JP5505030B2 - Composite base and composite fiber manufacturing method - Google Patents

Description

  The present invention relates to a composite die for discharging a composite polymer stream composed of two or more kinds of polymers, and a method for producing a composite fiber in which melt spinning is performed by a composite spinning machine using the composite die.

  Fibers using thermoplastic polymers such as polyester and polyamide are excellent in mechanical properties and dimensional stability, so they are widely used not only for clothing but also for industrial applications such as interior and vehicle interiors. Is getting higher and higher. In recent years, these uses have been diversified, and many fibers having various functionalities have been developed.

  For example, in apparel applications, single yarn fine cross-section with the aim of giving fine texture, soft filament, etc., improving water absorption, quick drying, changing glossiness, etc. Improvements such as polymer modification have been made with the aim of imparting new functionality such as realization of dyeing with excellent sharpness. In industrial applications, in addition to increasing the fineness of single yarns, increasing the number of filaments and cross-sections of single yarns, we aim to increase the strength and elasticity, as well as to add new functionality such as weather resistance and flame resistance. Improvements such as polymer modification have been made. In addition to the above improvements, composite fibers that combine two or more polymers to complement performance that is insufficient with a single component polymer or that give a completely new function are being actively developed. ing.

  As a method for producing this composite fiber, there are a composite spinning method using a composite base such as a core-sheath, a side-by-side, and a sea-island type, and a polymer alloy method in which polymers are melt-kneaded. The composite spinning method is not different from the polymer alloy method in terms of the principle of using two or more kinds of polymers as composite fibers, but the composite polymer flow is precisely controlled by a composite die, and particularly high in the running direction of the yarn. In terms of being able to form an accurate yarn cross-sectional shape, it is considered that the advantage is higher than the polymer alloy method.

  As an example using the composite spinning method, the core-sheath type has a core component covered with a sheath component, so that it has a sensibility effect such as texture and bulkiness that cannot be achieved with a single fiber, and strength, elastic modulus, and abrasion resistance. It is possible to impart mechanical properties such as. Moreover, a highly accurate deformed cross-section fiber can be obtained by configuring the sheath component as an easily eluting component and the core component as a difficult eluting component so as to have an irregular cross section and removing the sheath component. In this way, when a polymer such as polyester or polyamide is usually obtained by melt spinning, it often has a true circular cross section, but the irregular cross section gives a special texture that cannot be obtained with a true circular fiber. Or the weaving and knitting can be improved, the contact area with other resin coating the fiber can be increased, and problems such as peeling can be suppressed. Further, in the side-by-side type, it is possible to express crimpability, which is impossible with a single fiber, and to impart stretchability and the like. Further, in the sea-island type, by eluting the easily-eluting component (sea component) after melt spinning, only the difficult-to-elute component (island component) remains, and for example, an ultrafine fiber having a nano-order yarn diameter can be obtained. . Since these ultrafine fibers have a large surface area, they are excellent in touch and drape and are widely used as constituent materials for nonwoven fabrics and woven fabrics.

  Therefore, in these composite spinning methods, generally, a method in which two or more kinds of polymers are made into a composite polymer flow in the die and discharged from the same discharge hole is adopted. Is extremely important in determining the fiber morphology.

  As one of the above-mentioned composite bases, when the sea-island type composite base is roughly divided into two, it becomes a pipe-type base and a distribution-type base. As a typical example of a pipe-type base, as shown in FIG. 16, the composite base of Patent Document 1 is disclosed. FIG. 16 is a cross-sectional view of the composite base of Patent Document 1. In the figure, 30 is a pipe, 31 is a sea component polymer introduction flow path, 32 is an island component polymer introduction flow path, 33 is an upper base plate, 34 is a middle base plate, 35 is a lower base plate, and 40 is a sea component polymer distribution chamber. , 41 is a pipe insertion hole, and 42 is a base discharge hole. Hereinafter, in each drawing, when a member corresponding to the already-explained drawing exists, the description may be omitted by using the same reference numerals.

  Patent Document 1 is known as a pipe-type base for producing a general sea-island type fiber, and includes an upper base plate 33 provided with a sea component polymer introduction channel 31, an island component polymer introduction channel 32, and a pipe 30; The inner base plate 34 is provided with a pipe insertion hole 41 having a diameter equal to or larger than the outer diameter of the pipe 30, and the lower base plate 35 is provided with a base discharge hole 42. Therefore, the easily eluted component sea component polymer is guided from the ocean component polymer introduction channel 31 to the ocean component polymer distribution chamber 40 and fills the outer periphery of the pipe 30, whereas the hardly eluted component island component polymer is: After being guided from the island component polymer introduction flow path 32 to the pipe 30 and discharged from the pipe 30, the polymers of both components merge to form a sea-island composite cross section, and then through the pipe insertion hole 41 and from the die discharge hole 42. It is described that a composite polymer can be discharged to produce a sea-island composite fiber.

  On the other hand, as a typical example of the distribution method base, as shown in FIG. 17, the composite base of Patent Document 2 is disclosed. FIG. 17 is a plan view of the composite base of Patent Document 2. FIG. In the figure, black circle 1 indicates an island component discharge hole for discharging an island component polymer, white circle 4 indicates a sea component discharge hole for discharging a sea component polymer, 5 indicates a lowermost layer distribution plate, and 8 indicates a distribution groove. In Patent Document 2, a plurality of distribution plates are stacked, and a lowermost layer distribution plate 5 provided with distribution grooves 8, island component discharge holes 1, and sea component discharge holes 4 is disposed in the lowermost layer of the distribution plate. After the island component polymer and the sea component polymer are distributed in large numbers in advance, both the component polymer are discharged from the island component discharge hole 1 and the sea component discharge hole 4 of the lowermost layer distribution plate 5 and combined immediately after discharge. It is described that a complicated cross section can be formed.

JP 2009-91680 A International Publication No. 1989-02938 Pamphlet

However, the conventional composite base has the following problems.
The major problem of the pipe-type base of Patent Document 1 (see FIG. 16) is that the area per discharge hole is increased because the pipe thickness is added to produce one island. In addition, since the pipe 30 is press-fitted into the upper base plate 33 and fixed by welding for manufacturing the base, a welding allowance is required, and further, a hole for inserting the pipe 30 is provided. The gap between pipes cannot be reduced due to problems. Therefore, the pipes 30 cannot be densely arranged per unit area (referred to as pore filling density in the present specification), the pore filling density cannot be increased, and ultrafine fibers having a nano-order yarn diameter are manufactured. Is difficult. In addition, when the hole packing density is increased to the limit, the sea component polymer does not sufficiently reach the center side of the sea component polymer distribution chamber 40, and the island component polymers may merge. In addition, in order to obtain a desired fiber form, it is necessary to make a plurality of composite die prototypes and repeat the spinning evaluation several times. However, since the structure of this composite die is very complex, In this respect, there is a problem that the equipment cost is excessive. In addition, the degree of freedom of the arrangement of the pipes 30 is low, and there is a limit to the fiber cross-sectional shape that can be controlled, and it is difficult to manufacture a fiber in which a complicated cross-section is multilayered.

  Further, in the composite base of Patent Document 2 (see FIG. 17), the island component discharge holes 1 are arranged in the arrangement (staggered arrangement) of the island component discharge holes 1 and the sea component discharge holes 4 provided in the lowermost layer distribution plate 5, for example. In some cases, the island component polymers may be merged immediately after discharge, and a desired fiber cross-sectional shape may not be obtained. In particular, since the sea component polymer is eluted after being melt-spun, from the viewpoint of productivity, the polymer discharge rate ratio is preferably less sea component polymer to be eluted and more island component polymers. The confluence of the island component polymers becomes more prominent. In addition, once the island component polymers join together, the problem may not be resolved even if the spinning conditions such as the discharge amount of each component polymer and the discharge amount ratio are changed. If the value is not changed, production becomes impossible and productivity may deteriorate. If the staggered arrangement is adopted as the arrangement pattern of the discharge holes 1 and 4, the hole filling density can be increased due to the distance between the wall surfaces of the distribution grooves 8 of the distribution plate for supplying the polymer to the discharge holes 1 and 4. In some cases, it is difficult to produce ultra-fine fibers with a nano-order yarn diameter. In addition, when the hole packing density cannot be increased, the composite die becomes large, and there may be a problem that productivity and operability are not preferable in a multi-spindle type spinning facility in the fiber field.

