formed body of the present invention can be produced by carbonizing the above-mentioned refractory polyphenylene ether formed body or the above-mentioned refractory polyphenylene ether fiber formed body.

[0107] Carbonization can be carried out by a known method, specifically, by heating in the presence of an inert gas. Examples of the inert gas include nitrogen and argon. The heating temperature is usually 400 to 2500° C., preferably 800 to 1500° C. The heating time is usually 0.2 to 10 hours, preferably 0.5 to 5 hours.

[0108] 7. Method for producing activated carbon molded body

[0109] The activated carbon molded body of the present invention can be produced by activating the above-mentioned refractory polyphenylene ether molded body, the above-mentioned refractory polyphenylene ether fiber molded body, or the above-mentioned carbon molded body.

[0110] The activation can be performed by a known method, and specific examples thereof include a gas activation method and a chemical activation method. However, from the viewpoint of improving the mechanical strength and purity of the molded body, the gas activation method is preferred.

[0111] In the gas activation method, the activating gas is brought into contact with the above-mentioned refractory polyphenylene ether molded body or the above-mentioned carbon molded body to activate. As the activating gas, for example, water vapor, air, carbon monoxide, carbon dioxide, hydrogen chloride, oxygen or a mixed gas thereof can be cited. The temperature during gas activation is usually 600 to 1200° C., preferably 800 to 1000° C. The time during gas activation is usually 0.2 to 10 hours, preferably 0.5 to 3 hours.

[0112] In the chemical activation method, alkali metal hydroxides such as sodium hydroxide and potassium hydroxide; alkaline earth metal hydroxides such as calcium hydroxide; inorganic acids such as boric acid, phosphoric acid, sulfuric acid and hydrochloric acid; inorganic salts such as zinc chloride are brought into contact with the above-mentioned refractory polyphenylene ether molded body or the above-mentioned carbon molded body to activate. The temperature during chemical activation is usually 400 to 1000° C., preferably 500 to 800° C. The time during chemical activation is usually 0.2 to 5 hours, preferably 0.5 to 5 hours.

[0113] The BET specific surface area of ​​the activated carbon formed body of the present invention is preferably 500 m 2 / g or more, more preferably 650m 2 / g or more, more preferably 800m 2 / g or more, more preferably 1000m 2 / g or more, more preferably 1200m 2 / g or more, more preferably 1400m 2 The upper limit of BET specific surface area is usually 3000m2 / g or less, there are also 2500m 2 / g or less.

[0114] When the activated carbon molded body of the present invention is an activated carbon fiber, its fiber diameter may be larger than the fiber diameter of the conventional activated carbon fiber, preferably 11 μm or more, more preferably 17 μm or more, further preferably 22 μm or more, further preferably 30 μm or more. The upper limit of the fiber diameter is usually 150 μm or less, and there are also cases where it is 100 μm or less or 70 μm or less.

[0115] When the activated carbon formed body of the present invention is an activated carbon fiber nonwoven fabric, its gram weight can be appropriately adjusted according to the application, and is preferably 15 g / m 2 More preferably 40g / m 2 More preferably, 100 g / m 2 More preferably, 150 g / m 2 More than, preferably 1000g / m 2 Below, more preferably 700g / m 2 Below, more preferably 500g / m 2 the following.

[0116] From the viewpoint of mechanical strength, the tensile strength (longitudinal and transverse) of the activated carbon fiber nonwoven fabric of the present invention is preferably greater than 0.5 N / cm, more preferably greater than 1.0 N / cm, and further preferably greater than 1.5 N / cm. The upper limit of the tensile strength is usually less than 10 N / cm, and there are also cases where it is less than 5 N / cm or less than 3 N / cm.

[0117] From the viewpoint of mechanical strength, the elongation at break (longitudinal and transverse directions) of the activated carbon fiber nonwoven fabric of the present invention is preferably 2% or more, more preferably 4% or more. The upper limit of the elongation at break is usually 15% or less, and may be 10% or less.

[0118] The pressure loss coefficient of the activated carbon fiber nonwoven fabric of the present invention is preferably 0.60 mmAq·s / cm 2 Below, more preferably 0.40 mmAq·s / cm 2 Below, more preferably 0.30 mmAq·s / cm 2 The lower limit of the pressure loss coefficient is usually 0.10 mmAq·s / cm 2 above.

