Note: Descriptions are shown in the official language in which they were submitted.
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Use of Water-Based Lubricants for Textile Machines
Specification
This invention relates to the use of water-based lubricants for textile
machines, in
particular the use as needle oils and/or sinker oils in textile knitting
machines.
Lubricants that must meet high requirements are used for lubricating textile
knitting
machines. The compositions of a needle oil or sinker oil should have a
constant viscosity at
different machine speeds and temperatures. In this case, the operating
viscosity of the
lubricant should lie in the range of ISO VG 15 ¨ ISO VG 100. The compositions
of the
needle or sinker oils, moreover, should be resistant to aging.
The lubricants are to be present in the form of a colorless and clear solution
as
possible. These colorless lubricants are to have a good-to-excellent
scourability, i.e. washing
out ability; in particular, it should be possible to scour the lubricants at
low temperatures.
When a lubricant can be scoured only incompletely, it results in problems in
the subsequent
treatments of knit fabrics. In particular, a uniform dyeing of the knit goods
is no longer
possible, and irreversible color defects are the result.
In addition, the lubricants are also to have a long shelf life even at low
temperatures
without the formation of precipitates. The formation of precipitates can
result in the clogging
of the oil supply systems of the knitting machines.
The lubricant also must not have a tendency toward phase separation over the
overall
service temperature range of 0 C to 80 C. The phase separation of the
lubricant can result in
a deficient lubrication of the machine parts and thus can result in unevenness
of the knit
fabric, which also can result in defects in the knitwear in the subsequent
color treatment.
In addition to good protection against wear and tear and corrosion, the
lubricant must
also have the lowest possible level of friction. This results in a
considerable energy savings
and in reducing the noise level, which in turn results in improving work
conditions.
In addition, the lubricant has to be slightly biodegradable, since the
lubricant can get
into the waste water via the scouring process and correspondingly has to be
treated and
decomposed via the clarification process.
The textile oils that are used over time, which are present in the form of an
emulsion,
in most cases consist of more than 80% mineral oil, to which the usual wear-
and corrosion-
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reducing additives are added. In addition, emulsifiers are added to improve
the scourability.
In this connection, both anionic emulsifiers (e.g., sulfonates) and nonionic
emulsifiers (e.g.,
fatty alcohol ethoxylates or else NPE), as well as cationic emulsifiers (e.g.,
quaternary
ammonium compounds) can be used. At times, small amounts of water (less than
1%) have
to be added to emulsifier-containing textile oils to stabilize them or reduce
their tendency
toward precipitation. Higher concentrations of water result in unacceptably
high cloudiness
by forming an emulsion, which results in phase separation, or can produce
hydrolysis of the
additives that are used.
In addition, it is known to apply lubricating agent to textile yarns by a
roller, which
runs over the corresponding yarn, being immersed in a lubricating agent
emulsion to facilitate
the processibility of the yarns. To this end, a composition that contains 50
to 80 parts by
weight of poly(oxyethylene-oxy-1,2-propylene)glycol, 10 to 40 parts by weight
of emulsifier,
and 10 to 40 parts by weight of an ester is described in US 3 338 830 A. This
mixture is
present as a concentrate and is diluted with water, so that 1 to 25% by weight
of non-aqueous
components is present and is used in the form of an aqueous emulsion. From DE
30 08 500
C2, a water-soluble metal-working fluid that contains diethanol disulfide and
one or more
water-soluble polyoxyalkylene glycols are known. This liquid is used for
working metals,
whereby maximum pressure and anti-friction properties are ensured by preparing
a sufficient
amount of liquid.
The object of this invention is to prepare a liquid water-based lubricant for
textile
machines, with which the above-mentioned drawbacks, which develop when a
mineral oil is
used, are overcome, and which is present in the form of a solution.
So that the lubricant can be used in textile machines, it should be
biodegradable, and
it should be scourable at the lowest possible temperatures as well as used in
an overall service
temperature range without phase separation, should offer good protection
against wear and
tear and corrosion, and should have as low a friction level as possible.
