BACKGROUND OF THE INVENTION
[0001] This invention relates to a spin size and thermosetting aid for pitch fibers.
[0002] In order to convert pitch fibers into carbon fibers it is necessary to first thermoset
them before they can be carbonized to produce the desired final product. Generally,
such fibers are spun and further processed into carbon in the form of multifilament
yarn or tow. Because of the exothermic nature of pitch oxidation, however, hot spots
often develop in the multifilament bundle during thermosetting which cause the fibers
to melt or soften before they become infus- ibilized. As a result of this, deformation
of the individual filaments occurs along with exudation of molten pitch through the
filament surfaces which causes them to stick together at various points of contact
along the length of the yarn or tow. This deformation and sticking of the fibers in
turn causes the yarn or tow to become stiff and brittle and to suffer a loss of flexibility
and tensile strength. As a result, such yarn or tow cannot be further processed without
breaking a large number of filaments.
[0003] Spin sizes are conveniently applied to pitch fiber yarn or tow immediately following
spinning in order to maintain the integrity of the yarn or tow, to provide lubricity
at the filament-to-filament interfaces, and to impart abrasion resistance to the filament
bundle. However, while such sizes improve the handleability of the yarn or tow prior
to ther- mosctting, they often are of no value, or only of limited value, during thermosetting.
Thus, for example, while mixtures of plain water and glycerol impart good handling
properties to as-spun pitch fiber yarn or tow, such yarn or tow is still subject to
the same disadvantages encountered during thermosetting of unsized yarn or tow, i.e.,
melting and sticking of the fibers often occurs which causes a reduction of the flexibility
and tensile strength of the fiber bundle.
[0004] One attempt to overcome the sticking problem encountered during thermosetting is
disclosed in U.S.S.R. Pat. No. 168, 848. The approach to the problem suggested in
that reference is to fan the filaments with coal dust prior to thermosetting. However,
not only is this dirty and inconvenient, but it is also very difficult to apply a
uniform layer of particles to the filaments by this technique. Furthermore, because
coal has a high inorganic impurity content, significant pitting of the fiber surfaces
occurs during oxidation which is accompanied by a concomitant reduction in the strength
of the fibers after carbonization.
[0005] A similar attempt to surmount the sticking problem and at the same time accelerate
oxidation of pitch fibers is disclosed in U.S. Pat. No. 3,997,645 wherein it is suggested
that the fibers be dusted with activated carbon which has been impregnated with an
oxidizing agent. However, this procedure appears to suffer from the same disadvantages
as the process of U.S.S.R. Pat. No. 168,848. Furthermore, because of the hardness
and large size of the particles employed (60 microns), this procedure does not provide
sufficient separation of the filament bundle to allow maximum contact of the oxidizing
gas with the fiber surfaces or provide sufficient lubricity between the fibers to
prevent physical damage to the fiber surfaces.
SUMMARY OF THE INVENTION
[0006] The present invention provides a method of treating a multifilament bundle of pitch
fibers, such as yarn or tow, to prepare such multifilament bundle for further processing
which comprises applying to the fibers thereof an aqueous finishing composition comprising
a dispersion of graphite or carbon black in water in which is dissolved a water-soluble
oxidizing agent and a water-soluble surfactant.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0007] The aqueous dispersion employed to treat a multifilament bundle of pitch fibers according
to the present invention serves as both a size for the bundle and as an effective
thermosetting aid during the infusibilization step which must be conducted before
the fibers can be carbonized to produce the desired product. Because the graphite
or carbon black particles are applied as a finely-divided dispersion, more effective
penetration of these particles between the filaments of the bundle is achieved. As
a result of this increased penetration of the particles, greater lubricity is provided
between the filaments which helps prevent physical damage to the fiber surfaces during
subsequent processing. In addition, the separation of the fiber bundle caused by the
infiltration of these minute particles between the filaments allows improved penetration
of the oxidizing gas into the bundle during thermosetting, which helps reduce oxidation
time and the exothermic excursion and filament fusion which ordinarily occurs at that
time. As noted previously, such fusion reduces the flexibility and tensile strength
of the yarn or tow.