[0119] The carbon formed body, carbon fiber, carbon fiber formed body, activated carbon formed body, activated carbon fiber and activated carbon fiber formed body of the present invention can be used, for example, for the recovery of organic solvents such as dichloromethane; the removal of chlorine compounds such as trihalomethanes; the removal of odorous gases, harmful gases such as NOx and SOx; the removal of heavy metals such as lead, arsenic and manganese, etc.

[0120] [Example]

[0121] The present invention will be described in more detail below with reference to Examples and Comparative Examples, but the present invention is not limited to the following Examples. In addition, the evaluation methods of physical properties and the like are as follows.

[0122] (1) Minimum value of differential thermogravimetric curve

[0123] Using a thermal analysis device (product name STA7000, manufactured by Hitachi High-Technologies Corporation), 10 mg of the sample was placed in a platinum pan, and the temperature was raised from 35°C to 1050°C at 10°C / min under a nitrogen atmosphere for thermogravimetric measurement, and a thermogravimetric change curve (TG curve) was obtained with the x-axis being the temperature (°C) and the y-axis being the thermogravimetric change rate (%). The TG curve was further differentiated to obtain a differential thermogravimetric curve (DTG curve, unit: % / °C). When the thermogravimetric value of the sample increases, the differential thermogravimetric curve shows a positive value, and when the thermogravimetric value of the sample decreases, it shows a negative value. In the range of 400°C to 550°C, the peak with the minimum value of the differential thermogravimetric curve is obtained as the minimum value (% / °C) of the differential thermogravimetric curve.

[0124] (2) Fiber diameter

[0125] The fiber diameters of the polyphenylene ether fibers, flame-resistant polyphenylene ether fibers, and Novoloid fibers were determined by observing microscope images using a scanning electron microscope (product name: SU1510, manufactured by Hitachi High-Technologies Corporation), reading 100 points from the microscope images, and averaging the read fiber diameters.

[0126] The fiber diameters of carbon fibers and activated carbon fibers are measured according to the method described in JIS K-1477 7.3.1. The fiber diameter refers to the fiber diameter.

[0127] (3) Absorbance height ratio (C / B)

[0128] The nonwoven fabrics obtained in Examples 1 and 2 and Comparative Examples 1 to 6 were thinly stretched to prepare measurement samples.

[0129] The absorbance of the obtained sample was measured by a microscopic transmission method under the following conditions using an infrared spectrophotometer (FTIR) (product name: 3100FT-IR / 600UMA, manufactured by Varian).

[0130] (Measurement conditions)

[0131] Field of view: 80μm×80μm

[0132] Measurement wavelength range: 400cm -1 Up to 4000cm -1

[0133] Cumulative times: 128 times

[0134] Decomposition: 4cm -1

[0135] Draw the wavelengths of the spectrum obtained from 1550 to 1480 cm -1 The minimum value and 1900~1800cm -1 The peak height (peak absorbance height) from the baseline was used to evaluate the minimum value of 1610-1590 cm -1 The peak height of 1670-1650cm is taken as the absorbance height B. -1 The peak height is taken as the absorbance height C and is defined by the value of C / B.

[0136] (4) Moisture content

[0137] The measurement was performed according to the method described in JIS L-1015 8.1.1. A sample was used which had been left to stand for 3 hours in an atmosphere of a temperature of 20° C. and a relative humidity of 65%.

[0138] (5) Weight reduction rate

[0139] Using a thermal analyzer STA7000, 10 mg of the sample was placed in a platinum pan, and the temperature was raised from 35°C to 1050°C at 10°C / min in a nitrogen atmosphere. The weight D (mg) at 150°C and the weight E (mg) at 900°C were measured, and the weight reduction rate (%) when the temperature was raised from 150°C to 900°C was calculated by the following formula. The smaller the value of this reduction rate, the better the heat resistance.

[0140] Weight reduction rate (%) = {(DE) ÷ D} × 100

[0141] (6) Combustion test

[0142] The measurement was carried out using the method described in BSS 7239 (Boeing Standards). Hydrogen cyanide (HCN), nitrogen oxides (NO+NO 2 ) concentration was determined by Draeger tube.

[0143] (7) BET specific surface area

[0144] 30 mg of the sample was taken, vacuum dried at 130°C for 12 hours and weighed, and measured using an automatic specific surface area measuring device GEMINI VII2390 (manufactured by Micromeritics). The amount of nitrogen adsorbed at the boiling point of liquid nitrogen (-195.8°C) was measured in the relative pressure range of 0.02 to 0.95, and the adsorption isotherm of the sample was prepared. Based on the results in the relative pressure range of 0.02 to 0.15, the BET specific surface area per unit weight (m 2 / g).