According to the invention, a water-based lubricant for textile knitting
machines,
which contains 5 to 50% by weight of water-soluble polymer and/or 5 to 50% by
weight of
emulsifier add water up to 100% by weight, is therefore used.
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In accordance with one aspect of the present invention, there is provided a
use of a
water-based lubricant that contains 5 to 50 % by weight of water-soluble
polymer, selected
from the group consisting of polyalkylene glycols, water-soluble esters,
polyacrylates,
polymethacrylates, polyvinyl pyrrolidones, polyacrylamides, carboxymethyl
cellulose,
polyanionic cellulose, hydroxyl cellulose and hydroxyethyl cellulose; 5 to 50
% by weight of
emulsifier, selected from the group consisting of non-ionic, anionic and
cationic emulsifier;
2 to 5 % by weight of corrosion-reducing agent, 0.2 to 5 % by weight of a wear-
reducing
agent, 0.01 to 0.75 % by weight of biocide, 2 to 25 % by weight of an anti-
icing agent, and
water up to 100 % by weight as needle oil and/or sinker oil in textile
knitting machines, in
particular in circular and flat knitting machines.
In addition, the lubricant can also contain 0 to 15% by weight, in particular
2 to 5%
by weight, of corrosion-reducing and protecting, respectively agent; 0 to 10%
by weight, in
particular 0.2 to 5% by weight, of wear-reducing and protecting, respectively
agent; 0 to 1%
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by weight, in particular 0.01 to 0.75% by weight, of biocide; and 0 to 50% by
weight, in
particular 2 to 25% by weight, of an anti-icing agent.
The water-soluble polymer that is contained in the lubricant is selected from
the group
that consists of polyalkylene glycols, in particular polyethylene glycol with
molar masses of
1,000 to 35,000, water-soluble esters, polyacrylates, polymethacrylates,
polyvinyl
pyrrolidones, polyacrylamides, carboxymethyl cellulose, polyanionic cellulose,
hydroxy
cellulose, and hydroxyethyl cellulose.
The emulsifier that is contained in the lubricant is selected from the group
that
consists of nonionic, anionic and cationic emulsifiers, in particular alkylene
oxide polymers,
sulfonates, carboxylic acid and dicarboxylic acid derivatives with a chain
length of 6 to 16
carbon atoms, phosphate esters, and quaternary ammonium compounds.
The corrosion- and wear-reducing agent that is contained in the lubricant is
selected
from the group that consists of water-soluble phosphorus and/or sulfur
compounds, and
nitrogen compounds, the biocide is benzoic acid, and the anti-icing agent is
selected from the
group that consists of low-molecular glycols, in particular ethylene glycol,
propylene glycol,
trimethylene glycol, glycerol, salts or ionic liquids.
The lubricant according to the invention can also be used in the form of a
concentrate.
In this case, primarily the reduced goods traffic is advantageous, since the
finished
formulation can be produced directly by customers by dilution with water.
Moreover, the
storage space that is required at the user site is reduced. Besides, the user
can adjust the
lubricant directly to the desired viscosity for its application.
To ensure that the lubricant is biodegradable, can be scoured, i.e. washed out
at the
lowest possible temperatures, can be used in the overall service temperature
range without
phase separation, offers good protection against wear and tear and corrosion,
and has as low a
friction level as possible, water is used as a carrier liquid. Special water-
soluble additives,
such as polyalkylene glycol and/or water-soluble esters, are added to this
carrier liquid, and
then the corresponding operating viscosity is set between ISO VG 15 -ISO VG
100.
In this connection, it is pointed out expressly that the examples below do not
involve
any emulsions, but rather true clear aqueous solutions. The application is
exclusively the
lubrication of machines or machine parts and not the lubrication/finishing of
yarns.
The advantageous properties of the lubricant according to the invention are
shown
based on the subsequent examples and the comparison example.