[0008] Either finely-divided graphite or carbon black can be employed in the dispersions
employed in the present invention. Materials such as activated carbon and coal are
undesirable because they are abrasive and contain a high amount of inorganic impurities
(usually several percent) which is known to cause pitting of the fiber surfaces during
oxidation and a concomitant loss of fiber strength. For this reason, it is preferable
to use graphite or carbon black as they are softer, more slippery materials and are
available in a relatively pure state compared to other carbonaceous materials. For
best results, the graphite or carbon black should contain less than 0.5 percent by
weight of inorganic impurities. This inorganic impurity content is usually measured
by determining the ash content of such materials.
[0009] Any form of carbon black, e.g. gas blacks, furnace combustion blacks, furnace thermal
blacks, lampblacks, may be employed in the dispersions of the present invention. Likewise,
any form of graphite, either natural or synthetic, can be employed. In order to allow
maximum penetration of such particles between the filaments of the fiber bundle, they
should be no greater than 15 microns in size. Preferably, they have a size of from
0.3 micron to 5 microns. Because of the small size of these particles they readily
infiltrate the fiber bundle and uniformly coat the filaments. When the fiber bundle
is further processed, these soft and slippery particles readily slide over each other
and over the filaments so that the fibers are less subject to breakage and damage.
Furthermore, the separation of the fiber bundle caused by the infiltration of these
minute particles between the filaments facilitates permeation of the oxidizing gas
into the bundle during thermosetting. This increased permeation of oxygen into the
fiber bundle reduces the oxidation time and allows the fibers to be processed at greatly
increased speeds. Ordinarily, unless filament packing in the fiber bundle is kept
low and the oxidation process is very gradual, an exotherm excursion occurs during
oxidation which causes fusion of the filaments to occur. Because of the separation
of the fiber bundle caused by the infiltration cf the graphite or carbon black particles
between the filaments, however, the filament surfaces are brought into contact with
the oxidizing gas to a greater content during oxidation and such heat excursion is
prevented. As a result, the fibers can be more rapidly oxidized without the fusion
and filament sticking which formerly occurred. Thus, throughout speeds of at least
1.5 times that formerly attained without the use of such dispersions are now possible
without loss of fiber properties. As a result, production capacity and the economics
of the process have been greatly improved.
[0010] By adjusting the concentration and wetting characteristics of the dispersion employed
in the present invention, it is possible to control the amount of graphite or carbon
black which is deposited on the pitch fiber bundle. Generally, the dispersion contains
from about 0.1 part by weight to about 10 parts by weight of graphite or carbon black
per 100 parts by weight of mixture, preferably from 1 part by weight to 6 parts by
weight of graphite or carbon black per 100 parts by weight of mixture..
[0011] Any water-soluble compound which is capable of functioning as an oxidizing agent
at the temperature at which thermosetting is effected can be employed as a thermosetting
aid in the aqueous dispersions employed in the present invention, provided such compound
does not cause the suspension to flocculate. Because the compounds employed are water
soluble, their physical presence on the fiber surfaces during thermosetting is assured.
Oxidation and infusibilization of the fibers is thereby enhanced during thermosetting,
allowing the fibers to be processed at greatly increased speeds. Suitable oxidizing
agents include peroxygenated compounds, for example, peroxides, persulfates, pyrosulfates,
and perchlorates. Among the compounds which can be employed are sodium peroxide, potassium
peroxide, sodium persulfate, potassium persulfate, sodium pyrosulfate, potassium pyrosulfate,
sodium perchlorate, potassium perchlorate, and magnesium perchlorate. Sulfates, sulfites,
bisulfites sulfamater. and nitrates are alse suitable, including, for example, sodium
sulfate, potassium sulfate, sodium sulfite, potassium sulfite, sodium bisulfite, potassium
bisulfite, sodium sulfamate, potassium sulfamate, sodium nitrate, and potassium nitrate.
However, because such salts leave residues on the fibers and may cause pitting of
the fiber surfaces during oxidation, it is preferred to use the corresponding ammonium
salts or such compounds as hydrogen peroxide and sulfamic acid.
