Optically anisotropic carbonaceous pitch and process for producing the same

Claim 2

A substantially homogeneous, optically anisotropic carbonaceous pitch for use in carbon fibers or the like, characterized in that the major portion of said pitch consists of a continuous, optically anisotropic phase, said optically anisotropic phase containing spherules of an optically isotropic phase having diameters ranging from about 1 μm to about 100 μm and dispersed in said optically anisotropic phase, the content of said optically isotropic spherules being up to about 20% on the basis of said pitch as a whole, said pitch containing substantially no optically isotropic spherules having a diameter of about 200 μm or more, said pitch containing at least about 30 wt% of a quinoline-soluble component, 20 to 50 wt% of a benzene soluble component, 15 to 40 wt% of an n-heptane insoluble but benzene soluble component, and 5 to 15 wt% of an n-heptane soluble component, and wt%s being based on said pitch as a whole, and said pitch having a softening point of from about 230° C. to about 320° C. and a carbon-to-hydrogen atomic ratio C/H of up to 2.0.

Claim 3

The optically anisotropic carbonaceous pitch as defined in claim 1 wherein the diameter of said optically isotropic spherules is substantially up to about 50 μm.

Claim 4

The optically anisotropic carbonaceous pitch as defined in claim 1 wherein the content of said optically isotropic spherules is up to about 10% on the basis of said pitch.

Claim 5

The optically anisotropic carbonaceous pitch as defined in claim 1 wherein the softening point is within the range of from 240° C. to 290° C.

Claim 6

The optically anisotropic carbonaceous pitch as defined in claim 1 wherein the content of said quinoline-soluble component is at least 50 wt%.

Claim 7

The optically anisotropic carbonaceous pitch as defined in claim 1 wherein the viscosity of said pitch at 350° C. is within the range of from about 10 poise to about 200 poise.

Claim 8

The optically anisotropic carbonaceous pitch as defined in claim 1 wherein the viscosity of said pitch at 380° C. is within the range of from about 2 poise to about 50 poise.

Claim 9

The optically anisotropic carbonaceous pitch as defined in claim 1 wherein the content of a benzene-insoluble component is from 50 wt% to 80 wt% on the basis of said pitch and a benzene-insoluble but quinoline-soluble component in said benzene-insoluble component is from 20 wt% to 50 wt% on the basis of said pitch.

Claim 10

The optically anisotropic carbonaceous pitch as defined in claim 1 wherein the content of said quinoline-insoluble component is up to 40 wt% on the basis of said pitch.

Claim 11

The optically anisotropic carbonaceous pitch as defined in claim 9 wherein the content of said quinoline-insoluble component is up to 30 wt% to 40 wt% on the basis of said pitch.

Claim 12

The optically anisotropic carbonaceous pitch as defined in claim 1 wherein the carbon-to-hydrogen atomic ratio C/H is from 1.6 to 1.9.

Claim 13

The optically anisotropic carbonaceous pitch as defined in claim 11 wherein the carbon-to-hydrogen atomic ratio C/H is from 1.65 to 1.80.

Claim 14

A process for producing an optically anisotropic carbonaceous pitch for use in carbon fibers or the like comprising: settling the major portion of a starting carbonaceous pitch in its molten state into an upper layer and a lower layer under conditions of temperature and residence time wherein optically anisotropic spherules contained in said starting carbonaceous pitch deposit and coalesce in the lower layer but the decomposition polycondensation reaction thereof does not occur remarkably, said settling operation carried on at a temperature in the range of from 350° C. to 430° C. and without agitation or with gentle and slow agitation under conditions where unnecessary fluidization does not exist, and the residence time is from 5 minutes to 4 hours depending on the temperature employed; and separating and removing the upper layer having a smaller concentration of the optically anisotropic phase from the lower layer; wherein said starting carbonaceous pitch contains from about 20% to about 70%, on the basis of said pitch, of the optically anisotropic phase in an optically isotropic matrix, up to 25 wt%, on the basis of said pitch, of a quinoline-insoluble component and at least 25 wt%, on the basis of said pitch, of a benzene-insoluble but quinoline-soluble component, and has a softening point of up to about 250° C.; and wherein said produced optically anisotropic carbonaceous pitch of said lower layer consists of a continuous, optically anisotropic phase, said optically anisotropic phase containing spherules of an optically isotropic phase having diameters ranging from about 1 μm to about 100 μm and dispersed in said optically anisotropic phase, the content of said optically isotropic spherules being up to about 20% on the basis of said pitch as a whole, said pitch containing substantially no optically isotropic spherules having a diameter of about 200 μm or more, said produced pitch containing at least about 30 wt% of a quinoline-soluble component, 20 to 50 wt% of a benzene soluble component, 15 to 40 wt% of an n-heptane insoluble but benzene soluble component, and 5 to 15 wt% of a n-heptane soluble component, and wt%s being based on said pitch as a whole.

