LUBRICATING AGENTS FOR THE PRODUCTION OF CARBON YARNS

Abstract: Lubricating agents for the production of carbon yarns comprise at least one organo polysiloxane of the general formula I wherein R¹, R², R³, R⁵ and R⁶ each represent a methyl group or ethyl group; R⁴ represents a hydrogen atom, or an alkyl group with 1 to 5 carbon atoms or a -a phenyl group; R⁷ and R⁸ each represents a methyl group, ethyl group or hydroxyl group, and m and n are integers such that the viscosity of the organo polysilosane at 25°C is in the range of 5 to 1000 centistokes, together with at least one amino-modified polysiloxane. The amino-modified polysiloxane is preferably of the general formula (II) where R⁹ represents a hydrogen atom, or an alkyl group with 1 to 5 carbon atoms or phenyl group; R¹⁰, R¹¹, R¹² and R¹³ each represent a methyl group or an ethyl group; R¹⁴ and R¹⁵ each represent a methyl group, an ethyl group or a hydroxyl group; R¹⁶, R¹⁷ and R¹⁸ each represent a hydrogen atom, (a methyl group or an ethyl group; X represents an alkylene group with 3 to 5 carbon atom; Y represents an alkylene group with 2 to 6 carbon atoms; and p and q are integers such that the viscosity at 25°C of the amino-modified polysiloxane is in the range of 10 to 10000 centistokes.

Description: This invention relates to lubricating agents for the production of carbon yarns and more particularly to lubricating agents which, when applied to acrylic fiber to be used as a precursor (hereinafter to be referred to simply as the precursor), prior to the oxidizing process, can not only give to said precursor superior filament separability and processability but also prevent adhesion (fusing) after the oxidizing process, thus making it possible to produce carbon yarns with superior physical characteristics. Carbon yarns are generally produced first by obtaining flame resistant yarns from a precursor by a process for making the product flame resistant (hereinafter referred simply as the oxidizing process) wherein the precursor is heated and burnt at 200 - 300°C in an oxidizing atmosphere and then by a carbonization process wherein carbonization takes place in an inert atmosphere at a high temperature over 700°C. In such a case, a lubricating agent is applied prior to the oxidizing process, and usually during the process in which the precursor is produced. In addition to the generally desired characteristics such as lubricity, antistatic capability and cohesion, however, it is important, in view of the aforementioned processes for the production of carbon yarns, that the lubricating agent to be used for this purpose provide superior filament separability and infusibility. In the past, phosphates of alkali metals, various cationic surfactants, polyoxyalkylene ethers, etc. have been generally used as lubricating agents of this type. Although they are generally acceptable regarding antistatic capability, cohesion and lubricity, they are inferior regarding filament separability because their basic tendency to decompose. In addition, they have the disadvantage of generating tar during the oxidizing process, or of vaporizing mostly during the initial period of the heating and causing adhesion between the fibers. In order to overcome this difficulty, many silicone type lubricating agents have been considered such as dimethyl polysiloxanes, phenylmethyl polysiloxanes, epoxy polysiloxanes, polyether polysiloxanes, amino polysiloxanes, etc. (Japanese Patents Tokko 51-12739, Tokko 52-24136, Tokkai 52-148227, etc). These silicone type lubricating agents, however, are not free of disadvantages. Dimethyl polysiloxanes and phenylmethyl polysiloxanes are thermally superior but are poor in precursor filament separability and in preventing adhesion in the oxidizing process. This may be because they do not contain polar groups in their molecules and hence their adsorption on the precursor surface is insufficient. Moreover, since they are non-polar, problems of fuzz and yarn breakage can occur easily, caused by static electricity. As for epoxy polysiloxanes, fiber-to-fiber fixing takes place due, for example, to the ring-opening polymerization of epoxy groups within their molecules and since they themselves generate tar, they are totally incapable of preventing fusion during the oxidizing process. Their presence, therefore, makes the problem worse instead of solving it. As for polyether polysiloxanes, the ether bonds within their molecules are thermally weak so that they become decomposed in most parts and diffuse away, failing to exercise their capability of preventing fusion. Moreover, the heat of their thermal decomposition becomes a cause of abnormal oxidizing reactions of the yarns. As for amino-modified polysiloxanes, although they have more favorable characteristics than the other conventional silicone type lubricating agents discussed above, they are not stable enough thermally nor are their filament separability and infusibility property sufficient. From the point of view of industrial applications, furthermore, they are by no means free from the problems of fuzz and yarn breakage caused by gummy deposits on various guiding means and rollers during the processing. Combination of dimethyl polysiloxanes with amino-modified polysiloxanes