[0012] Any water soluble surfactant can be employed in the aqueous dispersions employed
in the present invention, provided such surfactant does not cause the suspension to
flocculate. Anionic and nonionic surfactants are preferred for this reason. Such surfactants
serve to increase wetting of the fibers by the dispersion by reducing the surface
tension of the water, thereby promoting the distribution of the graphite or carbon
black throughout the fiber bundle. As a result, oxidation and infusibilization of
the fibers during thermosetting is enhanced and the fibers can be processed at greatly
increased speeds. Suitable surfactants include tetramethyl sodium oleate, tetramethyl
sodium laurate, sodium laurate, and the like. However, because such salts leave residues
on the fibers and may cause pitting of the fiber surfaces during oxidation, it is
preferred to use the corresponding ammonium salts.
[0013] Generally, an amount of surfactant is employed which will impart a sirface tension
of less than about 50 dynes/cm. to the dispersion, preferably less than about 40 dynes/cm.
The amount of oxidizing agent employed should not exceed an amount of which will destroy
the stability of such dispersion. Generally, from about 0.1 part by weight to about
2.0 parts by weight, preferably from about 0.2 part by weight to about 0.8 part by
weight, per 100 parts by weight of mixture are satisfactory. If necessary, a suitable
dispersing agent may be employed to facilitate dispersion of the graphite or carbon
black in the water and maintenance of the dispersion. Suitable stabilizers, film formers,
etc. may also be employed if desired.
[0014] A water-soluble surfactant which is also capable of functioning as an oxidizing agent
at the temperature at which thermosetting is effected can be employed in the aqueous
dispersions employed in the present invention, provided such oxidation agent-surfactant
does not cause the suspension to flocculate. Anionic surfactants are preferred for
this reason. Such oxidizing agent-surfactants serve both to increase wetting of the
fibers by the dispersion and as a thermosetting aid during the subsequent infusibilization
step. By reducing the surface tension of the water they promote the distribution of
the graphite or carbon black throughout the fiber bundle and their own presence on
the fiber surfaces, thereby further enhancing the oxidation and infusibilization of
the fibers during thermosetting and allowing them to be processed at greatly increased
speeds. Suitable oxidizing agent-surfactants include alkali metal hydrocarbyl sulfates,
for example, alkali metal aryl sulfates and alkali metal alkyl sulfates. Among the
compounds which can be employed are sodium 2-ethylhexyl sulfate, sodium heptadecyl
sulfate, and sodium tetradecyl sulfate. These compounds are sold commercially under
the trademark "Tergitol"
*. However, because such salts leave residues on the fibers and may cause pitting of
the fiber surfaces during oxidation, it is preferred to use the corresponding ammonium
salts.
[0015] Generally, from about 0.2 part by weight to about 20 parts
* "Tergitol" is a registered trademark of Union Carbide Corporation. by weight, preferably
from about 0.6 part by weight to about 4 parts by weight, of the oxiding agent/surfactant
per 100 parts by weight of mixture can be employed in the dispersion. If necessary,
a suitable dispersing agent may be employed to facilitate dispersion of the graphite
or carbon black in the water and maintenance of the dispersion. Likewise, oxidizing
agents and wetting agents over and above the oxidizing agent/ surfactant employed
may be added to the dispersion to facilitate oxidation or wetting of the fibers, although
they are unnecessary. Suitable stabilizers, film formers, etc. may also be employed
if desired.
[0016] After the dispersion has been formed, it is applied to the fipers by any convenient
means, such as by spraying, brushing, rolling, or simply by immersing the fibers in
the dispersion-. A convenient means of applying the dispersion to the fibers is to
pass the fibers over a sizing wheel which rotates in a bath of the dispersion and
is coated with the dispersion. This, preferably, is done as the fibers emerge from
the spinnerette. By controlling the size and speed of the wheel it is possible to
control the amount of the dispersion which is applied to the fibers. In any event,
the fibers should be allowed to absorb a sufficient amount of the suspension to provide
from about 0.1 gram of the dispersion to about 1.5 grams of the dispersion per gram
of fiber.
[0017] The fibers treated in this manner are then thermoset in a conventional manner by
heating in an oxygen-containing atmosphere, such as pure oxygen or air. Drying of
the fibers is not necessary and the fibers can be thermoset while still wet if desired.
Such thermosetting, of course, must be carried out at a temperature below the temperature
at which the fibers soften or distort. Because the thermosetting action of the oxidizing
agent employed usually commences at a temperature below 200°C. where the rate of oxidation
is ordinarily quite slow, infusibilization can usually be effected at lower temperatures
than are normally required, or in shorter periods of time than are normally required.
