JPS6312172B2 - - Google Patents

Description

[Detailed description of the invention]

The present invention provides a novel composite fiber aggregate, a novel fiber,
Regarding those new manufacturing methods and manufacturing equipment.
do. The novel composite fiber aggregate of the present invention is (1) An aggregate of many fibers, (2) At least 90% of the cross section of the fiber is non-circular.
It has the shape of a shape, (3) At least 50% of the cross section of the fiber is
At least one of the shape and size is the same
Not, but (4) At least 50% of the fibers are
At least two types of differences in the cross section perpendicular to the fiber axis
each of the fiber-forming polymeric phases consisting of at least
A part of each fiber is exposed on the circumferential surface of the fiber.
At the very least, they were combined side-by-side in
also has two blocks, and the block's
At least one of the number, shape and size of the individual
It is noted that there is non-uniformity between the fibers.
At least two different fiber-forming properties characterized by
It is a collection of fibers made of polymer. According to the present invention, it has the features described above.
A new fiber aggregate is completely different from previously known fiber aggregates.
It can be manufactured using a spinning method and spinning device.
I found out what I can do. Traditionally, fibrous materials are manufactured from thermoplastic aggregates.
Many methods are known, but from the viewpoint of manufacturing principles,
It can be roughly divided into orifice molding type and compatible type described later.
It can be divided into separate molding type. The former is a spinneret with uniform holes drilled at regular intervals.
collected from a single, defined tubular hole (i.e. orifice).
The combined material is discharged and cooled and solidified while drafting.
It is a method to obtain a fibrous material by
uniform and based on the orifice geometry.
A fiber having a constant fiber cross-sectional shape is obtained.
In addition, according to this method, the block (directly with the fiber axis)
A unique structure consisting of heterogeneous aggregates in the corner fiber cross section.
To produce a composite fiber collection with a large number of vertical phases)
This makes the structure of the spinneret orifice extremely complicated.
This also makes the spinning operation more unstable.
This can be said to be extremely difficult in practice.
Ru. Also, according to this method, the number and shape of blocks
and size between individual fibers.
It is possible to stably produce composite fibers that are non-uniform.
Both can be said to be practically impossible. On the other hand, the latter phase separation molding type, for example,
Patent No. 3954928, Specification No. 3227664, VUA
“Industrial and
Engineering Chemistry Vol.48, No.8, page 1342
(1956)”,
of inert gas mixed and dispersed in the molten aggregate.
Explosive force, the molten body or solution of the aggregate is exposed to high temperature and high speed.
Means by jet flow or flash flow or
Circular nozzle or other phase separation means
The molten material or solution is passed through a slit-like nozzle into fine particles.
fibrous while allowing phase separation to form a coalesced phase.
A method of obtaining something, and according to such a method, in large quantities
A reticulated nonwoven fiber aggregate is obtained.
However, the fibers forming this fiber aggregate are
Each type has a different cross-sectional shape and size.
It's not uniform. In other words, according to this method
Obtaining fibers with controlled cross-sectional shape and size
is extremely difficult. Two different types of polymers can be produced by phase separation molding method.
A reticulated non-woven composite fiber aggregate consisting of
Methods of manufacturing are also known (European Patent Publication).
(See specification No. 6704). According to this method, the fiber
It is virtually impossible to control the cross-sectional shape and size of the fibers.
Not only is it possible to cut it off, but it also uses an inert gas.
Control the number, size and shape of blocks on a surface
It is extremely difficult to control. The production of fibrous products using these conventional techniques is
From the viewpoint of suitability as a material and productivity
Each has the following problems, and these problems
If this issue is solved, a new type of even better fiber will be created.
Not only can we provide textile materials, but we can also provide them at a lower price.
This makes it possible to provide fiber materials at high quality. Nana
Ru. The first problem with the orifice molding type is that the fiber
The geometry of the orifice depends on the orifice shape.
Therefore, it becomes a constant monotonous shape, and furthermore,
In the case of composite fibers, it depends on the structure of the orifice.
Blocks made of different polymers in the fiber cross section
The shape, size and number of phases also vary between fibers.
The shape is constant and monotonous in the axial direction. This applies in particular to textile products such as woven and knitted fabrics.
What is preferable when using it as a material for
No. The physical properties of a textile product depend on the fibers that make it up.
The properties of the matrix polymer as well as the fiber geometry
It depends greatly on the shape, i.e. the cross-sectional shape and size.
As is well known. for example,
The texture of products made from natural fibers depends on their cross-sectional shape and design.
Although it largely depends on the irregularity of the nail,
This is removed from the thermoplastic aggregate by rewiring.
It is extremely difficult to obtain fibers with such irregularities.
Have difficulty. In addition, in the case of composite fibers, the cross-sectional shape and
uniform in size, but one fiber is at least
It is usually formed from two different types of aggregates.
gives unusual physical properties compared to other fibers. but
However, the block consisting of different aggregates within the fiber
The number, shape and size of the locks are uniform, so
Therefore, this composite fiber has a uniform cross-sectional shape and size.
The physical properties exhibited by being one are due to the combination.
It is hard to say that it has been significantly improved. The second problem is molding high-density fiber aggregates in large quantities.
Multiple orifices are installed in one spinneret for the purpose of
If the orifice spacing is narrowed, the orifice
Balancing effect and mechanism of molten polymer that is associated with gas discharge
Discharge from orifice due to lutofracture phenomenon
The filamentous polymer melts are fused together.
If the original
This may cause problems between the
Industrially, the gap between the holes is only about 2 to 3 mm at most.
This is something that cannot be done in such a small space. At intervals like this
The number of fibers formed from the nozzle is 1cm.³At most 10~
Approximately 20 fibers, making high-density fiber aggregates highly productive.
It is impossible to mold in large quantities. That is, this
In technology, it is inevitable that improvements will be made in order to increase productivity.
This will increase the speed, which is normally 1000m/min.
It's becoming more popular. On the other hand, in the case of the phase separation molding type, the slit
If you use a method of forming from a shaped nozzle, the orifice
Molding fiber aggregates in large quantities compared to molding types
is possible, but in this case also a two-dimensional aggregate
can only be obtained. Also, the geometry of the fiber
Regarding the fiber assembly obtained by this technique,
Without exception, the cross section of each fiber in the body is irregularly shaped, and the fibers are irregularly shaped.
However, the shape and size of its cross section and
These fibers have extremely large variations in denier.
It is extremely difficult to control the elements of
Moreover, even controlling the average denier is difficult.
Therefore, its scope of application is self-limited. only
obtained by such a phase separation type method.
All of the fiber aggregates in the
A body or a branched short fibrous aggregate, with a network
The fiber length between eye or branch junctions is e.g. a few millimeters.
Very short, ranging from a meter to a few centimeters.
There is a disadvantage that there is a barrier. Therefore, the junction of each fiber
The distance between the
Or at least 50cm or more.
A fiber that functions like an aggregate of filaments.
The aggregate is the production of the above phase-separated type fiber aggregate.
It is impossible to manufacture by law. The objects and advantages of the present invention are that conventional fiber-forming
Fibers cannot be obtained by known methods of obtaining fibers from aggregates.
To provide a new type of composite fiber aggregate.
There it is. Other objects and advantages of the invention are
At least two fiber-forming masses in the corner cross-section
The combined phase is combined side-by-side.
Both have two blocks, and the block's
At least one of the number, shape and size of the individual
Many composites that are non-uniform between fibers
A new type of composite fiber assembly made up of fibers
It's about offering your body. Still other objects and advantages of the present invention are that the cross-section is
It is circular, and the cross-sectional shape and shape between the fibers are
a large number of people in which at least one of the following is not the same:
A new type of composite fiber made up of composite fibers of
The objective is to provide fiber aggregates. Still other objects and advantages of the present invention are as described above.
Individual fibers that form a new type of composite fiber aggregate
Composite fiber filament of
Within a certain range of variation, the cross-sectional area and sidewall
At least two blocks combined on the side
Composite fiber filament with varying size
It is about providing. Still other objects and advantages of the present invention are
A large number of irregular shapes with irregular periods along the direction
The composite fiber assembly of the present invention has crimps of
It's about offering your body. Still other objects and advantages of the present invention include spinning, knitting,
Materials for textiles, textiles, nonwovens, and other textile products
We provide a new composite fiber aggregate suitable as a material.
There are many things. Still other objects and advantages of the present invention are that the fiber axis
At least two fiber-forming properties in a perpendicular cross section
A small number of aggregate facies coalesced side-by-side.
has at least two blocks, and the block
At least one of the number, shape and size of
A large number of complex fibers are non-uniform between the fibers.
The above-mentioned composite fiber assembly of the present invention is formed by an assembly of composite fibers.
We propose a new manufacturing method that manufactures objects as an aggregate.
It is about providing. Yet another object of the invention is to
partitioned by a narrow partition member with uneven surfaces.
has a large number of slits, and some of the slits
Is the melt extruded from other slits adjacent to it?
The molten liquid extruded from the partition member passes through the recessed part of the partition member.
A mesh-like structure configured to allow access to each other.