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Examples
Example 1
The lubricant has the following composition:
Distilled water 68.0%
by weight
Water-soluble polymer, polyglycol 8000 S, Clariant Co. 22.0% by weight
Alcohol polyalkylene glycol ether, MarlowetTM 5056,
Sasol Co. 5.0%
by weight
Boric acid ester and alkanolamines, HostacorTM Bl,
Clariant Co. 2.0%
by weight
Sulfurized fatty acid, LUBIOTM EP 1, Schafer Additive
Systems GmbH 3.0%
by weight
Table 1 shows the results of the studies of the properties of the lubricating
agent
according to the invention in accordance with the invention compared to that
of a known
mineral-oil-based lubricating agent.
Table 1
Comparison Example Based Example 1
on Mineral Oil (KluberTM
Oil Tex 1-22 N)
Appearance, Colorless Clear, Hazen < 50 Colorless Clear,
Hazen < 50
Hazen Color Unit
Corrosion Protection on Very Good Very Good
Knitting Needles,
KLM Test
Scourability at 65 C with Very Good Very Good
Washing Agent
DIN EN ISO 105-A01
Scourability at 30 C Poor Very Good
without Washing Agent
DIN EN ISO 105-A01
Kin. Viscosity at 40 C 22 cst 22 cst
Protection Against Wear Very Good Very Good
and Tear (SRV) DIN
51834-1; DIN 51834-2
Friction Coefficient (SRV) 0.10 0.06
Biodegradability Very Good
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The KLM test is performed as follows:
In a Petri dish (diameter 80 mm), an acetone-purified knitting needle (length
44 mm)
is placed on a round filter (filter paper with a diameter of 55 mm, WhatmanTM)
and covered
with 10 ml of aqueous textile oil. After 48 hours of storage at room
temperature, the needle
5 (black spots) and the filter paper (yellow-red coloring) are checked for
corrosion.
The study results shown in Table 1 can be summarized as follows. The lubricant
that
is produced according to the invention is a virtually colorless, limpid
solution. The complete
scourability is itself added without washing agents at low temperatures, which
makes
possible a considerable savings in energy. The friction level that is
drastically reduced in
comparison to the conventional needle oils allows one to expect a clearly
improved energy
efficiency as well as a lower noise level and extended holding times during
operation. By the
exchange of mineral oil or a basic oil corresponding to the latter by water, a
greater focus is
placed on durability with the lubricant of this invention.
Example 2
Distilled water 68.0% by weight
Water-soluble polymer, polyglycol 20000 S, Clariant Co. 22.0% by weight
Alcohol polyalkylene glycol ether, Marlowef" 5056,
Sasol Co. 5.0%
by weight
Boric acid ester and alkanolamines, HostacorTM Bl,
Clariant Co. 2.0% by weight
Sulfurized fatty acid, LUBIOTM EP 1,
Schafer Additive Systems GmbH 3.0%
by weight
Example 3
Distilled water 68.0%
by weight
Water-soluble polymer, polyglycol 8000 S, Clariant Co. 22.0% by weight
Alcohol polyalkylene glycol ether, MarlowetTM 5056,
Sasol Co. 5.0%
by weight
Tolyl triazole, Rheinchemie Co. 2.0%
by weight
Sulfurized fatty acid, V 345, Schafer Additive Systems
GmbH 3.0% by weight
In Table 2, the properties of the formulations of Example 2 and 3 are listed.
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Table 2
Example 2 Example 3
Appearance, Colorless Clear, Hazen < 50 Colorless Clear,
Hazen < 50
Hazen Color Unit
Corrosion Protection on Very Good Very Good
Knitting Needles,
KLM Test
Scourability at 65 C with Very Good Very Good
Washing Agent
DIN EN ISO 105-A01
Scourability at 30 C Very Good Very Good
without Washing Agent
DIN EN ISO 105-A01
Kin. Viscosity at 40 C 46 cst 22 cst
Protection Against Wear Very Good Very Good
and Tear (SRV) DIN
51834-1; DIN 51834-2
Friction Coefficient (SRV) 0.07 0.06
Also here, the comparison with the comparison example shows the excellent
properties of the use according to the invention of a water-based lubricant
according to
Examples 2 and 3.