  As described above, while preventing the island component polymer from joining while increasing the hole filling density of the island component discharge holes, it is an extremely important factor in producing the sea-island type composite fiber. In addition, various problems remain, which has hindered the production of sea-island type composite fibers. Therefore, solving this problem has important industrial significance.

  Accordingly, an object of the present invention is to provide an island component polymer in a distribution plate type die for producing a sea-island type composite fiber, while the composite die can be manufactured at a low cost and the hole filling density of the discharge holes of the island component polymer is increased. A composite die that can prevent merging of each other, form various fiber cross-sectional shapes with high accuracy, and maintain high dimensional stability of the cross-sectional shape, and a composite fiber that performs melt spinning by a composite spinning machine using the composite die. It is to provide a manufacturing method.

In order to solve the above problems, the composite base of the present invention has the following configuration. That is, a composite base for discharging a composite polymer flow composed of an island component polymer and a sea component polymer,
One or more distribution plates formed with distribution holes and / or distribution grooves for distributing each polymer component;
Located on the downstream side in the polymer spinning path direction of the distribution plate, and is composed of a lowermost layer distribution plate in which a plurality of island component discharge portions and a plurality of sea component discharge portions are formed,
Each of the island component discharge portions is composed of one or more island component discharge holes for discharging the island component polymer.
Each of the sea component discharge portions is composed of one or more sea component discharge holes for discharging the sea component polymer.
At least a part of the sea component discharge unit exists in a region surrounded by the two island component discharge units adjacent to each other at the shortest center distance and the two common circumscribing lines of the two island component discharge units. It is characterized by doing.

  The present invention also relates to a composite fiber method in which melt spinning is performed by a composite spinning machine using the composite base of the present invention.

  In the present invention, the “polymer spinning path direction” refers to the main direction in which each polymer component flows from the measuring plate to the die discharge hole of the discharge plate.

  In the present invention, the “direction perpendicular to the direction of polymer spinning path” refers to a direction perpendicular to the main direction in which each polymer component flows from the metering plate to the die discharge hole of the discharge plate.

  In the present invention, the “hole filling density” refers to a value obtained by dividing the number of island component discharge holes for discharging the island component polymer by the discharge introduction hole diameter. The larger the pore packing density, the more the composite fiber is composed of a larger number of island component polymer components.

  According to the composite die of the present invention, it is possible to prevent the island component polymers from joining together over a long period of time while increasing the hole filling density of the discharge holes of the island component polymers. Moreover, various fiber cross-sectional forms can be formed with high accuracy.

It is a partial enlarged plan view of the lowest layer distribution board used for the embodiment of the present invention. It is a schematic sectional drawing of the composite nozzle | cap | die used for embodiment of this invention. It is a XX arrow line view of FIG. It is a schematic sectional drawing of the composite nozzle | cap | die used for embodiment of this invention, a spinning pack, and a cooling device periphery. It is the elements on larger scale of the lowest layer distribution board used for another embodiment of this invention. It is the elements on larger scale of the lowest layer distribution board used for another embodiment of this invention. It is the elements on larger scale of the lowest layer distribution board used for another embodiment of this invention. It is sectional drawing which showed the cross-sectional form of the typical composite fiber manufactured with the composite nozzle | cap | die used for embodiment of this invention. It is a general | schematic fragmentary sectional view of the distribution plate used for embodiment of this invention, and a lowermost layer distribution plate. It is a general | schematic fragmentary sectional view of the distribution plate used for embodiment of this invention, and a lowermost layer distribution plate. It is a top view of the lowest layer distribution board used for another embodiment of this invention, and is the arrow line view seen from the same direction as FIG. It is the elements on larger scale of the lowest layer distribution board used for another embodiment of this invention. It is a general | schematic fragmentary sectional view of the lowest layer distribution plate and distribution plate used for embodiment of this invention. It is a general | schematic fragmentary sectional view of the lowest layer distribution plate and distribution plate used for embodiment of this invention. It is a general | schematic fragmentary sectional view of the lowest layer distribution plate and distribution plate used for embodiment of this invention. It is a schematic sectional drawing of the composite nozzle | cap | die of a prior art example. It is the elements on larger scale of the lowermost layer distribution plate of the composite nozzle | cap | die of a prior art example. It is the elements on larger scale of the lowermost layer distribution board different from this invention.

  Hereinafter, embodiments of the composite base of the present invention will be described in detail with reference to the drawings. 2 is a schematic cross-sectional view of a composite base used in the embodiment of the present invention, FIG. 3 is a view taken along the line XX of FIG. 2, FIG. 1 is a partially enlarged plan view of FIG. 10, FIG. 13, FIG. 14 and FIG. 15 are schematic partial sectional views of a distribution plate and a lowermost layer distribution plate used in the embodiment of the present invention, and FIG. 11 is a composite used in another embodiment of the present invention. FIG. 5, FIG. 6, FIG. 7 and FIG. 12 are partial enlarged plan views of a composite base used in another embodiment of the present invention, and FIG. 4 is used in the embodiment of the present invention. It is a schematic sectional drawing of a composite nozzle | cap | die, a spinning pack, and the periphery of a cooling device. These are conceptual diagrams for accurately transmitting the main points of the present invention, which are simplified, and the composite base of the present invention is not particularly limited, and the number of holes and grooves and the size ratio thereof are not limited. These can be changed according to the embodiment.

  As shown in FIG. 4, the composite base 18 used in the embodiment of the present invention is mounted on the spinning pack 15, is fixed in the spin block 16, and the cooling device 17 is configured immediately below the composite base 18. Therefore, after the polymer of two or more components led to the composite base 18 passes through the measuring plate 9, the distribution plate 6, and the lowermost layer distribution plate 5 and is discharged from the base discharge hole 42 of the discharge plate 10, After being cooled by the air flow blown out by the cooling device 17 and given an oil agent, it is wound up as a multifilament yarn. In addition, in FIG. 4, although the cyclic | annular cooling device 17 which blows off airflow in cyclic | annular inward is employ | adopted, you may use the cooling device which blows off airflow from one direction. In addition, as for the member provided on the upstream side of the measuring plate 9, the flow path used in the existing spinning pack 15 may be used, and it is not necessary to dedicate specially.

  As shown in FIG. 2, the composite base 18 used in the embodiment of the present invention is configured by laminating a measuring plate 9, at least one distribution plate 6, a lowermost layer distribution plate 5, and a discharge plate 10 in order. In particular, the distribution plate 6 and the lowermost layer distribution plate 5 are preferably formed of thin plates. In that case, the measuring plate 9 and the distribution plate 6, and the lowermost layer distribution plate 5 and the discharge plate 10 are positioned by the positioning pins so that the center position (core) of the spinning pack 18 is aligned, You may fix with a volt | bolt etc. and you may carry out metal joining (diffusion joining) by thermocompression bonding. In particular, since the distribution plates 6 and the distribution plate 6 and the lowermost layer distribution plate 5 use thin plates, it is preferable to perform metal bonding (diffusion bonding) by thermocompression bonding.