Using a spinneret, the uneven surface of the spinneret is formed into a fiber shape.
This spinneret is directed toward the discharge side of the synthetic polymer melt.
A partition member surrounding the slit of this spinneret is added to the gold.
different, such that the length is longer than 1/4 of the average length of
A map with many continuous boundaries between aggregate melt phases
Supplying the macroblend melt, the macroblend
The melt is cut by the partition member of the spinneret and extruded.
The conjugate fiber aggregate of the present invention, which comprises
The objective is to provide a method for manufacturing as an aggregate.
Ru. Still other objects and advantages of the present invention are
Continuous and relatively long boundaries between coalescing melt phases
The macroblend melt phase containing a large number of
New laminated plate type states suitable for
The goal is to provide a mixer. Still other objects and advantages of the present invention are as described above.
Mesh-shaped spinneret and static spinneret of the present invention
The composite fiber aggregate of the present invention is made of
The objective is to provide a spinning device suitable for manufacturing. Further objects and advantages of the present invention are as follows.
It will become clear from tomorrow. The present invention will be explained in more detail below. [Manufacturing equipment and manufacturing method] Production of the novel composite fiber aggregate of the present invention
The device and manufacturing method will be explained first. A typical example of the composite fiber aggregate of the present invention is
A large number of fine particles are used to extrude the melt of the fiber-forming polymer.
There is a gap on the discharge side, and there is a discontinuous gap in the adjacent narrow gap.
A raised part (mountain) is provided, and the raised part (mountain)
through the slits or recessed areas (valleys) that exist between
Molten liquid extruded from a certain slit adjacent to it
Mutual interaction with other melt extruded from other slits
Metsu characterized by having a structure that allows
It can be produced using a shoe-shaped spinneret. To explain the manufacturing method of the present invention in more detail, a few
A narrow partition with unevenness on at least one side
It has many slits partitioned by materials, and
The molten liquid extruded through a certain slit of the slit is
The molten liquid extruded from other slits in contact with the partition
Constructed so that they can come and go each other through the recesses of the members
The uneven surface of the mesh-like spinneret is used to form fibers.
toward the discharge side of the molten polymer, at least
Consists of a molten phase of two different fiber-forming polymers
The macroblend melt is extruded, and at this time the spinneret
A cooling fluid is placed on the discharge surface of the molten gold and in the vicinity thereof.
is extruded through the gap while cooling.
The melt is collected into a large number of separated
Numerous fibers that transform into fibrous rivulets and solidify
A method for producing an aggregate of
The melt contains a molten phase of at least one polymer;
The melt phases of different polymers form different phases.
Macro blend
When assuming a cross section of the melt parallel to the spinneret,
Continuity between different polymer melt phases in this cross section
The length of the boundary line taken up one of the slits of the spinneret
It is longer than 1/4 of the length of the surrounding partition member.
control so that there are many valid boundaries such as
This creates a large number of boundaries between different polymer melt phases.
The partition member that divides the slit of the thread cap will be cut.
This method is characterized by the fact that As explained above, the method of the present invention
The discharge surface of the melt of the polymer is smooth,
The discharge holes (orifices) for the melt are arranged in a regular manner.
spinnerets with independently drilled
At least a certain quantity ratio relationship from each slit
Composite extrusion of a melt consisting of two different polymers
This is fundamentally different from the method of manufacturing fibers. Used in the method for producing composite fiber aggregate of the present invention
A mesh spinneret is used to discharge the polymer.
It has a characteristic surface with many uneven structures.
It has a large structure and a large number of polymer discharge holes. Such a concavity
The surface with convexities and discharge holes is suitable for the polymer solution of the spinneret.
Discontinuous protrusions in adjacent narrow gaps on the melt discharge side
(mountains) are provided, and there are
through the existing slits or recessed areas (valleys).
The melt extruded from the gap is adjacent to each other.
can come and go with the molten liquid extruded through the slits of the
It has a structure like this. Mesh-shaped spinneret used in the present invention
Some of these were previously published by some of the inventors.
It is stated in the specification of Japanese Patent Application No. 1983-38993.
This corresponds to one of the spinnerets. Mesh-shaped spinneret used in the present invention
For example, stainless steel or bronze material
plain woven wire mesh made of quality steel wire
weave mesh); like level weave, monoprene weave
Special woven wire mesh; the tip has a sawtooth shape (~~~~)
A large number of metal plates are placed at regular minute intervals.
Laminated bodies arranged vertically; e.g. made of stainless steel
Elaborate etching on the thin metal plate allows it to fit into narrow gaps.
Convex portions (mountains) remain and concave portions (valleys) are created between the convex portions.
Etched polygon with a large number of slits so that
Perforated plate; many tiny metal balls sintered and fixed in a thin layer
Sintered perforated plate; or a combination of these, etc.
can give. Among these, wire mesh, etched perforated plate or
A combination of the same or different types is preferably used.
I can stay. These are used as mesh spinnerets.
The wire mesh and etched perforated plate are shown in Figure 1, respectively.
-a, Figure 1-b, Figure 1-c and Figure 1-d
Illustrated in. In the present invention, a region containing a mesh-like spinneret
Generalization of any cross section in the region or forming region
A schematic enlarged view is shown in Fig. 2. This second figure
, Ai and Ai+1 portions are discharge ports. In addition, the adjacent arbitrary discharge ports Ai and Ai+1
The distance between each center line is called the distance between the discharge ports Pi.
The average of Pi in all cross sections is the average distance between the discharge ports
Define p. In addition, the right side adjacent section of the arbitrary discharge port Ai of the arbitrary cross section
The part of the surface that is closer to the surface of the molding area than the Ai part,
It is called the mountain Hi attached to Ai, and furthermore, the peak and Ai
The average space perpendicular to the plane hi is called the peak height of Hi.
Define the average of hi in all cross sections as the average peak height.
to justify In addition, the mountain Hi sandwiched between the discharge ports Ai and Ai+1
The width parallel to the average plane is called the peak width di, and it applies to all cross sections.
The average of di at is defined as the average mountain width. According to each definition described above, the molding device of the present invention
The molding area of the molten aggregate is (1) Average distance between discharge ports () is in the range of 0.03 to 4 mm.
circumference, preferably 0.03-1.5mm, especially 0.06-1.0mm
range of, (2) The average peak height () is in the range of 0.01 to 3.0 mm, preferably
Preferably in the range of 0.02 to 1.0 mm, (3) The average peak width () is in the range of 0.02 to 1.5 mm, preferably
or in the range of 0.04~1.0mm, and (4) Average mountain height () and average mountain width () are /
Expressed in d, the range is from 0.3 to 5.0, preferably from 0.4 to 5.0.
3.0 range Finely textured surface and numerous polymerizations that satisfy
It is advantageous to have a body outlet. As mentioned above, the values of , , and / are (1)
〜(4) and (−
d) the value represented by / is in the range of about 0.1 to about 0.8;
preferably in the range of about 0.15 to about 0.7.
It is even more advantageous to set the structure of the gold surface. this
In other words, the value of (-)/ is the formation of the discharge port.
Represents the area ratio (opening area ratio) in the shape area
It is a value. In the method of the present invention, the mesh-like
A spinneret (its uneven surface as described above is coated with a fiber forming material)
towards the discharge side of the melt of the coalescence), at least
Also, the solution of each of two different fiber-forming polymers is
Macroblend melt consisting of a combination of many melt phases
is a section parallel to the spinneret of the macroblend melt.
Different polymerizations in this cross section when assuming a surface
The length of the continuous boundary line between the molten phases is the length of the spinneret.
1/4 of the length of the partition member surrounding one of the gaps in
It seems that there are many valid boundaries that are longer than
During extrusion, the boundaries between different polymer phases are
A partition section that divides many of the boundary lines into slits of the spinneret.
The purpose of this project is to ensure that the material is sheared.
Necessary for manufacturing bright composite fiber aggregates
Ru. Transfer the macroblend melt from the spinneret as described above.
In order to extrude with good control, one is to
At least two different fiber types in the melt
The formation state of each melt phase of the synthetic polymer and
Both the slit size of the spinneret and
Must be. That is, according to the research of the present inventor, the above general
A partition surrounding one of the slots of the spinneret used for
Effective boundary line that is longer than 1/4 of the length of the member
By preparing a macroblend melt containing a large number of
Extruding the macroblend melt from the spinneret
or in the prepared macroblend melt.
Considering the effective boundary line between the molten phases, the boundary line is
a partition whose length surrounds one of the slots of the spinneret
Use a spinneret that is longer than 1/4 of the length of the material.
the macroblend melt from the spinneret using
By extruding the composite fiber aggregate of the present invention,
It has been shown that it can be manufactured. The macroblend melt fed to the spinneret
The formation state of the molten phase in the spinneret
The spinneret is removed from the spinning device, and the spinneret is
The macroblend melt is placed in the position where it was installed.
Sampling in a manner that does not destroy the formation of the molten phase of
Insert the cylindrical shape and pour the macroblend melt into it.
, and then remove the tubular material from the spinning device.
Then, the contents (macro blend melt) are rapidly cooled.
Let solidify and cut the solidified sample parallel to the spinneret.
