Flameproof polyphenylene ether formed body, flameproof polyphenylene ether fiber formed body, carbon formed body, activated carbon formed body, and method for manufacturing same
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Solution Overview
Problem
The use of phenolic fibers in manufacturing carbon and activated carbon fibers poses challenges due to the harmful effects of aldehydes on human health and the environment, and the fibers' brittleness and poor mechanical strength, which limits their application and processability, especially when increased in diameter. Additionally, existing methods for polyphenylene oxide fibers result in poor adsorption performance and high dry heat shrinkage rates.
Innovation Solution
A flameproof polyphenylene ether formed body with specific thermogravimetric and infrared spectroscopy characteristics is developed, allowing for the creation of carbon and activated carbon fibers with improved mechanical strength, reduced harmful gas emissions, and enhanced activation yield through a heat-treatment process that eliminates the need for harmful aldehydes and improves fiber diameter and processability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If phenolic fiber is used as precursor for carbon fiber and activated carbon fiber, then heat resistance and flame retardancy are improved, but harmful aldehydes affect human health and environment
Solution Approach 1:
The invention extracts and removes the harmful aldehyde component from the phenolic fiber manufacturing process by replacing it with a different chemical system (polyphenylene oxide-based resin) that achieves the same crosslinking and infusibilization effects without using formaldehyde or other aldehydes, thereby eliminating the harmful effects while maintaining heat resistance and flame retardancy
Solution Approach 2:
The invention changes the chemical composition parameters of the precursor material from phenolic resin to polyphenylene oxide-based resin, fundamentally altering the chemical pathway to achieve crosslinking without aldehydes, thus resolving the contradiction between maintaining reliable thermal properties and eliminating harmful chemical substances
2Productivity
If diameter of phenolic fiber is increased to reduce pressure loss, then adsorption performance is improved, but mechanical strength becomes insufficient
Solution Approach 1:
The invention uses a composite material system comprising polyphenylene oxide-based resin combined with specific crosslinking agents and inorganic fillers that provide reinforcement, enabling the production of large-diameter fibers with sufficient mechanical strength while maintaining high adsorption performance through optimized pore structure
Solution Approach 2:
The invention applies local quality enhancement by incorporating reinforcing agents and optimizing the microstructure distribution within the fiber, creating regions of enhanced mechanical strength that support larger fiber diameters without compromising overall structural integrity or adsorption capability
3Stability of the object's composition
If phenolic fiber is cured by three-dimensional crosslinking with aldehydes, then infusibilization is achieved, but flexibility deteriorates and brittleness increases
Solution Approach 1:
The invention changes the crosslinking chemistry from aldehyde-based to an alternative system using different crosslinking agents that produce a more flexible crosslinked network structure, maintaining infusibilization and dimensional stability while preserving fiber flexibility and processability through optimized crosslink density and structure
4Reliability
If polyphenylene oxide fiber is subjected to infusibilization treatment at 150-300°C, then flame resistance is improved, but dry heat shrinkage rate increases
Solution Approach 1:
The invention optimizes the infusibilization treatment parameters including temperature range, treatment time, and atmospheric conditions to achieve flame resistance with minimal heat shrinkage, and uses modified resin compositions with enhanced dimensional stability to reduce the shrinkage effect while maintaining flameproof properties
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a safer, more environmentally friendly method for producing carbon and activated carbon fibers with higher activation yield and improved mechanical properties, reducing harmful emissions and enabling larger fiber diameters for better processability and adsorption performance.
Implementation Method 1
heat-treating a polyphenylene ether formed body in air at 120° C. to 220° C. for 1 to 30 hours to infusibilize the polyphenylene ether formed body
Implementation Method 2
heat-treating the polyphenylene ether formed body in air at 220 to 250° C. for 0.1 to 20 hours to make the polyphenylene ether formed body flameproof
Implementation Method 3
carbonizing the flameproof polyphenylene ether formed body or the flameproof polyphenylene ether fiber formed body
Implementation Method 4
activating the flameproof polyphenylene ether formed body, the flameproof polyphenylene ether fiber formed body, or the carbon formed body
Data Source
AI summary
A flameproof polyphenylene ether formed body of the present invention has a minimum value (%/° C.) of −0.40%/° C. or more and −0.10%/° C. or less in a differential thermogravimetric curve in a range of 400° C. to 550° C.