While the time re÷ quired to oxidize the fibers to the desired degree will vary with
such factors as the particular oxidizing atmosphere, the temperature employed, the
diameter of the fibers, and the particular pitch from which the fibers were prepared,
at any given temperature such time is usually less than two-thirds of the time required
when the fibers are not treated with the dispersions of the present invention.
[0018] The thermoset fibers may then be carbonized in a conventional manner by heating them
in an inert atmosphere to a temperature sufficiently elevated to remove hydrogen and
other carbonizable by-products and produce a substantially all-carbon fiber. Fibers
having a carbon content greater than about 98 percent by weight can generally be produced
by heating to a temperature in excess of about 1000°C., and at temperatures in excess
of about 1500°C. the fibers are completely carbonized. Generally, carbonization times
of from about 2 seconds to about 1 minute are sufficient.
[0019] If desired, the carbonized fibers may be further heated in an inert atmosphere to
a graphitization temperature, e.g. from about 2500°C. to about 3300°C.
[0020] Pitch fibers suitable for use in the present invention can be prepared in accordance
with well-known techniques. Preferably, the fibers employed are prepared from mesophase
pitch as described in U.S. Pat. No. 4,005,183.
[0021] While the invention has been described with reference to pitch fiber yarn or tow,
it should be apparent that fibers of other carbonizable organic polymeric materials,
such as homopolymers and interpolymers or acrylonitrile, can be treated in a similar
manner.
[0022] The following examples are set forth for purposes of illustration so that those skilled
in the art may better understand this invention. It should be understood, however,
that they are exemplary only, and should not be construed as limiting this invention
in any manner. Tensile strength and pull strength properties referred to in the examples
and throughout the specification were determined as described below unless otherwise
specified.
TENSILE STRENGTH
[0023] Tensile strength was determined on an Instron testing machine at a cross-head speed
of 0.02 cm/min. All measurements were made on 10-inch length unidirectional fiber-epoxy
composites.
PULL STRENGTH
[0024] Pull strength was determined on Mechanical Force Gage Model D-20-T, manufactured
by Hunter Spring Co., Hatfield, Pa., a division of Ametak Inc. The filament or filament
bundle to be tested is passed over a pulley which is attached by means of a spring
to a gauge designed to record the force in pounds exerted on the pulley. Both ends
of the filament or filament bundle are then wrapped around a mandrel which is suspended
from the pulley by means of the filament or filament bundle. Typically, a distance
of from about 3 to 12 inches is provided between the pulley and the mandrel. Tension
is then exerted on the filament or filament bundle by pulling down on the mandrel
until the yarn breaks. The total force in pounds required to break the filament or
filament bundle is recorded on the gauge. This force is designated as the pull strength
of the filament or filament bundle.
EXAMPLE 1
[0025] Continuous pitch filaments were spun through two 1000 hole hot melt spinnerettcs
from a 322°C. softening point mesophase pitch having a mesophase content of 77 percent.
The capillary holes of the spinnerette were 4 mils in diameter and 8 mils in length.
As the filaments emerged from the spinnerette, they were combined into a single bundle
which was drawn down over a sizing wheel which rotated in a bath containing a suspension
of carbon black flour in an aqueous solution of ammonium persulfate and ammonium laurate.
The fibers were spread over the slowly rotating wheel as they were brought into contact
with it and were thoroughly wetted by and uniformly coated with the suspension by
this procedure. The coated fibers were then collimated into a yarn by means of a gathering
wheel having a "V" slot, and subsequently drawn down to a diameter of about 14 microns
by means of two godet wheels.
[0026] The suspension employed to coat the fibers contained 3.6 parts by weight of carbon
black, 0.8 part by weight of ammonium persulfate, and 0.4 part by weight of ammonium
laurate per 100 parts by weight of mixture. The carbon black particles present in
the suspension had an average size of 0.5 micron. The composition was prepared by
admixing (a) 3.2 parts by weight of an aqueous solution containing 25 parts by weight
of ammonium persulfate in 75 parts by weight of water with (b) 20 parts by weight
of an aqueous solution containing 2 parts by weight of ammonium laurate in 98 parts
by weight of water, and (c) 6.4 parts by weight of "Dylon"
* DS insulating carbon coating (a commercially available suspension of 56 parts by
weight of amorphous carbon in 44 parts by weight of water), and then adjusting the
pH of the mixture to 10 by means of ammonium hydroxide to give 100 parts of mixture.