Confirm by cutting and observing the cut surface.
can be done. Figure 3-a, Figure 3-b and Figure 3-c.
are the spinneret slit size and macrolobes, respectively.
Relationship between the formation state and the molten phase in the rend melt
In this connection, the above-mentioned control in the method of the present invention
Here is a schematic diagram to explain how this is done.
It is shown. Using this diagram, we will explain the present invention below.
The above control will be explained below. In Figure 3-a, partitioned by large quadrilaterals
The area is a part of the macroblend melt.
and the straight lines running from top to bottom within this area are adjacent
is the boundary between molten phases consisting of different polymers,
Also, the four small squares with different orientations are the spinnerets.
It should be understood that it is a slit between Partitions forming slits as shown in the figure
1/4 of the length of the member (one side of the small square)
(equal to the length of
If the yarn is long, it can be extruded through the slits of the spinneret.
The rivulet produced is from at least two different polymers.
at least two distinct melt phases (rivulet solidifies)
When the individual melt phases become fibers, the individual melt phases become fibers.
) to form a block within the
It is understood that The length of each line segment in the above figure has a relative meaning.
should be understood as representing a certain length. So
Therefore, for example, each side of a large quadrilateral is 10 mm.
, and if one side of the small square is 2 mm, then the upper
The diagram shows many elongated melt phases with a width of 1 mm.
The macroblend melt is placed in a partition with a side of 2 mm.
obtained when spun through a length of material
It is possible to teach the number of blocks contained in a composite fiber.
be understood. Contains many elongated melt phases with such narrow widths
When the macroblend melt is cut through a slit,
The average number of blocks contained in the rivulet obtained from the slit
The average value is as follows if shearing is carried out ideally.
It matches the theoretical block number ((B)). The theoretical block number ((B)) is the following formula Here, (w) is a partition surrounding one of the slits.
is the average length (mm) of the members, and (p) is the weight
is the length (mm) of the boundary line between the coalesced melt phases,
N(p) is the number of boundaries between polymer melt phases.
Ru. Therefore, the case shown in Figure 3-a above is given by
The theoretical block for the composite fiber obtained is
The number of locks is 3.5, with the different orientations shown in the figure.
The number of blocks contained in four small squares is
The value is almost equal to the average value of approximately 3.5.
Recognize. As understood from the above explanation, the method of the present invention
Desirable for producing composite fibers of the present invention
Control is the size of the slit in the spinneret, in other words, one
The length of the partition member surrounding the slit, and the length of the macroblock
In other words, the formation state of the molten phase in the rend melt.
controlled by the length and number of boundaries between molten phases.
You will see that you can do it. What can be further understood from the above figure is that the narrow and long
Macroblend melt containing many elongated melt phases
When partitioning with a slit, side-by-side
This means that a combined composite fiber is obtained. Another example will be further explained. Figure 3-b
is the inside of the matrix melt phase (sea) of a certain polymer.
a small number of other polymers that differ from this polymer
A slit cuts the molten liquid in which the molten phase (islands) of
Schematic diagram illustrating how the island is cut when
It is shown. In the figure, there are four positive points of medium size.
The squares indicate slits, and the smallest number of squares
The shape represents an island. Length of boundary line between molten phases
(perimeter of the island) is equal to 1/4 length of the slit in this case.
stomach. The theoretical number of blocks ((B)) in this case is
If you calculate it according to the formula, it will be 4.6 pieces. however,
A solution with many small islands like this is dispersed.
From the melt, it is completely contained within the four middle squares.
There are small squares (blocks) that are
Each small section occupied within the four squares of
This is because the area of the square (block) is small.
As you can see, the two were combined side by side.
one of the two blocks is too small and the sidebar
Unlike Yi-side, it is rather a see-core type.
It is understood that it becomes easier to obtain aggregates of composite fibers.
It will be. At least 2 combined side by side
Desirable composite fiber of the present invention having two blocks
According to the method of the invention, the aggregates are made of different polymer solutions.
The length of the continuous boundary line between the melt phases is the slit of the spinneret.
than 1/4 of the length of the partition member surrounding one of the
Macro blurring with many long effective boundaries
produced by using the spinneret and the spinneret.
It will be understood from the above description that the Another example will be explained. macro blend
The melt is illustrated in Figures 3-a and 3-b.
The polymer melt phase is orderly or relatively
Not only when they are adjacent to each other in an orderly manner, but also in Figure 3-c.
The polymer melt phase is relatively cluttered as shown.
A macroblend melt of a certain size is
The reason contained in the rivulet obtained when cutting with a slit
The number of logic blocks ((B)) is also calculated using the following formula: Here, (c) is also called the cord length (mm).
, and (p) and (p) are respectively
of continuous effective boundaries between different polymer phases.
Average length (mm) and number. Introducing the concept of chord length ((c)) expressed as
Therefore, the following formula Here, the definitions of (w) and (c) are the same as above.
It is. It can be expressed as Therefore, the ratio as illustrated in Figure 3-c
Even if the melt has a relatively messy melt phase,
The formation state of the molten phase in the liquid and the fineness of the spinneret
The code for each parameter of the gap size is
Depending on the length and the length of the partition member of the slit,
Side-by-side in the resulting composite fiber
It is possible to control the number of blocks that are combined into
It will also be understood that According to the method of the present invention,
This is a relatively messy melt phase.
Even if the length of the effective boundary between the molten phases is
It is longer than 1/4 of the length of the gold slit partition member.
If there are many such valid boundaries, the code
Partition member for spindle length ((c)) and spinneret slit
By controlling the length ((w)) of
Blocks integrated side by side of invention
It is possible to produce a desirable composite fiber aggregate with
can. Here, the chord length ((c)) is
A unit area consisting of a square of length (e.g. 10mm)
Any cutting straight line G intersects the boundary of this unit area
Length of line segment AB when two points are A and B ()
, within this unit area, the straight line G is from (w)/4
Set 1 to the number of intersections that intersect with the long polymer interphase boundary line.
Total average of the values divided by the plus total number (n(p))
(Draw many straight lines G within this unit area, and each straight line
is defined as the average of n(p) found for G
Ru. In fact, it follows the Monte Carlo method within the unit area.
The position coordinates (x, y) and angular coordinates are determined using the number table.
(θ), draw 100 straight lines G, and these 100
Calculate the value of /n(p) above for the straight line G of the book.
Calculate the average value of these values. The method of the present invention provides continuous flow between different polymer melt phases.
at least one of the length and number of effective boundaries
A controlled macroblend melt is prepared and this melt is
This is advantageously carried out by feeding the melt into a spinneret.
can be administered. The method of the invention also allows different polymer melts to be used.
The length of the continuous effective boundary between the phases is the length of the continuous effective boundary line of the spinneret.
longer than the length of the partition member surrounding one of the slits
Macro so that there are many valid boundaries such as
Even more advantageous by preparing blended melts
can be implemented. Such a macroblend melt is preferably
is the section parallel to the spinneret of the macroblend melt.
Assuming a surface, at least
One polymer melt phase forms a series of elongated narrow shapes.
In particular, it has a lamellar structure. The method of the present invention can also be used to melt different polymers as described above.
Average length of continuous effective boundaries between phases ((p))
and at least one of the number ((p)), and a spinneret.
The average length of the partition member surrounding one of the slits (
(w)) and the following formula Almost equal to the theoretical block number ((B)) defined by
Numerous fibers with low to almost double value
of different polymer solutions.
Many of the boundaries between the melt phases define the slits of the spinneret.
This can be advantageously carried out by cutting with a partition member.
be done. Such a method can be applied to different polymer melt phases.
As mentioned above, it has a long and narrow shape.
Macroblend melting with a relatively orderly shape
Applicable when using liquid. Analogy as a spinneret
One spinneret, such as when using plain woven wire mesh.
such that essentially one fiber is obtained from the slits of
In this case, this method can solve the problem defined by the above formula.
A complex with a value approximately equal to the number of logical blocks ((B))
Fiber aggregates can be produced. In addition, a level woven wire mesh, for example, can be used as a spinneret.
As in the case of
This method can be used in cases where fibers of
Theoretical block number ((B)) defined by the above formula
to produce composite fiber aggregates with a value almost twice that of
can be done. The laminated plate type state of the present invention will be described in detail later.
By using a mixer, at least 1
A series of long, narrow shapes of two polymer melt phases.
Polymer melting in a relatively orderly shape, such as forming layers
A macroblend melt having a phase is added to the polymer melt.
Controls the average length and number of consecutive effective boundaries of a phase.
can be fed to the spinneret. Therefore,
Using a stacked plate type static mixer
You can freely prepare the desired blend state by
As a result, the block of the composite fiber aggregate obtained can be
The number of locks can be easily controlled to the desired number of blocks.
I can do that. The method of the present invention can also be used to melt different polymers as described above.
Average length of continuous effective boundaries between phases ((p))
The following formula defined by and the number ((p)) The cord length ((c)) expressed by
The average length of the partition members surrounding one of the gaps (
(w)) and the following formula Almost equal to the theoretical block number ((B)) defined by
A large number of fibers with a new value or almost double the value.
of different polymers.