  Therefore, the polymer of each component supplied from the measuring plate 9 passes through the distribution groove 8 and the distribution hole 7 of the distribution plate 6 laminated at least one, and then discharges the island component polymer of the lowermost distribution plate 5. By discharging from the island component discharge hole 1 and the sea component discharge hole 4 for discharging the sea component polymer, the polymers of the respective components merge to form a composite polymer flow. Thereafter, the composite polymer flow passes through the discharge introduction hole 11 and the reduction hole 12 of the discharge plate 10 and is discharged from the base discharge hole 42.

  First, the principle that can prevent merging of polymers of island components while increasing the hole packing density of the composite die 18 which is the most important point of the present invention will be described. Here, in order to increase the hole packing density, the interval between the island component discharge holes 1 must be as close as possible, but in this case, the island component polymers merge between adjacent island component discharge holes. . In order to prevent the island component polymers from merging with each other, for example, as shown in FIG. 18, the island component discharge hole 1 is surrounded by the sea component discharge hole 4 for discharging the sea component polymer. Although it can be imagined relatively easily to suppress the merging of adjacent island component polymers, the distance between the island component discharge holes becomes too large to increase the hole filling density. In other words, there is a trade-off relationship between the hole packing density and the prevention of merging of the island component polymers.

  Therefore, preventing the merging of the island component polymers while increasing the hole packing density is an extremely important technique for producing the composite fiber. Accordingly, the present inventors have conducted extensive studies on the above-mentioned problem, which was not considered in the conventional technology, and as a result, have found a new technology of the present invention.

  That is, the lowermost layer distribution plate 5 of the embodiment of the present invention is surrounded by two island component discharge holes that are adjacent at the shortest distance between the center points, and two common circumscribing lines of the two island component discharge holes. Each discharge hole is arranged so that at least a part of the sea component discharge hole exists in the region. Specifically, as shown in FIG. 1, a certain island component discharge hole 1 is used as a reference, and the island component discharge hole 1 adjacent to the reference island component discharge hole 1 at the shortest center distance is referred to as an island component discharge hole 2a. The sea component discharge hole 1 in the region surrounded by the reference island component discharge hole 1, the island component discharge hole 2a, and the two common circumscribing lines 3 of the two island component discharge holes 1 and 2a. Each discharge hole is arranged so that at least a part of 4 is present. By adopting such a configuration, it is possible to prevent merging of the polymers between the reference island component discharge hole 1 and the island component discharge hole 2a, where the merging of the polymers is most likely to occur.

  Explaining the principle of the present invention along the flow form of the polymer, both the island component polymer and the sea component polymer are simultaneously discharged toward the discharge introduction hole 11 on the downstream side of the lowermost layer distribution plate 5, As each polymer widens in a direction perpendicular to the direction of the polymer spinning path, the polymer flows along the direction of the polymer spinning path, and the two polymers merge to form a composite polymer stream. At that time, in order to prevent the island component polymer discharged from the reference island component discharge hole 1 and the island component discharge hole 2a from joining, a sea component polymer that physically divides the island component polymer is interposed. Is effective. That is, a channel space connecting the reference island component discharge hole 1 and the island component discharge hole 2a (in this case, the reference island component discharge hole 1, the island component discharge hole 2a, and the two island component discharge holes 1 and 2a). In the region surrounded by the two common outer tangent lines 3), at least a part of the sea component discharge hole 2 for supplying the sea component polymer is present to prevent the island component polymers from joining each other. be able to.

  In the lowermost layer distribution plate 5 in the present invention, the island component discharge holes 1 are often formed with one or two types of cycles. For example, in the lowermost layer distribution plate 5 of FIG. 1, the island component discharge holes 1 are formed in two types of cycles. One is the distance between the center points of the reference island component discharge hole 1 and the island component discharge hole 2a, which is the shorter cycle. This shorter cycle is the aforementioned “shortest distance between center points”. The other is the distance between the center points of the reference island component discharge hole 1 and the island component discharge hole 2b, which is the longer cycle. When the island component discharge holes 1 are formed in one cycle, the distance between the center points of the reference island component discharge holes 1 and the island component discharge holes 2a, the reference island component discharge holes 1 and the island component discharge holes The distance between the center points with 2b is the same. In FIG. 1, the repeating directions of the two types of cycles are orthogonal, but may not be orthogonal.

  When the island component discharge holes 1 are formed with two types of cycles, (i) a reference island component discharge hole 1 and an island component discharge hole 2a adjacent to each other with a shorter cycle, and the two island component discharge holes 1 2a, at least part of the sea component discharge hole 4 exists in a region surrounded by the two common outer tangent lines 3 and (ii) a reference island component discharge hole adjacent in a longer cycle 1. Arranged so that at least a part of the sea component discharge hole 4 exists in a region surrounded by the island component discharge hole 2b and the two common outer tangents 3 of the two island component discharge holes 1 and 2b. It is preferable to do. The shortest distance between the center points, that is, the shorter distance between the center points, that is, the longer one, so that the island component polymers discharged from the two adjacent island component discharge holes 1 and 2a in the shorter cycle can be easily merged. The island component polymers discharged from the two adjacent island component discharge holes 1 and 2b with a period of are easily joined together. Therefore, the island component is arranged by disposing at least a part of the sea component discharge hole 4 for supplying the sea component polymer also in the channel space connecting the reference island component discharge hole 1 and the island component discharge hole 2b. Merge of polymers can be prevented.

  The lowermost layer distribution plate 5 according to the present invention has at least two sea component discharges in a region surrounded by two adjacent island component discharge holes and two common circumscribing lines of the two island component discharge holes. It is preferable that at least a part of each hole exists, and two sea component discharge holes are arranged across a line segment connecting the centers of two adjacent island component discharge holes. Specifically, as shown in FIG. 1, two adjacent island component discharge holes 1 (reference island component discharge hole 1 and island component discharge hole 2a, or reference island component discharge hole 1 and island component discharge hole 2b). And at least a part of each of at least two sea component discharge holes 4 and two adjacent island component discharge holes 1 (reference island component discharge hole 1 and island component discharge hole 2a, and The two sea component discharge holes 4 are arranged across a line segment A connecting the centers of the reference island component discharge hole 1 and the island component discharge hole 2b). By doing so, in the state where the adjacent island component discharge holes 1 are close to the processing limit level, the two sea component discharge holes 4 can be arranged at the closest positions, so that the hole filling density is increased to the limit. However, it is possible to prevent the island component polymer from joining. Moreover, although arrangement | positioning of the two sea component discharge holes 4 is not specifically limited, It is preferable to arrange | position so that the line segment A may be a line symmetry axis. The island component polymer discharged and widened from the island component discharge hole 1 is rejected to widen by the sea component polymer discharged from the two sea component discharge holes 4 and has a certain shape. It is preferable that the discharge holes 4 are arranged so that the line segment A is an axis of line symmetry, because the shape of the island component polymer after widening becomes a clean target shape having the line segment A as an axis of line symmetry.

  Further, by setting the minimum gap DA between the two adjacent island component discharge holes 1 and the minimum gap DB between the two sea component discharge holes 4 to be DB / DA ≦ 0.7, the island component polymer and the sea component polymer Regardless of physical properties such as melt viscosity, spinning conditions such as the discharge rate and discharge rate ratio of each polymer, merging of island component polymers is stable within the range of spinning conditions that allow industrial production of composite fibers. Can be prevented. When DB / DA> 0.7, merging of island component polymers may occur. In addition, the lower limit of DB / DA is not particularly defined, and the smaller the smaller, the more the island component polymers can be prevented from joining, but the minimum gap DA becomes larger and the hole filling density becomes smaller. And the lower limit can be set.

Next, another embodiment of the present invention shown in FIGS. 5, 6, 7, and 12 will be described.
Another embodiment of the present invention shown in FIG. 5 includes two adjacent island component discharge holes 1 (a reference island component discharge hole 1 and an island component discharge hole 2a, and a reference island component discharge hole 1 and an island component discharge hole. A sea component discharge hole 4 is disposed so as to completely block the flow path space connected in 2b). In this embodiment, since the sea component polymer is present in a path space where the island component polymers are expected to merge with each other, the island component polymers can be further prevented from joining. However, in this embodiment, the distance between the adjacent island component discharge holes 1 cannot be made smaller than the size of the sea component discharge holes 4.