Claim 15

A process for producing an optically anisotropic carbonaceous pitch for use in carbon fibers or the like comprising: settling the major portion of a starting carbonaceous pitch in its molten state into an upper layer and a lower layer under conditions of temperature and residence time wherein optically anisotropic spherules contained in said starting carbonaceous pitch deposit and coalesce in the lower layer but the decomposition polycondensation reaction thereof does not occur remarkably, said settling operation carried on at a temperature in the range of from 350° C. to 430° C. and without agitation or with gentle and slow agitation under conditions where unnecessary fluidization does not exist, and the residence time is from 5 minutes to 4 hours depending on the temperature employed; and separating and removing the upper layer having a smaller concentration of the optically anisotropic phase from the lower layer; wherein said starting carbonaceous pitch contains from about 20% to about 70%, on the basis of said pitch, of the optically anisotropic phase in an optically isotropic matrix, up to 25 wt%, on the basis of said pitch, of a quinoline-insoluble component and at least 25 wt%, on the basis of said pitch, of a benzene-insoluble but quinoline-soluble component, and has a softening point of up to about 250° C.; and wherein said produced optically anisotropic carbonaceous pitch of said lower layer consists of a continuous, optically anisotropic phase, said optically anisotropic phase containing spherules of an optically isotropic phase having diameters ranging from about 1 μm to about 100 μm and dispersed in said optically anisotropic phase, the content of said optically isotropic spherules being up to about 20% on the basis of said pitch as a whole, said pitch containing substantially no optically isotropic spherules having a diameter of about 200 μm or more, said produced pitch containing at least about 30 wt% of a quinoline-soluble component, 20 to 50 wt% of a benzene soluble component, 15 to 40 wt% of an n-heptane insoluble but benzene soluble component, and 5 to 15 wt% of a n-heptane soluble component, and wt%s being based on said pitch as a whole.

Claim 16

The process for producing an optically anisotropic carbonaceous pitch as defined in claim 10 wherein said starting carbonaceous pitch contains from about 30% to about 50% of the optically anisotropic phase portion in the optically isotropic matrix, up to 20 wt% of said quinoline-insoluble component and from 30 wt% to about 65 wt% of said benzene-insoluble but quinoline-soluble component.

Claim 17

The process for producing an optically anisotropic carbonaceous pitch as defined in claim 13 wherein the settling operation is carried out at a temperature in the range of from 360° C. to 390° C.

Claim 18

The process for producing an optically anisotropic carbonaceous pitch as defined in claim 13 wherein said starting carbonaceous pitch is obtained by carrying out heat-reaction and topping a starting carbonaceous heavy oil at a temperature within the range of from about 380° C. to about 460° C. in the stream of an inert gas.

Claim 19

The process for producing an optically anisotropic carbonaceous pitch as defined in claim 13 wherein said starting carbonaceous pitch is obtained by heat-reacting a starting carbonaceous heavy oil at a temperature within the range of from about 380° C. to about 460° C. under either normal pressure or elevated pressure and then removing low-molecular compounds such as decomposition products by vacuum distillation or in the stream of an inert gas.

Claim 20

The process for producing an optically anisotropic carbonaceous pitch as defined in claim 13 wherein the upper portion separated and withdrawn is recycled for re-use.