[0145] (8) Pressure loss coefficient

[0146] The nonwoven fabrics obtained in Examples 1 to 2 and Comparative Examples 1 to 6 were cut into a circular shape with a diameter of 27 mm, and a load was applied to a cylindrical tube with an inner diameter of 27 mm while filling the cylindrical tube so that the thickness became 30 mm and the filling density became 100 kg / m 3 Air at 25°C and 50% RH was supplied to the cylindrical tube at a linear velocity of 30 cm / s, and the static pressure difference (mmAq) between the primary and secondary sides of the filled nonwoven fabric was measured. The pressure loss coefficient (mmAq·s / cm 2 ).

[0147] Pressure loss coefficient = pressure loss ÷ line speed ÷ thickness

[0148] (9) Weight

[0149] Determine the mass per unit area of ​​the nonwoven fabric sample in g / m 2 The mass was measured in an absolutely dry state at 100° C. for 2 hours in an air atmosphere.

[0150] (10) Melt Adhesion

[0151] For the flame-resistant polyphenylene ether fiber nonwoven fabric (only Comparative Example 5 is a non-fire-resistant polyphenylene ether fiber nonwoven fabric) or the Novoloid fiber nonwoven fabric, it was visually confirmed whether the fibers of the sample were melt-adhered, and the fibers were further pulled by hand. If the fibers were not separated, it was judged that they were melt-adhered.

[0152] (11) Softness

[0153] For fire-resistant polyphenylene ether fiber nonwoven fabric (only Comparative Example 5 is non-fire-resistant polyphenylene ether fiber nonwoven fabric) or Novoloid fiber nonwoven fabric, prepare a sample with a width of 25 mm and a length of 50 mm, apply a load to the sample end until the sample is bent 90° in the length direction, and judge that the sample is soft if it does not break before reaching 90°.

[0154] (12) Toluene adsorption rate

[0155] According to JIS K1477 "7.8 Toluene adsorption performance", the toluene adsorption rate of the activated carbon fiber nonwoven fabric sample was measured.

[0156] (13) Activation yield

[0157] The weight F of the polyphenylene ether fiber nonwoven fabric or the Novoloid fiber nonwoven fabric before the non-melting treatment is measured in an absolutely dry state after being treated at 100°C for 2 hours in an air atmosphere. The weight G of the activated carbon fiber obtained by activating the fire-resistant polyphenylene ether fiber nonwoven fabric (only Comparative Example 5 is a non-fire-resistant polyphenylene ether fiber nonwoven fabric) or the Novoloid fiber nonwoven fabric is further measured in an absolutely dry state after being treated at 100°C for 2 hours in an air atmosphere. The activation yield is calculated by the following formula.

[0158] Activation yield (%) = {G ÷ F} × 100

[0159] Example 1

[0160] Poly(2,6-dimethyl-1,4-phenylene ether) (PPO640, glass transition temperature (Tg): 221°C, manufactured by SABIC Innovative Plastics) was extruded at 300°C using a twin-screw extruder manufactured by Technovel Co., Ltd. (product name: KZW15TW-30MG). A gear pump was set downstream of the extruder to measure the discharge rate of the polymer and extrude it into a nozzle maintained at 320°C. The polymer discharged from the nozzle was wound to obtain polyphenylene ether fibers. The obtained polyphenylene ether fibers were subjected to fiber curling processing, cut into a length of 76 mm, and passed through a needle punching machine with a needle density of 100 needles / cm 2 , needle depth 12mm (surface), 7mm (inside) conditions for surface and inside treatment to obtain polyphenylene ether nonwoven fabric. The obtained polyphenylene ether nonwoven fabric was heated from room temperature to 180°C at a heating rate of 10°C / min in air, maintained at 180°C, and heat treated for 24 hours. Further continue to heat from 180°C to 240°C in air at a heating rate of 0.2°C / min, and maintain a temperature of 240°C for 5 hours to obtain a flame-resistant polyphenylene ether nonwoven fabric. The evaluation results of the obtained flame-resistant polyphenylene ether nonwoven fabric are shown in Table 1. Furthermore, the obtained flame-resistant polyphenylene ether nonwoven fabric was activated in nitrogen, in the presence of 11vol.% water vapor, at 900°C for 1 hour to obtain an activated carbon fiber nonwoven fabric. The evaluation results of the obtained activated carbon fiber nonwoven fabric are shown in Table 1.