are known for other purposes. Thus, US-A 4 078 104 discloses a combination of an organopolysiloxane and an amino-modified polysiloxane for use as a release agent for bituminous products, although no reference is made to lubricant properties, in particular with reference to treatment of acrylic precursors for carbon fibre. US-A 3 717 575 discloses compositions containing at least three components: a mineral oil, a silione oil, and an amino-modified polyorganosiloxane, for use as lubricant in the knitting of Spandex fibres. It is therefore an object of this invention to eliminate the aforementioned disadvantages by providing lubricating agents which are superior in processability and filament separability in the subsequent processes including the production of precursors and the oxidizing process without causing problems such as fusion, and thus make it possible to produce high quality carbon yarns successfully. The above and the other objects of the present invention have been achieved by the present inventors who discovered that lubricating agents comprising specified types of organo polysiloxanes and amino-modified polysiloxanes are to be preferred. Detailed Description of the Invention This invention relates to a lubricating agent for a lubricating agent for an acrylic precursor yarn used in the manufacture of carbon fibres consisting of two lubricant ingredients:- (a) at least one organo polysiloxane of the general formula I (where R¹, R² and R³ all represent methyl groups; R⁴ represents a methyl group or a phenyl group; and m and n are integers) said organo polysiloxane having the viscosity at 25°C in the range of 5 to 1000 mm²/s (b) at least one amino-modified polysiloxane of general formula II (where R⁹ to R¹⁵ all represent methyl groups; R¹⁶, R¹⁷ and R¹⁸ each represent a hydrogen atom, a methyl group or an ethyl group; X represents an alkylene group with 3 to 5 carbon atoms; Y represents an alkylene group with 2 to 6 carbon atoms; and p and q are integers) said amino-modified polysiloxane have the viscosity at 25°C in the range of 10-10000 mm²/s and optionally, other non-lubricant co-ingredients. According to the present invention, organo polysiloxanes given by (I) must have viscosity in the range of 5 - 1000 square millimeters per second. (In the following, viscosity will always be presented by its value in units of mm²/s at 25°C). If viscosity is less than 5, this means that the molecular weight is not sufficiently large and such organo polysiloxanes will evaporate in most parts during an early stage of the precursor production process or the oxidizing process and the intended effects will not be obtained. If viscosity exceeds 1000, on the other hand, the capability of preventing adhesion is adversely affected. Those with viscosity in the range of 10 to 100 are preferable. Dimethyl polysiloxanes satisfying these conditions are good examples. Amino-modified polysiloxanes given by general formula (II) must have a viscosity in the range of 10 to 10000 mm²/s. Amino-modified polysiloxanes shown by (II) are effective for the purpose of this invention probably because two nitrogen atoms are contained per amino-modified group of their molecules and this improves the orientation characteristics with respect to the filaments. There are no particular limitations according to the present invention regarding the ratio at which aforementioned organo polysiloxanes and amino-modified polysiloxanes should be mixed together. From the point of view of the effects, however, the weight ratio of organo polysiloxanes/amino-modified polysiloxanes should be between 10/90 and 90/10, or preferably between 25/75 and 90/10. In addition to the aforementioned organo polysiloxanes and amino-modified polysiloxanes, the lubricating agents of the present invention may also contain appropriate amounts of any publicly known surface active agent, antioxidant or antiseptic for the production of carbon yarns as long as the desired effects of the present invention are not adversely affected. The lubricating agents of the present invention are applied during the acrylic precursor production process or before the oxidizing process. As for the mode of application, they may be applied either as an emulsion, as a solution with an organic solvent or neat. They may be applied by kiss- roll method, spray method or guide oiling method. The amount to be deposited in these cases is preferably 0.01 to 5 weight % with respect to the precursor in order to have the effects of the present invention fully realized and also to realize these effects appropriately in view of economy and corresponding to the amount used. As explained above, the lubricating agents of the present invention are superior in processability in the precursor production process and the oxidizing process and in particular regarding the filament separability of the precursor and the capability of preventing adhesion during the oxidizing. They can show better results than if organo polysiloxanes are used alone as in conventional practice. In what follows, test examples are described to illustrate the present invention and its effects but it should be remembered that the present invention is by no means limited by these examples. Test Examples Water emulsions