Define the slits of the spinneret with a large number of boundaries between the molten phases
This can be advantageously carried out by cutting with a partition member that
administered. Such methods require that different polymer melt phases are already
Macrobrain, which is relatively cluttered as mentioned above.
Applicable when using molten liquid. Also in this case
As mentioned above, for example, when a single thin wire mesh, such as plain woven wire mesh,
A spinneret that allows a single fiber to be obtained from the gap and
One fiber emerges from two slits like a level woven wire mesh.
When using a spinneret that yields
A collection of composite fibers each having a value approximately equal to (B)
body and a composite fiber with a value almost twice that of (B).
Aggregates can be manufactured. Of course, macromolecules with a relatively messy melt phase
Different polymer melts even in Roblend melts
The length of the continuous border between the phases is used in the spinneret
1/4 of the length of the partition member surrounding one of the gaps in
It is necessary to have a large number of valid boundaries such that the length is longer than
As mentioned above, this is important. Such a macroblend melt will be described later.
Use Kenics type static mixer
It can be manufactured more advantageously. Macrode supplied to the spinneret in the method of the present invention
Roblend melt has a relatively orderly melt phase.
Even if it is something, it is relatively untidy.
Also, the length of the continuous boundary between different polymer melt phases
The material that surrounds one of the slits in the spinneret used
Effective boundary line that is longer than 1/4 of the length of the cut part
between different polymer melt phases as long as they have a large number of
The length of the continuous border line is used to slit the spinneret
than 1/4 of the length of the partition member surrounding one of the
It's okay to have short boundaries.
stomach. Is it shorter than 1/4 of the length of such a partition member?
A molten phase with such a boundary line is herein referred to as a molten phase.
It is expressed as a blend phase, and such a blend phase
This state is described as a microblend. The microblend phase is used in the method of the invention.
It can be actively included in the molten liquid.
Wear. Also, microblend phases are often used
at least two different polymers are poorly compatible
It may also occur in some cases. In the method of the present invention, the macroblend melt is
When calculating the theoretical block number ((B)), use this method.
The microblend phase is left out of consideration. that
Therefore, in the present invention, the "effective" boundary line
It is used to exclude the boundary line of the Roblend phase.
Ru. In addition, in the present invention, a “continuous” boundary line
is one continuous boundary line included in an area
or one continuous border that is broken in an area
It means part of the boundary line. As understood from the above explanation, the method of the present invention
Extrusion of macroblend melt from spinneret
Expressed very conceptually, the spinneret
The supplied macroblend melt is transferred to the spinneret.
A partition member surrounding the slit allows the macroblock to
The macroblend state of the rend melt is substantially reversed.
The operation of cutting and converting into a large number of rivulets so as to be reflected
I can say that. A spinneret suitable for cutting in this way is
Numerous slits occupying the total area of the spinneret discharge surface
The opening area defined later is equivalent to the percentage of the total area of
The ratio is about 0.1 to about 0.8, more preferably about 0.15 to about 0.7.
are advantageously used. The opening area ratio is defined by the following formula. (Here, is defined as above) According to the method of the invention, preferably different polymerization
the total length of continuous boundaries between the molten phases and the boundaries;
The size, shape and area enclosed by the line.
and at least one parameter of the number described above.
and thus control the details that make up the spinneret.
Partitioning elements that partition at least 50% of the total number of gaps
cuts the boundaries between different polymer melt phases.
By making the composite fiber aggregate of the present invention
can be produced as an aggregate. As explained above, according to the method of the present invention, at least
Both are macros that are composed of a large number of two different polymer phases.
Form a blended melt and spin it into a mesh
The spinneret is supplied with the spinneret, and the spinneret is fed through the numerous slits of the spinneret.
Manufacture a large number of fiber aggregates by extruding the melt
To make the series of processes easier to understand
The fourth diagram schematically shows a schematic diagram of the manufacturing equipment.
This will be explained using figures. Of course, in Figure 4, the explanation
In order to simplify the
It is understood that other equipment or parts have been omitted.
Should be. And Figure 4 shows two types as an example.
Composite fiber aggregate of the present invention using different polymers of
The present invention is an apparatus for manufacturing two or more types of
Even with the above polymer, only a few changes can be made.
It is possible to produce fiber aggregates using similar equipment.
The previously explained macroblend melt and spinneret
This can be fully understood from the explanation of slits.
Well, there's no need to go into detail. In Fig. 4, the one installed on the A side is 1
Hopper 1a, feeder 2 for one polymer
a, melt extruder 3a, gear pump 4a and conduit
5a, and what is installed on the B side is another polymerization
Hopper 1b, feeder 2b, melt for body
extruder 3b, gear pump 4b and conduit 5b.
Ru. Quantitatively melted on A side and B side respectively
The sent-out molten polymers are combined in the mixer section 6.
It is guided to the extrusion die 7. This extrusion die
7 inside 8 or mixer section 6, mixer, especially
Install a static mixer and perform macro blending
A melt is formed. Of course, extrusion die 7
Both inside 8 and mixer section 6
A mixer may be installed. This static
The mixer forms the desired macroblend melt.
will be accomplished. Furthermore, it is located at the top of the extrusion die 7.
The one shown shows a pressure gauge. According to the method of the invention, the static mixer
It can be installed inside the die or outside the die.
As mentioned above, it can be installed in both locations.
It is. A spinning machine with a static mixer built into the die.
An example of the thread cap is illustrated in FIG. Figure 5
This figure schematically shows a vertical cross-sectional view of a spinneret.
21 is for maintaining the cap at the desired temperature.
Electric heater, 22 is at least two types of I-type die
is the flow path for different polymer melts, and here
No conscious mixing takes place. 23 is mesh-shaped
Stats provided on the surface of the spinneret 25
It is a mixer, and in the drawing it is a Kenics-type mixer.
- is installed. 24 is a state mixer
The macroblend melt that flows out is mesh-like.
This is the area before reaching the spinneret where the polymer solution
It serves as a reservoir for melt. 26 is metsushi
A fastener to prevent the U-shaped spinneret from being separated.
It is. Kenics type static mixer
Laminated plate type static mixer, which will be described later.
You can use the server in the same way. When installing a static mixer outside the die
In this case, the location of the mixer section 6 in Fig. 4 above
It can be installed in Therefore, there is static outside the die and inside the die.
When installing the mixer, as described above,
There are static screws on the inner side 8 and the mixer section 6.
Just install a kisser. The mixer installed inside the die will be described later.
Laminated plate type static mixer and mixer
Any type of static mixer is acceptable.
However, as a mixer installed outside the die, Kenikku
A static mixer is preferred. What is the Kenics type static mixer?
As illustrated in Figure 5, the polymer melt phase is an example.
A large number of split plates that can be split into two parts, for example.
For example, one with a structure that is divided into multiple stages of 1 to 10 pieces.
I can say that. Again in Figure 4, the lower part of this extrusion die
A mesh-like spinneret 9 is installed in the
The polymer melt is extruded and solidifies as a fibrous stream.
and becomes a fiber aggregate. What is needed here is Metsu
The melt discharge side surface of the U-shaped spinneret and its vicinity.
A cooling fluid (e.g. air) is supplied next to the
This is to solidify the molten liquid while taking it.
For this purpose, the cooling fluid supply device 11 has a mesh shape.
The cooling fluid is directed toward the discharge surface of the spinneret at a high velocity.
so that it is uniformly supplied to the entire discharge side surface.
It has a nozzle or slit. cooling
The fluid should have a solidification length (p(s)) of 2 cm or less.
It is preferable to supply the material near the upper discharge side surface.
Yes. The coagulation length (p(s)) is the convex surface of the spinneret.
Distance from a surface until a trickle leaves that surface solidifies
means. A large number of fiber aggregates 1 thus formed
0 is a take-up roller 12 (a pair of nips in the drawing).
rollers). drawing here
The width of the mesh-like spinneret as understood from
The fiber aggregate can be taken up with approximately the same width as the
The same width is then sent to the next process, such as the stretching process.
It is also possible to provide. In this figure 4, the stretching
There is a pair of Nitz rollers that also serve as take-up rollers.
-12 and the other pair of nip rollers 14.
A hot plate 13 is installed. This stretching device and method is merely an example.
and various other devices and devices as described below.
There is no problem in changing the method.
The stretched fiber aggregate 15 can be used as it is.
It can also be processed through other processing steps such as splitting.
Process, crimping process, cutting process (short fiber production), opening process
sending it to a process such as processing or web-forming process
You can also do it. Figure 4 shows these processes after the stretching process.
steps are not shown. In addition, according to the method of the present invention, fines from the spinneret are
The flow is taken over by the packing flag expressed by the following formula.
Cushion (PF) PF=1/Da Here, Da is the apparent draft ratio. is much larger than that of conventional melt spinning method.
value, i.e. 10^-Four~Ten^-1range (in the conventional method
10 at most^-Fiveorder).
can. Packing fraction (PF) is a spinneret
Total fiber aggregates formed per fiber forming area of
Indicates the total cross-sectional area of the fibers, and indicates the total cross-sectional area of the fibers.