  In another embodiment of the present invention shown in FIG. 6, the cross-sectional shape of the sea component discharge hole 4 is different from the round shape. In this case, since the sea component discharge hole 4 can be arranged even in a place where the hole shape cannot be arranged unless the hole diameter is reduced in the round shape, the sea component polymer can be locally discharged, and the merging of the island component polymers can be further prevented. At the same time, the adjacent island component discharge holes 1 can be brought close to the limit, and the hole filling density can be increased. When the sea component discharge hole 4 has a cross-sectional shape other than the round shape, a distribution hole 7 having a round cross-sectional shape is connected to the upstream side of the sea component discharge hole 4 so as to communicate with the distribution hole 7 directly above. It is preferable to discharge the sea component polymer through the sea component discharge hole 4 after ensuring the meterability of the sea component polymer. Moreover, by controlling the cross-sectional shape of the sea component discharge hole 4, the island component polymer discharged from the island component discharge hole 1 and widened can be controlled to have an arbitrary cross-sectional shape.

  Further, in another embodiment of the present invention shown in FIG. 7, the sea component discharge hole 4 is a circumferential slit surrounding the island component discharge hole 1. In this case, since the sea component polymer exists in the entire path space where the island component polymers are expected to merge, the island component polymers can be further prevented from joining. Even in the case where the sea component discharge hole 4 has such a cross-sectional shape, a distribution hole 7 having a round cross-sectional shape is arranged in communication with the upstream side of the sea component discharge hole 4 so that the sea component polymer is disposed in the distribution hole 7 directly above. It is preferable to discharge the sea component polymer through the sea component discharge hole 4 after securing the measurement property.

  In the lowermost layer distribution plate 5 in the present invention, the island component discharge holes 1 and the sea component discharge holes 4 may be arranged on the entire surface, or, as shown in FIG. The component discharge holes 4 may be densely arranged (portion surrounded by a virtual circle 19 in FIG. 3). In the case of the form as shown in FIG. 3, if the island component discharge holes 1 and the sea component discharge holes 4 in each virtual circle 19 are arranged as described above, the island component discharge in the virtual circle 19 is performed. The arrangement of the holes 1 and the sea component discharge holes 4 may be the same for all virtual circles 19 or may be different for each virtual circle 19. Furthermore, as shown in FIG. 11, the arrangement of the island component discharge holes 1 and the sea component discharge holes 4 may be partially different in one virtual circle 19 (the right side in the virtual circle 19 in FIG. 11). Half and left half). Also in this case, the island component discharge holes 1 and the sea component discharge holes 4 in the individual portions may be arranged as described so far.

  In addition, as shown in FIG. 12, the lowermost layer distribution plate 5 in the present invention collects a plurality of island component discharge holes 1 for discharging the island component polymers that join together in order to intentionally join the island component polymers together. A hole group (aggregate) may be formed. Further, in order to intentionally join the sea component polymers, a plurality of sea component discharge holes 4 for discharging the sea component polymers to be joined may be collected to form a hole group (aggregate). In this case, among the island component discharge holes 1 constituting one hole group, an area surrounded by a line connecting the outermost island component discharge holes 1 so as to be in contact with each other in sequence is an island component discharge unit. And In addition, among the sea component discharge holes 4 constituting one hole group, a region surrounded by a line connecting the outermost sea component discharge holes 4 so as to be in contact with each other sequentially is defined as a sea component discharge portion. In addition, only the island component discharge hole 1 exists in the island component discharge part, and only the sea component discharge hole 4 exists in the sea component discharge part. The hole group of the island component discharge hole 1 is the island component discharge hole portion 21, the hole group of the island component discharge hole 2 a is the island component discharge hole portion 22 a, and the hole group of the island component discharge hole 2 b is the island component discharge hole portion 22 b, The group of sea component discharge holes 4 is defined as a sea component discharge hole portion 24, and the island component discharge hole 1, the island component discharge hole 2a, the island component discharge hole 2b, and the sea component discharge hole 4 in the above description are respectively designated as islands. What is necessary is just to read as the component discharge part 21, the island component discharge part 22a, the island component discharge part 22b, and the sea component discharge part 24. In other words, in the lowermost layer distribution plate 5 of the embodiment shown in FIGS. 1, 5, 6 and 7, the island component discharge part is composed of one island component discharge hole, and the sea component discharge part has one sea component discharge. It is a lowermost layer distribution plate composed of holes. In the embodiment of FIG. 12, the island component polymer discharged from the island component discharge hole 1 (2a, 2b) in the island component discharge portion 21 (22a, 22b) or the sea component discharge hole in the sea component discharge portion 24 is used. The sea component polymers discharged from No. 4 are merged immediately after the discharge, but are originally intended to be merged, so there is no problem even if they merge.

  As described above, the composite base 18 of the present invention can easily distribute the sea component polymer in the fiber cross-sectional direction by using the lowermost distribution plate 5 and the distribution groove 8 of the distribution plate 6 immediately above the lower distribution plate 5. The sea component discharge portion 24 or the sea component discharge hole 4 can be easily arranged in a very narrow region between the two island component discharge portions 21 or the island component discharge holes 1. As a result, the hole filling density can be increased by bringing two adjacent island component discharge portions 21 or island component discharge holes 1 close to each other. Moreover, since the arrangement pattern of the island component discharge holes 1 can be easily changed by adding and overlapping the distribution plate 6 directly below the lowermost layer distribution plate 5, the time and cost associated with the design change are reduced. There are also advantages.

  Next, each member common to the composite nozzle | cap | die 18 of embodiment of this invention shown in FIG.1, FIG.5, FIG.6, FIG.7 and FIG. 12 and the shape of each member are demonstrated in detail.

  The composite base 18 in the present invention is not limited to a circular shape, and may be a quadrangle or a polygon. Further, the arrangement of the base discharge holes 42 in the composite base 18 may be appropriately determined according to the number of multifilament yarns, the number of yarns, and the cooling device 17. As the cooling device 17, in the case of an annular cooling device, the base discharge holes 42 are preferably arranged in a ring or in a row over a plurality of rows, and in the case of a one-way cooling device, the base discharge holes 42 are arranged in a staggered manner. Is good. The cross section of the nozzle discharge hole 42 in the direction perpendicular to the polymer spinning path direction is not limited to a round shape, and may be a cross section other than a round shape or a hollow cross section. However, in the case of a cross-sectional shape other than a round shape, it is preferable to increase the length of the die discharge hole 42 in order to ensure the meterability of the polymer.

  Moreover, the island component discharge hole 1 in the present invention is not limited to a round shape in a cross section perpendicular to the polymer spinning path direction, and may have a cross-sectional shape other than a round shape or a hollow cross-sectional shape. When the island component discharge hole 1 has a cross-sectional shape other than a round shape, the metering property of the polymer can be improved by the distribution hole 7 having a round cross-section shape communicating with the island component discharge hole 1 immediately above. After securing, it is preferable to discharge the polymer through the island component discharge holes 1 having a cross-sectional shape other than the round shape.

  Further, the discharge introduction hole 11 in the present invention is provided with a constant running section from the lower surface of the lowermost layer distribution plate 5 in the polymer spinning path direction, so that the flow velocity difference immediately after the island component polymer and the sea component polymer merge. Can be relaxed and the composite polymer stream can be stabilized. Further, the hole diameter of the discharge introduction hole 11 is larger than the outer diameter of the virtual circle 19 of each discharge hole group of the island component discharge hole 1 and the sea component discharge hole 4 disposed in the lowermost layer distribution plate 5 and is virtual. It is preferable that the cross-sectional area of the circle 19 and the cross-sectional area ratio of the discharge introduction hole 11 be as small as possible. Thereby, the widening of each polymer discharged from the lowermost layer distribution plate 5 is suppressed, and the composite polymer flow can be stabilized.