[0027] The fibers treated in this manner were then thermoset by transporting them through
a 40-foot long forced air convec-
* "Dylon" is a registered trademark of Dylon Industries. tion furnace at a speed of
6 inches per minute. The furnace contained eight zones, each 5 feet in length, and
the fibers were gradually heated from 175°C. in the first or entrance zone to 380°C.
in the eighth or exit zone while air was passed through the furnace at a velocity
of 4 feet/minute. Total rcsidence time in the furnace was 80 minutes. The fibers produced
in this manner were totally infusible. A 3- inch length of the thermoset fibers had
a pull strength of 5.1 lbs. and a 12-inch length had a pull strength of 3.1 lbs. (By
3-inch and 12-inch lengths is meant the distance between the pulley and the mandrel
of the Mechanical Force Gage employed in the determination.)
[0028] The thermoset fibers c then wound on a roller and carbonized by heating them in a
nitrogen atmosphere at a temperature of about 2200°C. for 3 seconds. After carbonization,
the fibers had a strand tensile strength of 302,000 psi.
EXAMPLE 2
[0029] The procedure of Example 1 was repeated employing a colloidal suspension of graphite
flour in an aqueous solution of ammonium persulfate and ammonium laurate. The suspension
contained 3.6 parts by weight of graphite, 0.8 part by weight of ammonium persulfate,
and 0.4 part by weight of ammonium laurate per 100 parts by weight of mixture. The
graphite particles present had an average size of 1 micron. This composition was prepared
by admixing (a) 3.2 parts by weight of an aqueous solution containing 25 parts by
weight of ammonium persulfate in 75 parts by weight of water with (b) 20 parts by
weight of an aqueous solution containing 2 parts by weight of ammonium laurate in
98 parts by weight of water, and (c) 16.4 parts by weight of "Aquadag"
* micro-graphite colloid in aqueous suspension (a commercially available col-
* "Aquadag" is a registered trademark of Acheson Colloids Company loidal suspension
of 22 parts by weight of graphite in 78 parts by weight of water), and then adjusting
the pH of the mixture to 9.7 by means of ammonium hydroxide to give 100 parts of mixture.
[0030] After thermosetting, a 3-inch length of the fibers had a pull strength of 4.7 lbs.
and a 12-inch length had a pull strength of 3.8 lbs.
[0031] When the procedure was repeated eliminating the ammonium persulfate from the colloidal
suspension employed to treat the fibers, a 3-inch length of the thermoset fibers had
a pull strength of 2.4 lbs. and a 12-inch length had a pull strength of 1.8 lbs.
EXAMPLE 3
[0032] Continuous pitch filaments were spun through two 1000 hole hot melt spinnerettes
from a 322°C scftening point mesophase pitch having a mesophase content of 77 percent.
The capillary holes of the spinnerette were 4 mils in diameter and 8 mils in length.
As the filaments emerged from the spinnerette, they were combined into a single bundle
which was drawn down over a sizing wheel which rotated in a bath containing a colloidal
suspension of graphite flour in an aqueous solution of ammonium 2-ethylhexyl sulfate.
The fibers were spread over the slowly rotating wheel as they were brought into contact
with it and were thoroughly wetted by and uniformly coated with the suspension by
this procedure. The coated fibers were then collimated into a yarn by means of a gathering
wheel having a "V" slot, and subsequently drawn down to a diameter of about 14 microns
by means of two godet wheels.
[0033] The colloidal suspension employed to coat the fibers contained 3.6 parts by weight
of graphite and 2.7 parts by weight of ammonium 2-ethylhexyl sulfate per 100 parts
by weight of mixture. The graphite particles present had an average size of 1 micron.
This composition was prepared by admixing 8.7 parts by weight of an aqueous solution
containing 31 parts by weight of ammonium 2-cthylhcxyl sulfate in 69 parts by weight
of water with 16.4 parts by weight of "Aquadag"* micro-graphite colloid in aqueous
suspension (a commercially available colloidal suspension of 22 parts by weight of
graphite in 78 parts by weight of water), and then adjusting the pH of the mixture
to 10 by means of ammonium hydroxide to give 100 parts of mixture.