Density of yarn (discharged) fibers, i.e. high-density spinning
It is a measure of performance. The above apparent draft ratio (Da) is calculated using the following formula:
defined. Da＝V_L/V_O Here, V_Lis the actual take-up speed of the fiber aggregate
degree (cm/min), V_OThe polymer melt is
Covers the entire discharge surface of the fiber forming area of the spinneret
Average linear velocity in the dispensing direction when dispensing
(cm/min) a melt of at least two different polymer phases;
to prepare a macroblend suitable for carrying out the method of the present invention.
the extrusion die to form a melt
7 or the mixer incorporated in the mixer section 6
explain about. Examples of mixers include
Various statics used for mixing melt polymers
The mold mixing unit can be used as is or in appropriate combinations.
Can also be used with perforated wavy plates
Arrange many vertically and densely at regular intervals or as they are.
rows, laminated porous bodies, plain weave and/or twill weave
A large number of wire meshes of various types such as
Layered porous material and many minute metal spheres are densely packed.
Thin layer of filled, aligned, sintered, and fixed porous material
You may also use objects. Use a commercially available static mixer
For example, Kenix's Stats
Mixer, Sluzer's State Mixer
Engineering Unit, Charles Ross Company Ross ISG Miki
Sir, Sakura Seisakusho Square Mixer, Komatsuku
Komatsu mixer, Bayer Systems Co., Ltd.
Examples include Bayer Container Mixer.
It can be done. According to the present invention, by using the above manufacturing apparatus,
the molten phase of at least two different polymers.
Mix with a vertical mixer and mix with a vertical mixer.
The mixed state of the polymer melt phase leaving the spinneret
by maintaining substantially until reaching
The composite fiber aggregate of the present invention can be advantageously manufactured.
can. In addition, as mentioned above, the method of the present invention includes at least
One polymer melt phase forms a series of elongated narrow shapes.
A polymer solution with a relatively well-ordered shape with successive phases.
Forms a melt phase, especially a mixed polymer melt phase with a lamellar structure
Because it is advantageous to do so,
A laminated plate, which will be explained in detail later as a mixer,
It is recommended to use a static mixer.
be done. [Laminated plate type static mixer] According to the research of the present inventors, the above-mentioned method of the present invention
Macrob used to produce fiber aggregates
The macro blend melt is used as the blend melt.
at least one in a cross section parallel to the spinneret
The polymer melt phase forms a continuous phase with a long and narrow shape.
in particular the polymerization of at least one of the
The body melt phase forms a lamellar structure.
What is formed is the shape and size of the polymer phase within the fiber.
It is possible to easily control the size, number of blots, etc.
to advantageously provide the desired fiber.
I found out that it is possible to do this. According to the invention, at least one polymerization of the aforementioned
A continuous phase with a narrow shape in which the molten phase is elongated, especially
The lamellar structure polymer melt phase is composed of the following (a) to (e).
By using a built-in static mixer,
is formed. (a) A stack of many plates with recesses
It is a layered body, (b) the recess in the plate is a fluid conductor in the laminate;
Shape the inlet and the fluid outlet that communicates with the fluid inlet.
accomplished, (c) the plate has at least two different recess shapes;
consisting of at least two types of plates having the shape
and (d) Fluid inlet of plate with same recess shape
form a common inlet for the same fluid.
and thus the laminate has at least two different
at least two common inlets for the fluid;
have, and (e) the fluid outlet is connected to at least two different fluids;
is configured to provide an adjacent fluid flow of . In this specification, a mixer composed of the above (a) to (e) is used.
“Laminated plate type static mixer”
It is sometimes abbreviated as. Such a laminated plate mold
To the best of the inventors' knowledge, the vertical mixer is
This is a new type of mixer that has not been known since.
By using such a mixer, at least 2
Polymer phases of different species form a lamellar structure,
In other words, many macroblens coalesce in a thin laminar flow.
molten liquid can be easily obtained. This laminate
According to rate-type static mixers, extremely
A thin layered melt can be obtained, and the polymer
The combination of phases can be changed arbitrarily, and the
Thickness controllable, uniform and regular layered
The melt is easily obtained and the structure is simple.
It has industrial advantages such as ease of production.
This is the object of the present invention.
Spinnerets and combinations for the production of composite fiber aggregates
Can be used for other purposes as well
It is. That is, the laminated plate type state
The Tsuku mixer is a laminar flow mixture inside.
Two or more fluids that are trying to form a
without contact and substantially in the discharge area of the fluid of the mixer.
At least two types of fluids will be in contact with each other.
surface tension, interfacial tension, viscosity, solubility parameters of
Differences in physical properties such as or chemical differences such as reactivity
Due to the nature of traditional mixers, macro
It was difficult to form a blended melt.
Can be advantageously applied to mixing at least two types of fluids
I can believe it. Based on Figure 6-a and Figure 6-b below, this
Laminated plate type static mixer by Akira
I will explain it in detail, but this is just to make it easier to understand.
However, the present invention is not limited to this.
It's not. Figures 6-a and 6-b are examples of laminated plates.
Shows an enlarged schematic diagram of a static mixer.
It is something. Components of a laminated plate static mixer
A flat plate is a plate with a concave part.
Although generally preferred, it does not necessarily have to be a flat plate.
However, as shown in Figure 6-a, there is a large wavy surface.
It may be a shaped plate. at least
When each plate is stacked and used, the flow
Body overflows or leaks outside the recess
The fluid flow leaving the recess is mutually multiple.
If the plate has a laminated structure,
good. Figure 6-a has two different concave shapes.
Two types of plates namely P-a and P-b
A mixer with alternating plates is shown.
For the sake of explanation, one plate P-a is shown in the drawing.
Shown off to the left. The recesses provided in each plate allow fluid to flow through the recesses.
It is a part that acts as a passage or groove, and P-
This is the shaded portion of a and P-b. This concave
If the plates are stacked, fluid will be introduced
(a for P-a)₁,a₂and a₃，
In case of P-b b₁,b₂,b₃and b_Fouris shown in
) and an outlet for fluid discharge (P-a).
The case is indicated by Xa, and the case of P-b is indicated by Xb)
and they are mutually exclusive in one plate.
It's communicating. The depth t of this recess₂is of the plate
Thickness t₁It is fine as long as it is smaller than , but it satisfies the following formula
Preferably. 0.2t₁≦t₂≦0.8t₁ (here t₁is the plate thickness (mm)
ri, t₂indicates the depth of the recess (mm) The particularly preferable depth of the recess satisfies the following formula:
It is something. 0.3t₁≦t₂≦0.7t₁ (here t₁and t₂(definition is the same as above) Thickness t of plate with recess₁are all the same thickness
generally of the same kind, although it is not necessary that they be the same
The materials must have the same thickness to ensure a homogeneous macroscopic blur.
desired for obtaining a molten liquid. In particular, all the same
at least two plates of the same thickness and the same depth
Stacking seeds to form a static mixer
is particularly advantageous. Plate thickness t₁is in the range of 0.05 to 2 mm, preferably
The range of 0.1 to 1 mm is preferable, and the range of 0.2 to 0.7 mm is preferable.
range is most preferred. In Figure 6-a, plates P-a and P-b
are stacked alternately, and the concave part of plate P-a is on the upper right
The concave part of plate P-b is indicated by diagonal lines, and the concave part of plate P-b is downward to the right.
It is indicated by diagonal lines, and the shapes of the recesses are different in both cases.
Ru. This recess shape satisfies the requirements as described above.
You can design it as freely as you like. The shape of this recess depends on the size and shape of the fluid inlet.
shape, number and position, size and shape of fluid outlet
and location.
Can be done. In addition, the concave part has an island-like convex part, for example, a plate.
Ia in plate P-a, plate P-b
Ib can be provided, and this island-like convex part is inside the concave part.
There may be one or more. To install this island-like convex part
Maintaining the shape of the mixer when stacking plates
Not only does the retention property improve, but the fluid flowing through the recesses also improves.
It becomes easy to control the pressure and flow rate. this
The island existing in the recess faces the outlet Xa like Ia.
Alternatively, a small hole may be made in the recess like Ib.
may have. As mentioned above, the laminated plate type static
Kisser is a plate fluid with the same recess shape
Inlets form a common inlet for the same fluid
and thus the laminate has at least two different
at least two common inlets for fluids
and the fluid outlet has at least two different
configured to provide contiguous fluid flow of fluid
It also has some characteristics. This point can be explained using the laminate shown in Figure 6-a.
To clarify, two different plates P-a and P
-b is because two different fluids provide adjacent fluid flows.
Therefore, two types of outlets Xa and Xb are formed on the same surface.
It is laminated in large numbers like this. Plate P-a and P
- b are all in the same direction towards the stacking direction
The fluid inlets of plate P-a are arranged alternately.
a₁,a₂and a₃are in the same position, each forming a strip
and fluid inlet b of plate P-b.₁，
b₂,b₃and b_Fouralso form a band at the same position.
is forming. For example, fluid introduction of plate P-a
mouth a₂is A₂A common band-shaped fluid inlet called
Similarly, fluid inlet a of plate P-a is formed.₃to
Common strip-shaped inlet A₃is formed.