  Further, the reduction hole 12 in the present invention is unstable such as draw resonance of the composite polymer flow by setting the reduction angle α of the flow path from the discharge introduction hole 11 to the die discharge hole 42 in the range of 50 to 90 °. It is possible to suppress the phenomenon and supply the composite polymer stream stably. Here, when the reduction angle α is smaller than 50 °, the instability phenomenon of the composite polymer flow can be suppressed, but the composite base 18 itself is enlarged, and when the reduction angle α is larger than 90 °, the composite polymer flow is reduced. Instability phenomenon may become more prominent.

  The island component discharge hole 1, sea component discharge hole 4 and distribution hole 7 in the present invention preferably have a constant hole cross-sectional area in the polymer spinning path direction, but the cross-sectional area gradually decreases or increases, Alternatively, it may be gradually decreased and gradually increased. This is because, in the distribution plate 6 and the lowermost layer distribution plate 5 according to the present invention, the hole cross-sectional area may not be constant when a minute hole is processed since the hole processing is mainly performed using an etching process. In this case, the processing conditions and the like may be appropriately optimized.

  Further, the lowermost layer distribution plate 5 in the present invention may be one, or a plurality of layers may be laminated. In this case, in the single lowermost layer distribution plate 5, when the polymer meterability of the island component discharge hole 1 and the sea component discharge hole 4 cannot be obtained and the fiber form changes with time, a plurality of sheets are laminated. Thus, the meterability of the polymer can be ensured.

  As shown in FIG. 9, the method of distributing one component polymer on the distribution plate 6 in the present invention may be a tournament type flow path that forms one distribution groove 8 for one distribution hole 7. As shown in FIG. 10, a slit system may be used in which one distribution groove 8 is formed for a plurality of distribution holes 7 or a plurality of distribution grooves 8 are formed for a plurality of distribution holes 7. A composite system combining the system and the slit system may be used. Here, the polymer of the other components also adopts the same distribution method as described above, but only one component polymer will be described for the sake of simplicity.

  The tournament system has the advantage that the distribution hole 7 is disposed at the end of the distribution groove 8, thereby eliminating abnormal stagnation of the polymer, high polymer distribution, and precise control. However, for example, when one distribution groove 8 or distribution hole 7 is blocked due to polymer clogging or the like during production, the polymer is not distributed downstream, and as a result, a desired composite cross-section fiber may not be obtained. is there.

  In addition, since the slit method has a plurality of distribution holes 7 for one distribution groove 8, it is highly compatible with problems such as blockage of the holes and grooves, and one distribution plate. 6 allows a large amount of polymer to be distributed in a direction perpendicular to the direction of the polymer spinning path. Therefore, the number of distribution plates 6 can be reduced, which has the advantage of reducing the manufacturing cost of the composite die 18. However, on the other hand, abnormal retention of the polymer is likely to occur, and the precise control of the polymer distribution may be inferior to the tournament method. Therefore, by adopting a composite system that forms a slit system on the upstream side (metering plate 9 side) and a tournament system on the downstream side (lowermost layer distribution plate 5 side), poor polymer distribution due to blockage in holes and grooves on the upstream side. However, it is preferable that the polymer is distributed in a direction perpendicular to the polymer spinning path direction, and the polymer is uniformly distributed on the downstream side by increasing the metering property of the polymer.

  Further, in the slit method, as a method for improving the measurement property of the polymer, when a one-component polymer passes through the distribution hole 7 (inflow side) -distribution groove 8-distribution hole 7 (outflow side), the distribution on the inflow side is performed. The diameter of the distribution hole 7 on the outflow side is smaller than the diameter of the distribution hole 7 on the inflow side with respect to the hole 7, and the diameter of the far side is increased. In other words, the hole diameter is adjusted so that the flow path pressure loss is equal between the distribution hole 7 (outflow side) closer to the inflow side distribution hole 7 and the distant distribution hole 7 (outflow side). preferable. Further, the flow path pressure loss may be adjusted by the groove width of the flow path groove 8. Further, as described above, in order to equalize the flow path pressure loss in all the distribution plates 6, the dimensions of the distribution holes 7 and the distribution grooves 8 may be adjusted, but the distribution plate in contact with the lowermost layer distribution plate 5. Only the six distribution holes 7 may be adjusted in diameter so that all the flow path pressure losses on the upstream side are equal.

  Further, in the tournament method, as a method for suppressing the blockage of the holes and grooves, it is preferable to increase the hole diameter of the distribution holes 7, the groove width and the groove depth of the distribution grooves 8, and particularly in the direction of the polymer spinning path. In accordance with the upstream side (metering plate 9 side), the thickness of the distribution plate 6 constituting the distribution groove 8 should be increased, and the groove depth of the distribution groove 8 should be increased, and the upstream side in the polymer spinning path direction According to the (measuring plate 9 side), the groove width of the distribution groove 8 should be increased, and the hole diameter of the distribution hole 7 should be increased. As a result, a larger flow space is usually secured as the flow rate of the polymer passing through the distribution groove 8 and distribution hole 7 in the distribution plate 6 on the upstream side (metering plate 9 side) in the polymer spinning path direction increases. As a result, an increase in flow path pressure loss can be suppressed. Further, by increasing the thickness of the upstream distribution plate 6 where the flow path pressure loss is likely to increase, the deflection of the distribution plate 6 can be suppressed. Further, regarding the polymer distribution method on the distribution plate 6, the distribution groove 8 and the distribution hole 7 of the distribution plate 6 may be appropriately arranged according to the desired fiber cross-sectional shape, and the method is not particularly limited to the above method. Absent.

  Further, only one distribution hole 7 may be provided in one distribution plate 6 of the present invention, only the distribution groove 8 may be provided, or distribution may be performed upstream of the distribution plate 6. A hole 7 may be provided, and a distribution groove 8 (downstream side) may be provided so as to communicate with the hole 7. A distribution groove 8 may be provided upstream of the distribution plate 6, and communicate with the distribution groove 8. 7 (downstream side) may be disposed.

  Here, when the hole filling density of the island component discharge holes 1 of the lowermost layer distribution plate 5 is increased, that is, when the arrangement interval of the island component discharge holes 1 is decreased, the sea component is disposed between the adjacent island component discharge holes 1. In order to provide the discharge holes 4, the distribution plate 6 and the lowermost layer distribution plate 5 of the present invention have a laminated structure of thin plates. The distribution holes 7 arranged in the distribution plate 6 distribute the polymer mainly in the polymer spinning path direction, and the distribution groove 8 distributes the polymer mainly in the direction perpendicular to the polymer spinning path direction. By alternately laminating the distribution plate 6 provided with the distribution holes 7 and the distribution plate 6 provided with the distribution grooves 8, the polymer can be distributed freely and easily in the fiber cross-sectional direction. By utilizing this, the sea component discharge holes 4 can be arranged in a very narrow region between the adjacent island component discharge holes 1.

  In particular, as shown in FIG. 13, the distribution hole 6 and the distribution groove 8 may be provided in the distribution plate 6 immediately above the lowermost layer distribution plate 5. In this case, the island component discharge hole 1 is communicated with the distribution hole 7, and the sea component discharge hole 4 is communicated with the distribution groove 8. In this way, in the distribution plate 6, the distribution groove 8 can be disposed at a position closer to the distribution hole 7, and the sea component discharge hole 4 communicating therewith can be disposed closer to the island component discharge hole 1. While increasing the hole packing density, it is possible to prevent merging of the polymers. Further, as shown in FIG. 14, the distribution plate 6 immediately above the lowermost layer distribution plate 5 may have a distribution hole 7 communicating with the downstream side of the distribution groove 8 in the polymer spinning path direction. As shown, even if the distribution groove 8 communicates with the distribution hole 7 on the downstream side in the polymer spinning path direction, the same effect as described above can be obtained.