[0161] Example 2

[0162] The flame-resistant polyphenylene ether nonwoven fabric was obtained by the same method as in Example 1 except that the conditions of the flame-resistant treatment were changed to: heating from room temperature to 180°C at a heating rate of 10°C / min in air, maintaining a temperature of 180°C for 24 hours, and further continuing to heat from 180°C to 240°C at a heating rate of 0.2°C / min in air, maintaining a temperature of 230°C for 5 hours. The evaluation results are shown in Table 1.

[0163] Comparative Example 1

[0164] The refractory polyphenylene ether nonwoven fabric was obtained by the same method as in Example 1 except that the conditions of the refractory treatment were changed to: heating from room temperature to 200°C at a heating rate of 10°C / min in air and maintaining the temperature at 200°C for 5 hours. The activated carbon fiber nonwoven fabric obtained by activating the refractory polyphenylene ether obtained had a BET specific surface area almost the same as that of Example 1, but an extremely low activation yield. The evaluation results are shown in Table 1.

[0165] Comparative Example 2

[0166] The refractory polyphenylene ether nonwoven fabric was obtained by the same method as in Example 1, except that the conditions of the refractory treatment were changed to: heating from room temperature to 180°C at a heating rate of 10°C / min in air, maintaining a temperature of 180°C for 5 hours, and further continuing to heat from 180°C to 280°C at a heating rate of 0.2°C / min in air, and maintaining a temperature of 280°C for 5 hours. However, the activated carbon fiber nonwoven fabric obtained by activating the obtained refractory polyphenylene ether has a BET specific surface area that is almost the same as that of Example 1, but the activation yield is extremely low. The evaluation results are shown in Table 1.

[0167] Comparative Example 3

[0168] The refractory polyphenylene ether nonwoven fabric was obtained by the same method as in Example 1 except that the conditions of the refractory treatment were changed to: heating from room temperature to 200°C at a heating rate of 10°C / min in air and maintaining the temperature at 200°C for 24 hours. The activated carbon fiber nonwoven fabric obtained by activating the refractory polyphenylene ether obtained had a BET specific surface area almost the same as that of Example 1, but an extremely low activation yield. The evaluation results are shown in Table 1.

[0169] Comparative Example 4

[0170] The flame-resistant polyphenylene ether nonwoven fabric was obtained by the same method as in Example 1 except that the flame-resistant treatment conditions were changed to: heating from room temperature to 180°C at a heating rate of 10°C / min in air, further heating from 180°C to 250°C at a heating rate of 0.2°C / min in air, and maintaining a temperature of 250°C for 2 hours. However, the flame-resistant polyphenylene ether nonwoven fabric obtained had a width shrinkage of more than 70% before and after the flame-resistant treatment, was extremely lacking in softness, and did not maintain the shape of the nonwoven fabric. The evaluation results are shown in Table 1.

[0171] Comparative Example 5

[0172] The polyphenylene ether nonwoven fabric obtained in Example 1 was not subjected to flame retardant treatment and various evaluations were performed, and the results are shown in Table 1. Furthermore, the obtained polyphenylene ether nonwoven fabric was activated in nitrogen, in the presence of 11 vol.% water vapor, at 900°C for 1 hour, and as a result, the shape of the nonwoven fabric was not maintained due to fiber melting, and an activated carbon fiber nonwoven fabric was not obtained. The evaluation results are shown in Table 1.

[0173] Comparative Example 6

[0174] Novoloid fibers (Kynol, manufactured by Gunei Chemical Industry Co., Ltd.) with a fiber length of 70 mm and no curling were used and needled at a needle density of 100 strands / cm 2 The Novoloid fiber nonwoven fabric was obtained by treating the surface and the inside with the needle depth of 12 mm (surface) and 7 mm (inside). The Novoloid fiber used was made non-meltable by formaldehyde in its manufacture and contained 5% by mass of behenic acid amide. The evaluation results of the obtained Novoloid fiber nonwoven fabric are shown in Table 1. Furthermore, the obtained nonwoven fabric was activated in nitrogen, in the presence of 11 vol.% of water vapor, at 900°C for 1 hour to obtain an activated carbon fiber nonwoven fabric. The evaluation results are shown in Table 1.