[0034] The fibers treated in this manner were then thermoset by transporting them through
a 40-foot long forced air convection furnace at a speed of 6 inches per minute. The
oven contained eight zones, each 5 feet in length, and the fibers were gradually heated
from 175°C. in the first or entrance zone to 380
0C. in the eighth or exit zone while air was passed through the furnace at a velocity
of 4 feet/minute. Total residence time in the furnace was 80 minutes. The fibers produced
in this manner were totally infusible. A 3- inch length of the thermoset fibers had
a pull strength of 4.9 lbs. and a 12-inch length had a pull strength of 4.6 lbs. (By
3-inch and 12-inch lengths is meant the distance between the pulley and the mandrel
of the Mechanical Force Gage employed in the determination.)
[0035] The thermoset fibers were then wound on a roller and carbonized by heating them in
a nitrogen atmosphere at a temperature of about 2200°C. for 3 seconds. After carbonization,
the fibers had a strand tensile strength of 247,000 psi.
[0036] When the procedure was repeated substituting a like amount of sodium 2-ethylhexyl
sulfate for ammonium 2-ethylhexyl sul-
* "Aquadag" is a registered trademark of Acheson-Colloids Company.
fate in the colloidal suspension employed to treat the fibers, a 12-inch length of
the thermoset fibers had a pull strength of 4.1 lbs. The carbonized fibers had a strand
tensile strength of 193,000 psi.
[0037] When the procedure was again repeated substituting 0.4 part by weight of ammonium
laurate for ammonium 2-ethylhexyl sulfate in the colloidal suspension employed to
treat the fibers, a 3-inch length of the thermoset fibers had a pull strength of 2.4
lbs. and a 12-inch length had a pull strength of 1.8 lbs. These fibers were stiff,
brittle, and too fused and weak to be wound on a roller and carbonized.
[0038] When the fibers were treated in like manner with suspensions containing from 1 part
by weight to 3 parts by weight of colloidal graphite and from 0.08 part by weight
to 0.39 part by weight of tetramethyl ammonium oleate per 100 parts by weight of mixture,
12-inch lengths of the thermoset fibers had pull strengths of from 0.3 lbs. to 2.6
lbs. These fibers were stiff, brittle, and too fused and weak to be wound on a roller
and carbonized.
EXAMPLE 4
[0039] The procedure of Example 3 was repeated employing a suspension of carbon black flour
in an aqueous solution of sodium 2-ethylhexyl sulfate. The suspension contained 3.6
parts by weight of carbon black and 2.7 parts by weight of sodium 2-ethylhexyl sulfate
per 100 parts by weight of mixture. The carbon black particles present in the suspension
had an average size of 0.5 micron. The composition was prepared by admixing 6.8 parts
by weight of an aqueous solution containing 40 parts by weight of sodium 2-ethylhexyl
sulfate in 60 parts by weight of water with 6.4 parts by weight of "Dylon"
* DS insulating carbon coating (a commercially avail-
* "Dylon" is a registered trademark of Dylon Industries. able suspension of 56 parts
by weight of amorphous carbon in 44 parts by weight of water), and then adjusting
the pH of the mixture to 10 by means of ammonium hydroxide to give 100 parts of mixture.
[0040] After thermosetting, a 12-inch length of fibers had a pull strength of 7.5 lbs. The
carbonized fibers had a strand tensile strength of 307,000 psi.
[0041] When the procedure was repeated eliminating the sodium 2-ethylhexyl sulfate from
the suspension employed to treat the fibers, 12-inch lengths of the thermoset fibers
had a pull strength of 0.8 lbs. These fibers were stiff, brittle, and too fused and
weak to be wound on a rcller and carbonised.
[0042] When the procedure was again repeated substituting a like amount of ammonium 2-ethylhexyl
sulfate for sodium 2-ethylhexyl sulfate in the suspension employed to treat the fibers,
a 3-inch length of the thermoset fibers had a pull strength of 5.4 lbs and a 12-inch
length had a pull strength of 3.1 lbs. The carbonized fibers had a strand tensile
strength of 297,000 psi.
[0043] When 0.4 part by weight of ammonium laurate was substituted for sodium 2-ethylhexyl
sulfate in the suspension, a 3-inch length of the thermoset fibers had a pull strength
of 1.7 lbs and a 12-inch length had a pull strength of 1.6 lbs. These fibers were
stiff, brittle, and too fused and weak to be wound on a roller and carbonized.