  Next, the manufacturing method of the composite fiber common to the composite nozzle | cap | die 18 of embodiment of this invention shown in FIG.1, FIG.5, FIG.6 and FIG. 7 is demonstrated in detail.

  The composite fiber manufacturing method of the present invention may be a known composite spinning machine using the composite base 18 of the present invention. For example, in the case of melt spinning, the spinning temperature is set to a temperature at which a high melting point or high viscosity polymer mainly exhibits fluidity among two or more types of polymers. The temperature indicating the fluidity varies depending on the molecular weight, but the melting point of the polymer is a guideline and may be set at a melting point + 60 ° C. or lower. If it is less than this, the polymer is not thermally decomposed in the spinning head or the spinning pack, and the molecular weight reduction is suppressed, which is preferable. The spinning speed varies depending on the physical properties of the polymer and the purpose of the composite fiber, but can be about 500 to 6000 m / min. In particular, when high mechanical properties are required for industrial material applications, it is preferable to use a high molecular weight polymer, set to 500 to 2000 m / min, and then stretch at a high magnification. In stretching, it is preferable to appropriately set the preheating temperature using as a guide the temperature at which the polymer can be softened, such as the glass transition temperature of the polymer. The upper limit of the preheating temperature is preferably a temperature at which yarn path disturbance does not occur due to spontaneous elongation of the fiber during the preheating process. For example, in the case of PET having a glass transition temperature in the vicinity of 70 ° C., this preheating temperature is usually set at about 80 to 95 ° C.

  Moreover, it is preferable to control the discharge rate ratio of the polymer of each component discharged from the island component discharge hole 1 and the sea component discharge hole 4 of the present invention by the discharge amount, the hole diameter, and the number of holes. (The discharge speed is a value obtained by dividing the discharge flow rate by the cross-sectional area of the island component discharge hole 1 or the sea component discharge hole 4.) The discharge speed range is the discharge speed of the island component polymer per single hole. When the discharge rate of Va and sea component polymer is Vb, the ratio (Va / Vb or Vb / Va) is preferably 0.05 to 20, more preferably 0.1 to 10. In this range, since the polymer discharged from the lowermost distribution plate 5 is led as a laminar flow through the discharge introduction hole 11 to the reduction hole 12, the cross-sectional shape is remarkably stabilized and the shape is maintained with high accuracy. be able to.

  Moreover, the composite polymer flow can be stably formed by setting the melt viscosity ratio of the polymer used in the present invention to less than 2.0. When the melt viscosity ratio is 2.0 or more, the island component polymer and the sea component polymer become unstable when they merge, and there are cases where uneven thickness of the yarn occurs in the traveling direction of the obtained fiber cross section.

  Next, as a manufacturing method of the distribution plate 6 and the lowermost layer distribution plate 5 of the present invention, a pattern is transferred to a thin plate, which is usually used for processing of electric / electronic parts, and fine processing is performed by chemical processing. Etching is preferred. Since this processing method does not require consideration for distortion of the workpiece, the lower limit of the thickness of the workpiece is not limited as compared with the other processing methods described above, and the present invention refers to an extremely thin metal plate. The merge groove 8, the distribution hole 7, and the island component discharge hole 1 can be formed. In addition, since the distribution plate 6 and the lowermost layer distribution plate 5 manufactured by etching can be reduced in thickness per sheet, the effect on the total thickness of the composite base 18 even if a plurality of sheets are stacked. There is almost no need to newly install another pack member in accordance with the composite fiber having a desired cross-sectional shape. In other words, if only the distribution plate 6 and the lowermost layer distribution plate 5 are exchanged, the cross-sectional shape can be changed. Further, as another manufacturing method, it is possible to use a lathe, machining, press, laser processing, or the like, which is a drill processing or metal precision processing used in conventional base manufacturing. However, since these processes are limited in the lower limit of the thickness of the processed plate from the viewpoint of suppressing distortion of the workpiece, the thickness of the distribution plate 6 is applicable to the composite die of the present invention in which a plurality of distribution plates are laminated. Need to be considered.

  Next, the fiber obtained by the composite base of the present invention means a fiber in which two or more kinds of polymers are combined, and two or more kinds of polymers are present in the form of a sea island or the like in the fiber cross section. Say the fiber you are doing. Here, it is needless to say that the two or more types of polymers referred to in the present invention include the use of two or more types of polymers having different molecular structures such as polyester, polyamide, polyphenylene sulfide, polyolefin, polyethylene, and polypropylene. However, matting agents such as titanium dioxide, silicon oxide, kaolin, anti-coloring agents, stabilizers, antioxidants, deodorants, flame retardants, yarn friction reducing agents, coloring, as long as the yarn-making stability is not impaired. Examples include various functional particles such as pigments and surface modifiers, additives such as organic compounds, and different amounts of particles added, different molecular weights, and copolymerization.

  Further, the single yarn cross section of the fiber obtained by the composite base 18 of the present invention may be not only a round shape but also a shape other than a round shape such as a triangle or a flat shape, or a hollow shape. Further, the present invention is an extremely versatile invention, and is not particularly limited by the single yarn fineness of the composite fiber, is not particularly limited by the number of single yarns of the composite fiber, and further, the number of yarns of the composite fiber Is not particularly limited, and may be a single yarn or a multi-yarn of two or more yarns.

  As shown in FIG. 8A, the sea-island composite fiber obtained by the composite base of the present invention has a sea-island structure (here, the sea-island structure) in a cross section in which two or more different types of polymers are perpendicular to the fiber axis direction. The fiber in which the island part comprised by the island component polymer 13 is formed into the structure which is distinguished in multiple by the sea part comprised by the sea component polymer 20 is said. In that case, there is no restriction on the cross-sectional shape of the island part, and the cross-sectional shape of the island part may be constituted by one island component discharge hole 1, and the island component discharge part 21 in which a plurality of island component discharge holes 1 are gathered. The cross-sectional shape may be configured. By collecting the plurality of island component discharge holes 1 into an arbitrary shape to form the island component discharge portion 21, the island portion can be formed into an arbitrary shape. For example, as shown in FIG. 8B, by arranging a plurality of island component discharge holes 1 in a star shape to form an island component discharge portion 21, the shape of the island portion can be changed to a star shape. Further, by eluting the sea component polymer 20 which is an easily eluted component, not only so-called ultrafine fibers but also split fibers can be obtained. In addition, by controlling the island component polymer 13 and the sea component polymer 20, in the cross section perpendicular to the fiber axis direction, the island portion can be arranged with dots, so unlike the pipe-type base described in the prior art, The number of islands can be greatly increased, that is, the hole packing density can be increased. Regarding the number of islands, it is theoretically possible to produce an infinite range from two islands within the range allowed by the space, but 2 to 10,000 islands is a preferred range as a practically feasible range. The range for obtaining the superiority of the composite die of the present invention is more preferably 100 to 10,000 islands.

In the present invention, the hole filling density is preferably 0.1 hole / mm ² or more. If the hole packing density is 0.1 hole / mm ² or more, the difference from the conventional composite die technology becomes more clear. In the range examined by the present inventors, the hole filling density could be implemented if it was in the range of 0.1 to 20 holes / mm ² . From the viewpoint of the hole filling density, a range in which the superiority of the composite die of the present invention is obtained is preferably 1 to 20 holes / mm ² .