Although not shown in Figure 6-a, the plate P
-a fluid inlet a₁Common band-shaped inlet A₁
It is easy to understand that they are formed similarly.
cormorant. On the other hand, each fluid inlet in plate P-b
b₁,b₂,b₃and b_Fourhave a common band-like shape.
Fluid inlet B₂,B₃and B_Fouris formed, and the
Figure 6 - a is b₂B based on₂,b₃B based on₃Oyo
b_FourB based on_FourIt is shown as. Plates P-a and P-b each have 3 pieces or
and four fluid inlets, but each plate has
The number of fluid inlets in the port is 1 to 4.
Can be selected arbitrarily. installed on homogeneous plates
For the purpose of the present invention, a plurality of fluid inlets are used.
It is desirable that the same polymer melt be introduced.
However, it is not necessarily necessary for other purposes.
Alternatively, a different fluid may be introduced.
It is possible. Number and location of fluid inlets on each plate
flows out from the fluid outlet Xa of plate P-a
The fluid flowing from the fluid outlet Xb of plate P-b
The ejected fluid forms a layer and contacts on the same surface and is evenly distributed.
A macroblend melt with a uniform lamellar structure is formed.
of the fluid introduced into each plate so that
It is determined by taking into consideration the type, amount, etc. Laminated plate type static mixer according to the present invention
In the circuit, each common fluid inlet is
Can exist on the same side of the body or on different sides
You may do so. For example, Figure 6-a shows the common
Inlet port B₂,A₂and B₃is A on the same plane₃and
B_Fourare provided on different other surfaces. In addition,
Furthermore, a provided on another surface₁common based on
Inlet and b₁Figure 6 shows the common introduction points based on
- Not shown in a. On the other hand, plate P-a has an outlet indicated by Xa.
and the plate P-b has an outlet indicated by Xb.
have. These two types of outlets Xa and Xb are
are located on the same side of the layer and have one outflow area.
and at least two fluids are injected into the concavities of each plate.
After passing through each section, the first person enters this spill area.
substantially adjacent to each other to form one fluid with a lamellar structure.
to be accomplished. have the same recess shape in this outflow area.
The fluid outlet of the plate is substantially in the same plane.
The actual shape of the plate with different concave shapes exists in
Qualitatively different from a fluid outlet that exists on the same plane
Can also exist in the plane, but with different concave shapes
All of the fluid outlets of different plates having the shape
Preferably, they are substantially coplanar. Laminated plate type static mechanism according to the present invention
Width of the plate with the recess that makes up the kisser
(W) is generally 5 mm to 100 cm, preferably 1 cm
~50cm range. Also, a plate with this recess
The height (H) of the seat is 5mm to 50cm, preferably 1cm.
~30cm range is good. Recesses or recesses in plates with further recesses
There is one small hole penetrating the plate in the part that is not
There may be one or more. Figure 6-
In a, Ha is a small hole that exists in a part that is not a concave part.
, and Hb indicates the small pores present in the recess.
It is. Small pores as shown by Ha and Hb
is between two plates with the same recess shape (e.g.
For example, between two P-a or between two P-b
between) or two plates with different recess shapes.
Pressure adjustment between rates (for example, between P-a and P-b)
Provided for the movement of constant or small proportions of fluid.
The diameter, number and location of the small holes may vary depending on the
It will be determined as appropriate depending on the purpose. Fluid flow in plates with further recesses
The shape of the outlet (e.g. Xa, Xb)
The shape is preferably straight, but it is not limited to that.
Instead of using a step-like uneven shape or a sawtooth shape.
You may do so. All you need is the same type of outlet
For example, as gives adjacent fluid flows of different fluids
For example, on the same plane, preferably on the same plane.
It means that it forms a flat shape as a whole on the surface.
Ru. Laminated plate type states shown in Figure 6-b
The mixer is a pre-mixer with two different concave and convex shapes.
There are two types of
Similar fluids coalesce in a uniform and regular layer
suitable for obtaining a mixed fluid with a lamellar structure.
This is what I did. However, as shown in Figure 6-a, there are two different
Alternately stacking plates with concave shapes
is not necessarily necessary; for example, [P-a+P
-a+P-b+P-b], [P-a+P-a+P-
b] or [P-a+P-b+P-b]
You can also stack two types of plates by appropriately combining them.
It also has three or more types of concave shapes.
Assemble the plates alternately or in any combination.
They can also be laminated together. Furthermore, the laminated plate type static mixer
- has at least two different recess shapes as described above.
By stacking only a large number of plates with
It is preferable that the
Smooth plate-like bodies without recesses, porous plate-like bodies (e.g.
For example, sintered metal plates, fibrous webs, textiles, gold
It is also possible to laminate layers (such as nets). Next, we will introduce another type of static mixer with laminated plate type.
A typical example is shown in Figure 6-b. This figure 6
-b is an enlarged schematic view from the outflow surface side where the fluid flows out.
It shows a perspective view. The mixers shown in Figure 6-b are P-c and P-
d plates with two different concave shapes intersect.
They are stacked regularly on top of each other, and the individual plates
One fluid in each of ports P-c and P-d.
It has an inlet. and the introduction of a large number of P-c
A common fluid inlet port A with ports clustered together in a band shape₁
, and a large number of P-d inlets are gathered together.
One band-shaped common fluid inlet B₁formed separately
are doing. Also, in this plate P-c and P-d
Each concave part has a number of island-like convex parts Ic and Id.
have. In addition, in this Figure 6-b, the plate
Plate P-d stacked inside P-c
What is a laminate in order to make the perspective view easier to understand?
They are shown separated. Common fluid inlet A₁and B₁more introduced
The fluids flowed through the plates P-c and P-, respectively.
d, and each outlet Xc
and emitted from Xd. Fluid outlets Xc and Xd in Figure 6-b, respectively.
From this, two different fluids form a thin layer.
flow out, come into contact with another fluid adjacent to each other, and coalesce.
A mixed fluid with an integrated lamellar structure is formed.
It can be done. Therefore, the layer thickness in the lamellar structure is
The thickness of the plate, especially the depth of the recess in the plate.
is related to. Using the laminated plate type static mixer mentioned above,
One of the preferred embodiments of the method of the present invention is
Melting at least two different fiber-forming polymers
A macroblend melt phase consisting of a
The melt phase is at least
One polymer melt phase forms a series of elongated narrow shapes.
A continuous melt phase, especially one with a lamellar structure.
A continuous molten phase is formed, and this molten phase is
The foregoing without substantially disturbing the continuous phase of the molten phase.
is fed to a mesh-like spinneret and transformed into a fibrous stream.
As mentioned above, this is a method for replacing Formed using a laminated plate type static mixer.
at least two different fiber-forming weights as described above.
A macroblend melt phase consisting of a coalesced melt phase,
Boundaries between different polymer melt phases in their melt phase
Mesh-like spinneret in a stable state without disturbing the
of the polymer in the static mixer.
The distance between the outlet and the mesh spinneret is too long.
and during the flow of the molten phase.
It is desirable that there be as few obstacles as possible.
more preferably, the static mixer
The area of the molten polymer flowing out from the mesh is
There is no substantial difference from the area of the shaped spinneret.
, and there has also been a major change in the shape of the area of both.
There is no change. However, in some cases the laminated plate
Type static mixer and mesh spinneret
between at least two different polymer melt phases during
Further statics are required unless the boundaries are significantly disturbed.
It is also possible to have a mixer present. [Stretching method of fiber aggregate] Polymers produced by the method of the present invention as described above
Several fiber aggregates are unstretched without being stretched.
Can also be used as a span
However, it can also be stretched. by stretching
As the average denier of fibers decreases,
Physical properties, especially strength, degree of orientation, etc.
span), but the present invention improves
Even if a large number of fabricated fiber aggregates are stretched,
At least two different polymerizations in the cross section of the fiber
Blocked body phase is often essentially unstretched
The fiber of the present invention is similar to that of yarn (as span).
The characteristics of the bar aggregate are maintained as they are. Below
Below, the method of drawing fiber aggregates is explained in detail.
Ru. Stretching of fiber aggregate produced by the method of the present invention
Generally, fibers made of thermoplastic synthetic polymers are stretched.
It can be carried out in the same manner as in the case of elongation. However, the method for producing fiber aggregates according to the method of the present invention
According to
Since the aggregate is obtained in the form of a thin sheet, its
Sheet-like aggregate (fibers arranged almost parallel)
) can be stretched to its original width, and
That is more advantageous. To facilitate understanding of stretching in the method of the present invention
One specific embodiment will be explained below.
Ru. Produced by the spinning method of the present invention as described above
A collection of undrawn fibers is placed on a friction guide or the like.
That is, at least one or more tubular friction bodies (e.g.
4, leading to 12) in Figure 4, the unextended state in the tubular friction body
Feeding speed of stretched fiber aggregate (V₁) and after stretching
The withdrawal speed of the fiber assembly at (V₂)
The formula V between₁＜V₂and the spinneret
Balance the tension so that the tension does not reach the
and the width of the spinneret (approximately the width of the aggregate)
A collection of fibers drawn stably and continuously
You can get a combination. In addition, the friction guide and the fiber aggregate after stretching
A heating retention area (for example, as shown in Fig. 4) is provided between the
In this case, it is shown as heat plate 13.
