—Quite recently numerous experiments have been carried out with the object of finding methods for employing the cellulose esters of organic acids in the preparation of fabrics. The acetate, which is generally used, gives solutions from which fibres can be obtained which are comparable to natural silk in strength, and which have the further advantage of being non-inflammable, and far less readily affected by water than artificial fabrics obtained by the above methods. It is prepared by treating cellulose with dilute acid, by which the so-called ‘hydrocellulose’ is obtained; this is treated with a mixture of glacial acetic acid and acetyl chloride, and the whole, after addition of a little concentrated sulphuric acid, warmed to 65°-70°C. As early as 1894, Cross and Bevan[531] had patented a process for this preparation by the action of acetyl chloride in the cold on an intimate mixture of cellulose and zinc chloride.
[531] E. 9676, 1894.
From the solution obtained, the acetates are precipitated by water, washed and dried. The mixture of esters dissolves in chloroform, nitromethane, acetic acid, phenol, pyridine, etc., and is re-precipitated by addition of alcohol, benzene, or ligroin (petroleum ether). On account of its non-inflammable character, cellulose acetate, as the product is called, is being used instead of the nitrate in the manufacture of celluloid; it is also used for non-inflammable cinematograph films. Fibres can be obtained by forcing the solutions through jets, and removing the solvent, as in the above processes; these are spun into threads which are coming into increasing use, on account of their extremely low conducting power, for the insulation of very fine electric leads. The product is at present too expensive, however, for use in the textile industries, or for the manufacture of mantles.
A solvent which had at one time some technical importance is zinc chloride.[532] The concentrated aqueous solution of the salt will take up cellulose in considerable quantity; and the solution has been used in the preparation of carbon filaments for glow lamps.
[532] Gulbrandsen, Prog. Age, 1912, 30, 77; Wynne and Powell, E. 16805, December, 1884.
The fabrics prepared by the processes which have been mentioned above are of great technical value. In lustre they far surpass natural silk, and they take dyes very well, but owing to the ease with which they tear, they cannot be woven alone for textiles, but are always used in ‘mixed’ materials. The acetate silk, which approaches the natural fibre in strength, is not much less expensive. Whilst the price of natural silk is roughly 35 francs per kilo. (approx. 13s. 3d. per lb.), the costs of production of the artificial fabrics are—Chardonnet 15 frs., Pauly 12 frs., Viscose 7 frs. per kilo. (respectively 5s. 8d., 4s. 6d., and 2s. 8d. per lb.). Artificial silk, however, has uses distinct from the natural fibre, and is at present a competitor with it in one or two small fields only. Thus the production of natural silk is ten times that of artificial silk (50,000,000 kilos. per annum to 5,000,000 kilos.) in spite of the difference in price.
Artificial silk is very susceptible to the action of water, which weakens it very considerably. Its resistance is said to be greatly increased by the action of formaldehyde; the fabric is plunged into a bath containing an aqueous solution of the aldehyde, to which a little lactic acid has been added. The chemistry of the change is discussed at length by Beltzer (loc. cit.).
The threads of artificial silk far surpass in lightness those spun from vegetable fibres. A thread of twenty strands weighing one pound avoirdupois would be more than twenty miles long. At the same time the filaments have not the irregular tubular structure of vegetable fibres, but are solid cylinders. The fact that the filaments are continuous, so that there is relatively little torsion in threads spun from them, gives artificial silk its great advantage over the natural vegetable fibres for the manufacture of mantles. For this purpose the Pauly or Cuprammonium silk is most suitable, though Viscose silk is almost as good; the fibre obtained by the Chardonnet process is not quite so useful in this direction.
The Manufacture of Mantles from Artificial Silk.
—Whilst the fabrics made by the various processes outlined above are more expensive than the cotton and ramie formerly exclusively used in the mantle industry, they have the advantage, in addition to the fact that they produce better and more lasting mantles, that they do not need the laborious and troublesome process of washing which is so essential in the case of the vegetable fibres. From the nature of the methods used in its manufacture, artificial silk can contain no mineral residue; hence the fabric is immediately ready for impregnation.