  In addition, the sea-island composite fiber in the present invention is a fiber having a fiber diameter of 10 to 1000 nm and a fiber diameter variation as a very reduced ultrafine fiber that cannot be obtained by single spinning by eluting the sea component polymer 20. A long-fiber nanofiber having excellent uniformity with a diameter CV% of 0 to 30% can be produced. By forming the long fiber type nanofibers into a sheet-like material, the long fiber type nanofibers can be suitably used for finishing the aluminum alloy substrate or the glass substrate used for a magnetic recording disk or the like with ultrahigh precision. As another application, it is also possible to produce a sheet-like material in which some islands are intentionally joined and the fiber diameter distribution is freely controlled.

  Moreover, a core-sheath composite fiber can also be obtained by comprising the island part of a sea-island composite fiber with two types of island component polymers. As shown in FIG. 8C, the core-sheath composite fiber is configured such that the sheath component covers the core component in a cross section perpendicular to the fiber axis direction by two or more different polymers. .

  As a method for producing the core-sheath conjugate fiber, in the lowermost layer distribution plate 5 of the composite base 18 of the present invention, for example, the arrangement of the discharge holes 1 of the island component polymer (A) 13 is collected on the center side of the island portion, What is necessary is just to comprise the island component discharge part 21 of the island component polymer (B) 14 different from the island component polymer (A) 13 so as to surround the island component discharge portion 21. After spinning as a conjugate fiber, the core-sheath conjugate fiber can be obtained by eluting the sea component polymer 20. Moreover, it can be set as a multi-core sheath fiber by laminating | stacking two or more island component polymer (A) 13 and island component polymer (B) 14 in a cross-sectional direction.

  The use of this core-sheath composite fiber is not limited to being excellent in quality and sensitivity when used for clothing, but also from the standpoint of mechanical properties, chemical resistance, and heat resistance. Since it becomes the fiber which has the characteristic which cannot be taken out with a polymer, it can be used effectively also for an industrial material use. In particular, bending fatigue and wear characteristics are improved as compared with conventional products, and it can be suitably used not only for rubber reinforcement applications such as tire cords and tire cap layer materials, but also for fishing nets and agricultural materials, as well as screen rods.

  Moreover, a side-by-side composite fiber can also be obtained by configuring the island portion of the sea-island composite fiber with two types of island component polymers. As shown in FIG. 8 (d), the side-by-side composite fiber constitutes a form in which two or more different polymers are bonded to each other in a cross section perpendicular to the fiber axis direction. Refers to fibers that are regularly arranged with a spacing of.

  As a method for producing this side-by-side composite fiber, the island component discharge hole 1 for discharging the island component polymer (A) 13 and the island component polymer (A) 13 in the lowermost layer distribution plate 5 of the composite base 18 of the present invention are: The island component discharge holes 4 for discharging different island component polymers (B) 14 are collected as discharge hole groups, and the discharge hole groups are arranged adjacent to each other and arranged symmetrically or asymmetrically. That's fine. After spinning as a composite fiber, a side-by-side composite fiber can be obtained by eluting the sea component polymer. Thus, two or more types of polymers may be laminated together, and it is also preferable to impart three or more types of properties by bonding three or more types of polymers.

  As an application of this side-by-side composite fiber, a fiber having shrinkage characteristics and dyeing characteristics changed in the cross-sectional direction in the fiber cross-sectional direction can be obtained. For example, if a polymer that exhibits shrinkage due to moisture absorption is placed on one side, the mesh of the fabric changes due to moisture absorption, so that the fabric has a breathable self-adjusting function and a moisture-permeable waterproof function for clothing.

  As described above, the composite form that can be manufactured by the composite base 18 of the present invention has been described by exemplifying a conventionally known cross-sectional form. However, in the composite base 18 of the present invention, the cross-sectional form can be arbitrarily controlled. Therefore, a free form can be produced without being restricted by the above form.

  In addition, the strength of the composite fiber of the present invention is preferably 2 cN / dtex or more, and is preferably 5 cN / dtex or more in view of mechanical properties required for industrial material applications. A practical upper limit is 20 cN / dtex. The elongation is preferably 2 to 60% for drawn yarn, particularly 2 to 25% in the industrial material field where high strength is required, and 25 to 60% for clothing. Further, the conjugate fiber of the present invention can be used in various fiber products such as fiber winding packages, tows, cut fibers, cotton, fiber balls, cords, piles, woven and knitted fabrics, non-woven fabrics, paper, and liquid dispersions.

Hereinafter, the effects of the composite die of the present invention will be specifically described with reference to examples. In each of the examples and comparative examples, the island-component composite fiber is formed by using the lowermost layer distribution plate in which the island component discharge portion is composed of one island component discharge hole and the sea component discharge portion is composed of one sea component discharge hole. Spinning was performed, and the presence or absence of the island component polymer was determined as described below. Example 4 is a reference example.

(1) Precipitation of island component of sea-island type composite fiber In order to deposit island component from sea-island type composite fiber, remove the composite fiber by immersing it in a solution that can elute sea component, which is an easily eluted component. The fiber of the island component was obtained. When the easily eluting component was copolymerized PET or polylactic acid (PLA) in which 5-sodium sulfoisophthalic acid or the like was copolymerized, an alkaline aqueous solution such as an aqueous sodium hydroxide solution was used. Further, when the aqueous alkali solution is heated to 50 ° C. or higher, the progress of hydrolysis can be accelerated, and if it is processed using a fluid dyeing machine or the like, it can be processed in a large amount at a time.

(2) Island component polymer joined or not The sea-island composite fiber at the start of spinning is cut at an arbitrary position in the fiber axis direction, and the fiber cross section is applied to VE-7800 scanning electron microscope (SEM) manufactured by Keyence Corporation. The image was taken at a magnification of 3000 times. Use the image processing software (WINROOF) to measure the total number of islands of the fibers obtained from the cross-sectional photograph taken above, and the total number of islands is the total number of discharge holes (close to the discharge holes arranged in the lowermost distribution plate) If the value divided by the sum of the discharge holes is 1, there is no merging between the island component polymers (no merging), and if it is less than 1, there is merging between the island component polymers (with merging). In addition, in order to evaluate the change of the cross-sectional shape over time, spinning was performed continuously for 72 hours from the start of spinning, and the cross section of the sea-island type composite fiber after 72 hours was photographed in the same way, The presence or absence of merging with each other was determined.

(2) Intrinsic viscosity [η]
Measurement was performed at 25 ° C. using orthochlorophenol as a solvent.

[Example 1]
Polyethylene terephthalate (PET) with intrinsic viscosity [η] 0.65 as the island component polymer and PET copolymerized with 5.0 mol% 5-sodium sulfoisophthalic acid with intrinsic viscosity [η] 0.58 as the sea component polymer (Copolymerized PET) is separately melted at 285 ° C., and using the composite die 18 according to the embodiment of the present invention, the sea / island component is discharged at a discharge ratio of 30/70, and then cooled by the cooling device 17. Thereafter, refueling, entanglement treatment, and thermal stretching were performed, and winding was performed with a winding roller at a speed of 1500 m / min, and unstretched fibers of 150 dtex-10 filament (single hole discharge amount 2.25 g / min) were collected. The wound unstretched fiber was stretched 2.5 times between rollers heated to 90 ° C. and 130 ° C. to obtain a stretched fiber of 60 dtex-10 filament.

The lowermost layer distribution plate of the composite base was configured as shown in FIG. The island component discharge holes 1 had 1200 holes, a hole packing density of 2.0 holes / mm ² , a diameter of 0.2 mm, a longer period of 0.6 mm, and a shorter period of 0.45 mm. Two adjacent island component discharge holes 1 (reference island component discharge hole 1 and island component discharge hole 2a in FIG. 1, reference island component discharge hole 1 and island component discharge hole 2b), and these two islands A line connecting at least a part of each of the two sea component discharge holes 4 and connecting the centers of two adjacent island component discharge holes 1 in a region surrounded by the two common outer tangents 3 of the component discharge holes 1 Two sea component discharge holes 4 are arranged as line targets with the minute as a line target axis. The diameter of the sea component discharge hole 4 was φ0.2 mm. The ratio DB / DA between the minimum gap DA of the two island component discharge holes 1 and the minimum gap DB of the two sea component discharge holes 4 was 0.35. Either the case where the minimum distance between the reference island component discharge hole 1 and the island component discharge hole 2a is DA, or the case where the minimum distance between the reference island component discharge hole 1 and the island component discharge hole 2b is DA. Also, DB / DA = 0.35.