[0044] When 0.02 part by weight and 0.07 part by weight of tetramethyl ammonium oleate was
substituted for sodium 2-ethylhexyl sulfate in the suspension, 12-inch lengths of
the thermoset fibers had pull strengths of 0.6 lbs. and 1.1 lbs., respectively. Once
again, the fibers were stiff, brittle, and too fused and weak to be wound on a roller
and carbonized.
1. A method of treating a multifilament bundle of pitch fibers to prepare such bundle
for further processing which comprises applying to the fibers thereof an aqueous finishing
composition comprising a dispersion of finely-divided graphite or carbon black particles
in water in which is dissolved a water-soluble oxidizing agent and a water-soluble
surfactant, preferably wherein the graphite or carbon black particles are no greater
than 15 microns in size and more preferably are from 0.3 micron to 5 microns in size,
optionally the said graphite or carbon black containing less than 0.5 percent by weight
of inorganic impurities.
2. A method aa in claim 1 wherein the water-soluble oxidizing agent is a peroxygenated
compound, in particular a persulfate and notably ammonium persulfate.
3. A method as in claim 1 wherein the water-soluble oxidizing agent is selected from
the group consisting of sodium peroxide, potassium peroxide, ammonium peroxide, sodium
persulfate, potassium persulfate, ammonium persulfate, sodium pyrosulfate, potassium
pyrosulfate, ammonium pyrosulfate, sodium perchlorate, potassium perchlorate, ammonium
perchlorate, magnesium perchlorate, sodium sulfate, potassium sulfate, ammonium sulfate,
sodium sulfite, potassium sulfite, ammonium sulfite, sodium bisulfite, potassium bisulfite,
ammonium bisulfite, sodium sulfamate, potassium sulfamate, ammonium sulfamate, sodium
nitrate, potassium nitrate, ammonium nitrate, hydrogen peroxide and sulfamic acid.
4. A method as in claim 1, 2 or 3 wherein the water-soluble surfactant is an anionic
or nonionic surfactant, which is preferably selected from the group consisting of
tetramethyl sodium oleate, tetramethyl ammonium oleate, tetramethyl sodium laurate,
tetramethyl ammonium laurate, sodium laurate and ammonium laurate.
5. A method as in claim 1 wherein the water-soluble oxidizing agent is ammonium persulfate
and the water-soluble surfactant is ammonium laurate.
6. A finishing composition for a multifilament bundle of pitch fibers comprising a
dispersion of finely-divided graphite or carbon black particles in water in which
is dissolved a water-soluble oxidizing agent and a water-soluble surfactant, preferably
wherein the graphite or carbon black particles are no greater than 15 microns in size.
7. A method of treating a multifilament bundle of pitch fibers to prepare such bundle
for further processing which comprises applying to the fibers thereof an aqueous finishing
composition comprising a dispersion of finely-divided graphite or carbon black particles
in water in which is dissolved a water-soluble surfactant which is also capable of
functioning as an oxidizing agent, preferably wherein the graphite or carbon black
particles are no greater than 15 microns in size and more preferably are from 0.3
micron to 5 microns in size and optionally the said graphite or carbon black containing
less than 0.5 percent by weight of inorganic impurities.
8. A method as in claim 7 wherein the water-soluble surfactant is an anionic surfactant,
notably an alkali metal hydrocarbyl sulfate or an ammonium hydrocarbyl sulfate which
is in particular selected from the group consisting of sodium 2-ethylhexyl sulfate,
sodium heptadecyl sulfate, sodium tetradecyl sulfate, ammonium 2-ethylhexyl sulfate,
ammonium heptadecyl sulfate, and ammonium tetradecyl sulfate, and preferably sodium
2-ethylhexyl sulfate or ammonium 2-ethylhexyl sulfate.
9. A method as in claim 7 or 8 wherein the pitch fibers are prepared from mesophase
pitch.
10. A finishing composition for a multifilament bundle of pitch fibers comprising
a dispersion of finely divided graphite or carbon black particles in water in which
is dissolved a water-soluble surfactant which is also capable of functioning as an
oxidizing agent, preferably wherein the graphite or carbon black particles are no
greater than 15 microns in size.