of lubricating agents comprising 85 weight % of the lubricating agents shown in Table 1 and Table 2 (Test Examples 1 - 15 and Comparison Examples 1 - 15) and 15 weight % of polyoxyethylene nonylphenylether were prepared. These water emulsions were applied to acrylic filament yearns (16000 denier/12000 filaments) at the rate of 0.5 ± 0.1 weight % (exclusive of water component) by immersion method. The yarns were then dried for 4 seconds at 115°C by means of a dry heat roller to prepare a precursor tow and this was used as sample to evaluate its filament separability by the method described below. The precursor tows were then processed for 60 minutes inside an oven of forced circulation type at 240°C to obtain oxidized fibers and they were used as samples to evaluate their capacities of resisting adhesion by the method to be described later. Furthermore, the aforementioned water emulsions were applied to acrylic filament yarns (75 denier/40 filaments) at the rate of 0.5 ± 0.1 weight % respectively by the kiss-roll method to prepare samples and the coefficients of friction and generation of static electricity were evaluated by the method to be described later. The results of these evaluations are also shown in Tables 1 and 2. Filament Separability ("Sep" in the Tables) The sample precursor yarn was cut to 2cm/lengths and shaken lightly over a black sheet of paper and its filament separability was evaluated according to the following standards: 000 : very good; 00 : good; 0 : fair; 1 : bad X : very bad. Infusibility ("Inf" in the Tables The sample of oxidized yarn was cut to 2 cm lengths and shaken lightly over a white sheet of paper and its infusibility was evaluated according to the following standards: 000 : No fusion 00 : Very little fusion 0 : Little fusion 1 : Some fusion X : Fusion to a considerable degree. Measurement of the coefficient of friction ("Fric" in the Tables The sample was left for 24 hours under the conditions of 20°C and 65% relative humidity and caused to run in contact with a cylindrical chromium-plated pin under the same conditions with initial tension 20g and yarn velocity of 100m/min. Coefficient of friction was measured by using a µ-meter (made by Eiko Sokki-sha) was evaluated according to the following standards: 00 : Coefficient of friction less than 0.25 0 : Coefficient of friction equal to or greater than 0.25 and less than 0.28 1 : Coefficient of friction equal to or greater than 0.28 and less than 0.31 X : Coefficient of friction equal to or greater than 0.31 Evaluation of static electricity ("Volt" in the Tables) Concurrently with the aforementioned measurement of coefficient of friction, electrostatic voltage of the yarn after the contact with the chromium-plated pin was measured by means of a static electrometer (made by Kasuga Denki Kabushiki Kaisha) and the results were evaluated according to the following standards: 0 : Voltage less than 100V 1 : Voltage 100V to less than 300V X : Voltage 300V or greater. In Tables 1 and 2, DMS means dimethyl polysiloxane, PS means phenyl methyl polysiloxane, PES means polyether-modified polysiloxane, ES means epoxy-modified polysiloxane; the numbers in parentheses are viscosity; AS represent amino-modified polysiloxane: AS-A is AS-B is AS-C is AS-D is (where a, b, d, e and f are integers) The results of Tables 1 and 2 clearly show the effects of the present invention

Claims: A lubricating agent for an acrylic precursor yarn used in the manufacture of carbon fibres consisting of two lubricant ingredients:- (a) at least one organo polysiloxane of the general formula 1 (where R¹, R² and R³ all represent methyl groups; R⁴ represents a methyl group or a phenyl group; and m and n are integers) said organo polysiloxane having the viscosity at 25°C in the range of 5 to 1000 mm²/s. (b) at least one amino-modified polysiloxane of general formula II (where R⁹ to R¹⁵ all represent methyl groups; R¹⁶, R¹⁷ and R¹⁸ each represent a hydrogen atom, a methyl group or an ethyl group; X represents an alkylene group with 3 to 5 carbon atoms; Y represents an alkylene group with 2 to 6 carbon atoms; and p and q are integers) said amino-modified polysiloxane have the viscosity at 25°C in the range of 10-10000 mm²/s and optionally, other non-lubricant co-ingredients. A lubricating agent according to claim 1, wherein the viscosity of 25°C of the organo polysiloxane of formula (I) is in the range of 10 to 100 mm²/s. A lubricating agent of according to claim 1 wherein the weight ratio of said organo polysiloxane to said amino-modified polysiloxane is in the range of 10/90 to 90/10. A lubricating agent according to claim 3 wherein the weight ratio of said organo polysiloxane to said amino-modified polysiloxane is in the range of 25/75 to 90/10. A method of lubricating an acrylic precursor yarn used in the manufacture of carbon fibres comprising applying to the yarn a lubricating agent according to any of claims 1 to 4. A method according to claim 5, in which the lubricating agent is applied at a level of 0.01 to 5% by weight based on said acrylic precursor yarn.

Inventors: FUJII, TSUKASA, ISOBE, JUN
Applicants: TAKEMOTO YUSHI KABUSHIKI KAISHA
Application year: 1985
Main classification: C10M107
IPC codes: D06M101, D01F9, D06M15, C10M107