  As shown in Table 1, there was no merge of island component polymers both at the start of spinning and after 72 hours.

[Example 2]
The same composite die as in Example 1 was used except that the island component discharge holes 1 had 2400 holes, a hole filling density of 4.0 holes / mm ² , a longer period of 0.5 mm, and a shorter period of 0.35 mm. Using the same polymer, discharge ratio, equivalent fineness, and spinning conditions as in Example 1, a sea-island type composite fiber was produced.
As shown in Table 1, the island component polymers did not merge at the start of spinning and after 72 hours had passed.

[Example 3]
The same composite base as in Example 1 is used except that the position of the sea component discharge hole 4 is changed to DB / DA = 0.6, and spinning is performed with the same polymer, discharge ratio, equivalent fineness, and spinning conditions as in Example 1. As a result, a sea-island type composite fiber was produced.
As shown in Table 1, the island component polymers did not merge at the start of spinning and after 72 hours had passed.

[Example 4]
The lowest distribution plate of the composite base was configured as shown in FIG. The island component discharge holes 1 had 1020 holes, a hole filling density of 1.7 holes / mm ² , a diameter φ of 0.2 mm, a longer period of 0.6 mm, and a shorter period of 0.5 mm. Two adjacent island component discharge holes 1 (reference island component discharge hole 1 and island component discharge hole 2a, reference island component discharge hole 1 and island component discharge hole 2b in FIG. 5), and these two island component discharge holes One sea component discharge hole 4 is provided so as to completely block the region surrounded by the two common outer tangents 3 of the hole 1. The diameter of the sea component discharge hole was φ0.2 mm.
Using this composite die, spinning was performed under the same polymer, discharge ratio, equivalent fineness, and spinning conditions as in Example 1 to produce a sea-island composite fiber.
As shown in Table 1, the island component polymers did not merge at the start of spinning and after 72 hours had passed.

[Comparative Example 1]
A sea-island type composite fiber was produced using the same composite die as in Example 1 except that the sea component discharge hole 4 was eliminated, and spinning with the same polymer, discharge ratio, equivalent fineness, and spinning conditions as in Example 1.
As shown in Table 1, the island component polymer did not merge at the start of spinning, but after 72 hours, the island component polymer merged, and a composite fiber having a desired cross section could not be obtained.

[Comparative Example 2]
The same composite die as in Example 1 was used except that the position of the sea component discharge hole 4 was changed to DB / DA = 0.8. However, since the minimum interval DB between the two sea component discharge holes 4 has increased, the area between the two adjacent island component discharge holes 1 and the two common circumscribing lines 3 of the two island component discharge holes 3 In addition, a part of the sea component discharge hole 4 no longer exists.
Using this composite die, spinning was performed under the same polymer, discharge ratio, equivalent fineness, and spinning conditions as in Example 1 to produce a sea-island type composite fiber.
As shown in Table 1, the island component polymer merged at the start of spinning and after 72 hours had elapsed, and a composite fiber having a desired cross section could not be obtained.

[Comparative Example 3]
The lowest distribution plate of the composite base was configured as shown in FIG. The island component discharge holes 1 had 900 holes, a hole filling density of 1.5 holes / mm ² , a diameter of 0.2 mm, a longer period of 0.6 mm, and a shorter period of 0.55 mm. The sea component discharge holes 4 were arranged so that DB / DA = 0.35. The diameter of the sea component discharge hole was φ0.2 mm. A part of the sea component discharge hole 4 did not exist in a region surrounded by the two adjacent island component discharge holes 1 and the two common outer tangents 3 of the two island component discharge holes.
Using this composite die, spinning was performed under the same polymer, discharge ratio, equivalent fineness, and spinning conditions as in Example 1 to produce a sea-island type composite fiber.
As shown in Table 1, the island component polymer did not merge at the start of spinning, but after 72 hours, the island component polymer merged, and a composite fiber having a desired cross section could not be obtained.

  The present invention is not limited to a composite die used for a general solution spinning method, but can be applied to a melt blow method and a spun bond method, and also to a die used for a wet spinning method and a dry and wet spinning method. However, the application range is not limited to these.

DESCRIPTION OF SYMBOLS 1 Island component discharge hole 2a Island component discharge hole 2b adjacent to the reference island component discharge hole in a shorter cycle Island component discharge hole 3 adjacent to the reference island component discharge hole in a longer cycle 3 Common outer tangent 4 Sea component Discharge hole 5 Lowermost layer distribution plate 6 Distribution plate 7 Distribution hole 8 Distribution groove 9 Metering plate 10 Discharge plate 11 Discharge introduction hole 12 Reduction hole 13 Island component polymer (A) (island portion)
14 Island component polymer (B) (island part)
15 Spin pack 16 Spin block 17 Cooling device 18 Composite base 19 Virtual circle 20 Sea component polymer (sea part)
21 Island component discharge unit 22a Island component discharge unit 22b adjacent to the reference island component discharge unit in the shorter cycle Island component discharge unit adjacent to the reference island component discharge unit in the longer cycle
24 Sea component discharge part 30 Pipe 31 Sea component polymer introduction flow path 32 Island component polymer introduction flow path 33 Upper mouth plate 34 Middle mouth plate 35 Lower mouth plate 40 Sea component polymer distribution chamber 41 Pipe insertion hole 42 Base discharge hole DA 2 Minimum gap DB of island component discharge holes Minimum gap α of two sea component discharge holes Reduction angle L Running section

Claims (5)

A composite base for discharging a composite polymer flow composed of an island component polymer and a sea component polymer,
One or more distribution plates formed with distribution holes and / or distribution grooves for distributing each polymer component;
Located on the downstream side in the polymer spinning path direction of the distribution plate, and is composed of a lowermost layer distribution plate in which a plurality of island component discharge portions and a plurality of sea component discharge portions are formed,
Each of the island component discharge portions is composed of one or more island component discharge holes for discharging the island component polymer.
Each of the sea component discharge portions is composed of one or more sea component discharge holes for discharging the sea component polymer.
At least each of the at least two sea component discharge units in a region surrounded by the two island component discharge units adjacent to each other at the shortest center distance and the two common circumscribing lines of the two island component discharge units. A composite base in which a part of the two sea component discharge portions are arranged across a line connecting the centers of the two island component discharge portions . The plurality of island component discharge portions are arranged in two kinds of cycles,
At least two of the seas in a region surrounded by the two island component discharge portions adjacent in the shorter cycle and the two common circumscribing lines of the two island component discharge portions adjacent in the shorter cycle. At least a part of each of the component discharge portions exists, and the two sea component discharge portions are arranged across a line segment connecting the centers of the two island component discharge portions,
In a region surrounded by two island component discharge portions adjacent in the longer cycle and two common tangent lines of the two island component discharge portions adjacent in the longer cycle, at least two of the sea 2. The composite base according to claim 1 , wherein at least a part of each of the component discharge portions is present, and the two sea component discharge portions are arranged across a line segment connecting the centers of the two island component discharge portions . The composite die according to claim 1 or 2 , wherein a minimum gap DA between the two island component discharge portions and a minimum interval DB between the two sea component discharge portions satisfy the following formula.
・ DB / DA ≦ 0.7 Either composite spinneret of claims 1-3 hole packing density of the island component discharge hole is 0.1 holes / mm ² or more. A method for producing a composite fiber, wherein melt spinning is performed by a composite spinning machine using the composite die according to any one of claims 1 to 4 .

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