) by providing continuous hot rolling after spinning.
It is possible to stretch, thereby increasing the capacity.
Producing easily drawn fiber aggregates
Can be done. The friction guide is made of an undrawn fiber aggregate.
Speed (V₁), if it is a friction guide that can regulate
The mounting position and angle can be arbitrarily selected, and the shape can also be used as an example.
plate-shaped, tubular, square, tooth-shaped, roller, etc.
At least one piece, multiple pieces, or two or more types
A combination of the above may also be used. Also, at least one pair or more
Even if you use a nip-gripping roller, etc.
good. Furthermore, heating the friction guide body appropriately
Regulation of insertion speed and tension of the unstretched aggregate by
Equilibrium can easily be chosen arbitrarily. Na
Regarding the surface roughness of the friction guide, its surface
Mirror finish plating processing or satin finish processing, special
Subject to surface unevenness processing, resin coating processing, etc.
However, the speed of the undrawn fiber aggregate (V₁)
If the friction guide body can be regulated, its material,
Any object can be used regardless of its shape.
is possible. The degree of stretching of the fiber aggregate (V₂/V₁)teeth,
of the fiber-forming polymer constituting the fiber aggregate.
Type, shape of friction guide, surface form and material, processing
Change the combination of heating elements and temperature in the heat retention area as appropriate.
This can be changed by setting the
A stretching ratio of 1.1 to 10 times, preferably 1.5 to 5 times is preferred.
Delicious. In particular, the fiber aggregates handled in the present invention are
The fiber has an irregular circumference along its length.
The cross-sectional area changes over time and at least
Also, two different polymer phases are placed side by side.
Since it has a cross-sectional structure that merges with the
As you expand and increase the magnification, a certain point will be reached.
The entire assembly will not be cut off at the same point.
As the stretching ratio increases, some frames partially
The eyebar is gradually cut or partially split.
There are things to do. However, in such a case
Also, if the aggregate you are trying to stretch does not cut as a whole,
Unless otherwise specified, they are included in the method of the present invention. In other words
Stretching of the aggregate of the present invention involves such partial cutting or
Even if partial fiber splitting occurs, there will be no problem.
It has the advantage and feature that the whole can be stretched.
I can say that. To carry out drawing of the fiber assembly of the present invention
In this case, the temperature of the aggregate ranges from room temperature to fiber
Even if the temperature is below the temperature at which the polymer forming the
Bye. The preferred temperature is to form a fiber.
the type and combination of at least two different polymeric phases present;
Matching, ratio, block shape, number of blocks, etc.
It depends on the temperature, but generally at a temperature above room temperature.
of at least two different polymeric phases,
the apparent melting point of the polymer phase with the lowest apparent melting point;
When a point is expressed as an absolute temperature (〓), the temperature
The temperature that is lower than the temperature multiplied by 0.9 (〓) is
desirable. The stretching temperature depends on the stretching means, speed, and stretching times.
Since it is greatly influenced by factors such as
can be determined by repeating simple experiments.
can. As mentioned above, the unstretched material to be stretched in the present invention
In the fiber aggregate, each filament has a long internal cross-sectional area.
fluctuates irregularly along the horizontal direction, and
each of the filaments forming the aggregate.
The cross-sectional shape and size are different, and the cross-sectional shape and size are different.
The size of the block to be used is not uniform along the length.
Since it has some unique characteristics, it has not been known
As seen in the drawing of a uniform fiber aggregate,
The stability of the stretched state changes due to subtle temperature differences.
Never. Therefore, according to the method of the present invention,
Easy stretching within a wider temperature range than conventional stretching temperature ranges
and an aggregate of partially cut fibers,
Alternatively, it is possible to obtain partially split aggregates.
It is Noh. Applying this phenomenon to spinning
Agglomerates similar to slivers can also be spun.
Directly removes bulky filamentous materials with similar properties to yarn.
It can also be easily manufactured. Next, regarding the heating body in the heating retention area,
At least one or more fiber aggregates move along the trajectory.
It is preferable to install it on the road. In addition, one heating element
In this case, the heating temperature gradient can be moderately controlled.
It is desirable to be able to do so. In addition, the heating stagnation area is divided into multiple areas.
In the heating retention area, which is divided into multiple areas,
A plurality of heating elements are provided, and an appropriate temperature is set for each heating element.
By setting the degree, you can of course do one stage stretching.
Multi-stage stretching is also easily possible. As a heating body in such a heating retention area, for example,
Heating of flat plates, curved plates, uneven plates, bottles, etc.
Structured contact type, radiant heat, electric heat
It can be used regardless of the non-contact type, such as water, steam, or hot air.
Available for use. Especially for contact type heating elements
Since the stretching is sensitive to its surface roughness,
The surface is mirror-finished, gold-plated, or satin-finished.
For example, by subjecting the surface to roughening or
For example, coating with fluorocarbon resin etc.
Therefore, the blocking phenomenon and spreading of the fiber aggregate are
It is possible to slightly change the expansion ratio. Applicable
The length of the heating body on the trajectory of fiber aggregate movement is also arbitrary.
However, preferably in the width direction of the fiber aggregate
It is better to have a structure that supplies heat evenly to
desirable. When drawing the fiber aggregate, an oil agent is
Apply or contain a surface treatment agent such as
Stretching can also be facilitated by soaking.
Ru. The fiber assembly according to the present invention has the following characteristics:
Very specific crimp by developing symptoms
It can be made into thread. That is, the facade of the present invention
Fiber aggregates are made by crimping ordinary fibers.
Complications such as mechanical crimping that are often performed during processing
It can be made into a crimped thread in a simple way without requiring any special operations.
It is possible. In other words, the fiber aggregate of the present invention
is subjected to dry heat treatment under tension or non-tension, and boiling water treatment.
heat treatment such as
Crimp can be easily imparted by stretching to
Ru. The crimped yarn thus obtained has a crimp shape,
The structure is extremely distinctive. In other words, the present invention
At least 90% of the Ivar aggregate has a cross-section of
They are non-circular, and most of them have different cross-sectional shapes.
and at least one of the sizes are not the same.
and, and at least 50% of the aggregate is less
Both have two different polymer phases side by side.
having at least two blocks joined together in a block;
Moreover, the number, shape and size of the blocks are small.
At least one is non-uniform between individual fibers.
Since the points have characteristics, by crimping them
The shape of the block obtained by conventional melting method is uniform.
This block is better than crimped yarn from composite fiber, which is one
A more complex crimp based on the shape of the crimp is developed, resulting in irregular crimp.
As a rule, three-dimensional and fine crimp occurs. In particular, the present invention
Each fiber that makes up the fiber assembly
has an irregular periodic cross-section along its length
Since the block has a change in size,
Coupled with the above characteristics of the shape, extremely fine and irregular
In addition, it is possible to obtain a three-dimensional crimped yarn,
In this way, the material is bulky with crimps and has a low elastic recovery rate.
Excellent fiber aggregates can be obtained. good
The preferred average number of crimps is 3 to 20 crimps/inch, particularly preferred.
The thickness is 5 to 15 pieces/inch, and the crimp rate is
High crimpability in the range of 10-50%, preferably 15-45%
An aggregate of fibers is obtained. The crimped fiber aggregate can be crimped as is.
Used as tushion material, heat insulating material, and filler for insulation materials.
It can also be made into a web and made into a non-woven fabric.
It can also be used as a material. As mentioned above, the composite fiber aggregate of the present invention can be
A partially split fiber aggregate is given by stretching.
can be done. Partially split fiber aggregate provided by the present invention
In addition to stretching, physical processing such as kneading and raising
Addition of external force, heat treatment, swelling treatment, etc.
It may also be manufactured by means or a combination thereof.
I can do that. The composite fiber aggregate of the present invention that can be partially split is
at least two different polymer types and
It basically depends on the shape of the block. adhesive
Poor polymer combinations, e.g. polyethylene tere
A combination of phthalate and polypropylene or
It looks like the rock boundary line is relatively long.
In this case, partial splitting occurs relatively easily. [Composite fiber aggregate] According to the method of the present invention explained above, at least
The present invention comprises two different fiber-forming polymers.
A composite fiber assembly is produced. That is, the composite fiber aggregate of the present invention is (1) An aggregate of many fibers, (2) At least 90% of the cross section of the fiber is non-circular.
It has the shape of a shape, (3) At least 50% of the cross section of the fiber is
At least one of the shape and size is the same
Not, but (4) At least 50% of the fibers are
In the cross section perpendicular to the fiber axis, at least two types of
Each of the different fiber-formable polymer phases
At least a portion of each fiber is exposed on the circumferential surface of the fiber.
A small body that was combined side by side with
It has at least two blocks, and the block
At least one of the number, shape, and size of the twigs
is non-uniform between individual fibers. It has the characteristic of
It can also be clearly distinguished from composite fiber aggregates. The fibers constituting the aggregate of the present invention are
When cut at an arbitrary position perpendicular to the fiber axis, the
90% or more of the surface, preferably 80% or more, particularly preferably
More than 70% of them have a non-circular shape. From the already cited figures 7 to 16, etc., it is clear that the present invention
Most of the cross sections of the fibers that make up the aggregate are non-circular.