[0175]

Table 1

[0176]

[0177] As shown in Table 1, the refractory polyphenylene ether fibers of Examples 1 to 2 have an extremely high activation yield compared to the refractory polyphenylene ether fibers of Comparative Examples 1 to 3, so activated carbon fibers can be produced from a small amount of polyphenylene ether fibers, and the decomposition gas, carbon dioxide, etc. generated during the activation treatment can be suppressed from being released into the atmosphere. Compared with the Novoloid fibers of Comparative Example 6, the refractory polyphenylene ether fibers of Examples 1 to 2 do not use harmful chemicals such as aldehydes in their production. In addition, the refractory polyphenylene ether fibers of Examples 1 to 2 do not produce harmful decomposition gases (HCN and NOx) when burned. In addition, since the activated carbon fiber nonwoven fabric obtained by activating the refractory polyphenylene ether nonwoven fabrics of Examples 1 to 2 has a larger fiber diameter and a smaller pressure loss coefficient than the activated carbon fiber nonwoven fabric obtained by activating the Novoloid nonwoven fabric of Comparative Example 6, it can be used for filters and the like. In addition, it can be seen that the refractory polyphenylene ether fibers of Examples 1 to 2 have a small difference in weight reduction rate at 150°C and 900°C, so they are excellent in heat resistance.

[0178]

Industrial Applicability

[0179] The flame-resistant polyphenylene ether fiber of the present invention is suitable for use as a precursor of carbon fiber or activated carbon fiber having excellent adsorption performance and physical properties, for example, to replace phenolic fiber.

Claims

1. A fire-resistant polyphenylene ether molded body, characterized in that: The minimum value of the differential thermogravimetric curve in the range of 400°C to 550°C is not less than -0.40% / °C and not more than -0.15% / °C, and the unit of the minimum value of the differential thermogravimetric curve is % / °C. In the measurement based on infrared spectrophotometry, the wave number derived from the stretching vibration of C=O is 1660 cm -1 The absorbance height C is related to the wave number 1600cm of the skeleton vibration caused by the stretching between carbon and carbon in the benzene ring. -1 The absorbance height ratio C / B of the absorbance height B is greater than or equal to 0.40 and less than or equal to 0.

75.

2. The flame-resistant polyphenylene ether molded body according to claim 1, wherein The moisture content is less than 3.5%.

3. The flame-resistant polyphenylene ether molded body according to claim 1, characterized in that: The flame-resistant polyphenylene ether formed body is a flame-resistant polyphenylene ether fiber.

4. The flame-resistant polyphenylene ether molded body according to claim 3, wherein The fiber diameter is 10 μm or more and 200 μm or less. 5 . A flame-resistant polyphenylene ether fiber formed body comprising the flame-resistant polyphenylene ether formed body according to claim 3 .

6. The flame-resistant polyphenylene ether fiber formed body according to claim 5, wherein: The flame-resistant polyphenylene ether fiber formed body is a flame-resistant polyphenylene ether nonwoven fabric.

7. A carbon formed body obtained by carbonizing the flame-resistant polyphenylene ether formed body according to claim 1 or 2, or the flame-resistant polyphenylene ether fiber formed body according to claim 5 or 6.

8. An activated carbon formed body obtained by activating the refractory polyphenylene ether formed body according to claim 1 or 2 or the refractory polyphenylene ether fiber formed body according to claim 5 or 6.

9. An activated carbon molded body obtained by activating the carbon molded body according to claim 7.

10. A method for producing a fire-resistant polyphenylene ether molded body, characterized in that: The production method comprises the steps of heat treating the polyphenylene ether molded body in air at 120° C. to 220° C. for 1 to 30 hours to prevent melting, and heat treating the polyphenylene ether molded body in air at 220° C. to 240° C. for 0.1 to 20 hours to make it fire-resistant. 11 . A method for producing a carbon molded body, the method comprising the step of carbonizing the flame-resistant polyphenylene ether molded body produced by the production method according to claim 10 . 12 . A method for producing an activated carbon molded body, the method comprising the step of activating a refractory polyphenylene ether molded body produced by the production method according to claim 10 or a carbon molded body produced by the production method according to claim 11 . 13 . A method for producing a carbon formed body, the method comprising the step of carbonizing the refractory polyphenylene ether formed body according to claim 1 or 2 or the refractory polyphenylene ether fiber formed body according to claim 6 or 7.

14. A method for producing an activated carbon molded body, the method comprising the step of activating the refractory polyphenylene ether molded body according to claim 1 or 2, or the refractory polyphenylene ether fiber molded body according to claim 5 or 6. 15 . A method for producing an activated carbon molded body, the method comprising the step of activating the carbon molded body according to claim 7 .

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