Example 4
Distilled water 60.0%
by weight
Water-soluble dicarboxylic acid ethoxylate 35.0%
by weight
Sulfurized fatty acid 3.0%
by weight
Boric acid ester and alkanolamines 2.0% by weight
Example 5
Distilled water 60.0%
by weight
Water-soluble dicarboxylic acid ethoxylate 17.0%
by weight
Water-soluble polyethylene glycol 18.0%
by weight
Sulfurized fatty acid 3.0% by weight
Boric acid ester and alkanolamines 2.0%
by weight
In Table 3, the properties of the formulations of Examples 4 and 5 are listed.
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Table 3
Example 4 Example 5
Appearance, Colorless Clear, Hazen < 50 Colorless Clear,
Hazen < 50
Hazen Color Unit
Corrosion Protection on Very Good Very Good
Knitting Needles,
KLM Test
Scourability at 65 C with Very Good Very Good
Washing Agent
DIN EN ISO 105-A01
Scourability at 30 C Very Good Very Good
without Washing Agent
DIN EN ISO 105-A01
Kin. Viscosity at 40 C 22 cst 22 cst
Protection Against Wear Very Good Very Good
and Tear (SRV) DIN
51834-1; DIN 51834-2
Friction Coefficient (SRV) 0.11 0.10
Advantageously, the water that is used can be used both in the distilled/
demineralized form and as tap water, which simplifies a possible application
in the form of a
concentrate.
To achieve the required operating viscosity of ISO VG 15 ¨ ISO VG 100, it may
be
necessary to adjust the aqueous lubricant to a lower viscosity. By evaporating
a portion of
the water at the friction site, the target viscosity is then achieved.
The emulsifiers that are optionally contained in the lubricant comprise all
non-ionic,
anionic and cationic systems from the cleaning agent industry and the metal-
working
industry.
Examples of the nonionic emulsifiers that are used are alkylene oxide
polymers, such
as alcohol ethoxylates that consist of, e.g., ethylene oxide and/or propylene
oxide with
alkylene oxide units of 5-50 and linear or branched alkyl radicals with a
chain length of Clo
to C2O.
Examples of anionic emulsifiers are sulfonates, carboxylic acid and
dicarboxylic acid
derivatives with a chain length of 6 to 16 carbon atoms, as well as phosphate
esters.
Examples of cationic emulsifiers are quaternary ammonium compounds.
Water-soluble polymers comprise polyalkylene glycols, whereby polyethylene
glycols
with molar masses of 1,000 to 35,000 are preferred. Moreover, water-soluble
esters, such as,
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for example, polyacrylates or polymethacrylates, can be used, as well as
polyvinyl
pyrrolidones or polyacrylamide, cellulose or sugar derivatives, in particular
carboxymethyl
cellulose, polyanionic cellulose, hydroxycellulose, and hydroxyethyl
cellulose. The desired
viscosities can be set by different molecular weights of the polymers.
Typical usable corrosion- and wear-reducing additives originate from the
(cool)lubricant industry and comprise phosphorus- and/or sulfur-containing
water-soluble
compounds as well as boron compounds, such as boric acid derivatives, or
nitrogen
compounds, such as, e.g., triazole derivatives or VCIs (volatile corrosion
inhibitors, e.g.,
secondary amines).
To avoid bacterial growth in the aqueous solution accompanied by sludge
formation,
bactericides can be added, e.g., benzoic acid. To improve the low-temperature
behavior, anti-
icing agents, such as low-molecular glycols, in particular ethylene glycol,
propylene glycol,
trimethylene glycol, glycerol, salts or ionic liquids, can be used.
The advantages of the lubricant according to the invention can be listed as
follows:
They can be scoured, i.e. washed out with tap water at room temperature
without
washing agents, thus energy is saved in the washing process,
Water pollution is significantly reduced by the elimination of mineral oil and
washing
agent; a clarifying step can be eliminated.