I understand that. According to the present invention, the degree of non-circularity of the cross section can be determined quantitatively.
can be expressed by the irregularity coefficient (D/d).
Wear. The deformity coefficient (D/d) is illustrated in Figure 17.
As shown, the maximum distance between two parallel lines circumscribing the fiber cross section
The ratio of (D) to the minimum distance (d) between its two circumscribed parallel lines
It is expressed as The non-circular cross section constituting the aggregate in the present invention is
Each fiber preferably has a shape factor of at least
It is 1.1. The fibers constituting the aggregate of the present invention are
When cut at an arbitrary position perpendicular to the fiber axis, the
50% or more of the surface, preferably 45% or more, particularly preferably
or more than 40% of the shape and size
are not the same. According to the invention, the shape and/or size of
Non-identical cross sections are shown in Figures 7 to 16.
As you can see, it is difficult to distinguish by microscopic observation.
Wear. Further, according to the present invention, fragments having different sizes can be used.
The surface is quantitatively expressed by the following formula In the formula, (A) randomly selects 100 pieces from the collection.
Extract a subset of fibers and
of each fiber cross section at the position of
By measuring the size by microscopic observation.
The cross section of the 100 fibers required for
σ(A) is the average value of the size of the 100 pieces.
is the standard deviation of the cross-sectional area of the fiber. Coefficient of variation of fiber cross-sectional area within the aggregate [CV
(A)]. The present invention
The cross sections of non-uniform size that make up the aggregate are
The fibers preferably have a CV(A) of 0.05 to 1.5, and
Preferably 0.1 to 1.5, particularly preferably 0.2 to 1.
Ru. The composite fiber aggregate of the present invention can be randomly produced from now on.
Extract a subset of 100 fibers and
The cross section of each fiber at an arbitrary location
When observed with a microscope, randomly extracted
At least 50% of the two cross-sections produced are preferably
teeth, (1) Anomaly coefficient deviation rate (α) expressed by the following formula, α=(D/d)i−(D/d)j/(D/d)i×
100 (%) Here, (D/d)i is the larger variant
number, (D/d)j is the smaller irregularity coefficient
show. Does it have a shape distribution expressed by (2) Cross-sectional area deviation rate expressed by the following formula β=Si−Sj/Sj×100(%) In the formula, Si is the size of the larger cross-sectional area (mm²),
Sj is the size of the smaller cross-sectional area (mm²),So
and β is the cross-sectional area deviation rate. It has a size distribution expressed by . The composite fiber aggregate of the present invention further preferably has:
The fibers that appear when observed under a microscope
A small number of two cross sections randomly extracted from the cross sections.
At least 50% (1) Anomaly coefficient deviation rate (α) of at least 2 (%)
have a difference in shape represented by and/
or (2) The cross-sectional area deviation rate (β) is at least 5 (%).
have a difference in the cross-sectional area represented. The fibers constituting the aggregate of the present invention are
When cut at an arbitrary position perpendicular to the fiber axis, the
50% or more of the surface, preferably 45% or more, particularly preferably
or more than 40% of the fibers contain at least two different fiber types.
at least a portion of each of the synthetic polymer phases is
side-by-side with the fibers exposed on the periphery.
has at least two blocks merged into the
However, the number, shape and size of the blocks
At least one of the fibers is non-uniform between the individual fibers.
be. Blocks combined side by side
is completely contained within the fiber cross section and exposed to the fiber circumference.
Understood as a block that excludes blocks that have not been published.
It should be. According to FIGS. 7 to 16, the assembly of the present invention
The cross section of the constituent fibers has side-by-side
At least two blocks can be seen that have merged into
Ru. The fibers constituting the aggregate of the present invention meet the above definition.
Therefore, at least the side-by-side
also covers at least 50% of the cross section with two blocks.
Contains. A small group that has been combined side by side.
The proportion of cross sections with at least two blocks is
According to the description of the production method of the present invention, macroblen
The formation state of the molten phase of the melt and the slits of the spinneret
Easy to change depending on size and selection
be understood. The number of blocks merged side by side and
is exposed at least in part to the fiber periphery.
should be understood as the number of independent blocks
Ru. For example, in Figure 3-a already explained,
The number of blocks contained in the small square on the upper right is 4.
and the number of blocks contained in the small square at the bottom right
There are 3 pieces. The collection of the present invention will be made up of 100 pieces at random from now on.
Extract a subset of fibers and select any part of it.
Observe the cross section of each fiber at the location using a microscope.
If the cross section of the fiber is at least
There are also two different fiber-forming polymeric phases.
In both cases, a portion of the fiber is exposed on the circumferential surface of the fiber.
Inside the fiber of the polymer phase coalesced side by side
The average number of blocks ((B)) is preferably 1.5 to 30,
More preferably, it has 2 to 5 pieces. More preferably, the aggregate of the present invention has the following formula: In the formula, (B) is randomly selected from 100 pieces from the collection.
Extract a subset of fibers and
Blots of each fiber in the cross section at the position of
By measuring the number of cracks by microscopic observation.
The cross section of the 100 fibers determined by
is the average value of the number of blocks in σ(AB)
is the standard number of blocks for the 100 fibers.
This is the standard deviation value. The variation coefficient of the number of fiber blocks within the aggregate is expressed as
[CV(AB)] is in the range of 0.05 to 1.0, preferably 0.1 to
0.8, particularly preferably in the range 0.15 to 0.7.
It has a distribution of lock numbers. In the aggregate of the present invention, fibers according to the above definition
The shape and size of the block itself between
The difference in size can be seen from the drawings already cited.
It can be revealed by microscopic observation of sea urchins.
Ru. If quantification is required, for each block
Corresponds to the irregular shape coefficient and cross-sectional area variation coefficient mentioned above.
It is sufficient to introduce the concept of The composite fiber aggregate of the present invention has each of the following definitions.
The average denier () within the fiber aggregate is 0.01~
1000 denier, more preferably 0.05-800 denier
denier, particularly preferably 0.1 to 500 denier.
provided. Average fineness (average denier,
De) is a random subset of 100 lines from the set.
Extract 10 pieces of the body (if you want to do it easily, extract 3 pieces)
It's okay. When extracting 3 pieces and when extracting 10 pieces
), the fibers of each subassembly
Randomly select one location in the fiber axis direction and move in the direction perpendicular to it.
The cross section was photographed using a microscope and approximately
Individual fiber cross-sections can be seen from photographs enlarged 2000 times.
Cut out and weigh the total weight of each section.
Divide by the number of photos, average it, and calculate the value [m(A)]
This is the value converted to de. Therefore, the average fineness within this aggregate is expressed by the following formula:
Calculated from =K・m(A) [However, m (A) in the formula is the cross section of the cut photographic fiber.
Weight average value, K denier (de) conversion factor
and Formula K9×10^Five・ρ／γ・δ is required. Here, γ is the unit area weight of the photo
amount (g), δ is the area enlargement magnification of the photograph, and ρ is the fiber
The specific gravity of the fibrogenic polymer, and these are all
Value expressed in c.g.s. units. ] The composite fiber aggregate of the present invention includes 2 to 5 types, preferably
or contains two or three different fiber-forming polymeric phases.
You can In the composite fiber aggregate of the present invention, each fiber contains
At least two blocks included in the
can consist of one polymeric phase, and can consist of one polymeric phase.
at least one other polymer in the body matrix
It consists of a dispersed phase (microblend phase) in which the particles are dispersed.
You can also Therefore, according to the invention, preferably each
It is proposed that the block consists of a single polymer phase.
The fibers were also subjected to microscopic observation.
At least one block appearing in the cross section is
It forms a clear boundary line and merges with the block.
and the at least one block has at least one
a single polymer matrix and this matrix
at least one other polymer dispersed in the Tux
A dispersed phase is provided. 16th
The figure shows this aspect. According to the present invention, the composite fiber of the present invention is further constructed.
Preferably, each fiber comprising
The size of the cross-sectional area changes irregularly and periodically.
are doing. Such a change in the size of the cross-sectional area is due to the
Select 3cm of any one fiber and
The size of the cross-sectional area at every 1 mm interval was observed by microscopy.
The average value of the 30 cross-sectional areas (
(F)) and the standard deviation of its 30 cross-sectional areas (σ
(F)) is obtained, and the fiber internal cross-sectional area is calculated from the following formula.
Measure the coefficient of variation [CV (F)], This CV (F) can be expressed numerically.
Ru. Each fiber constituting the composite fiber aggregate of the present invention is
Preferably, the fiber internal cross-sectional area coefficient of variation [CV
(F)] has a value in the range of 0.05 to 1.0. This frame
The coefficient of variation of the cross-sectional area inside the eyebar is determined according to the example described later.
The following is an example of measurements made on the fibers obtained.
It is shown in Figure 18. Furthermore, according to the present invention, the composite fiber of the present invention
At least 50% of the fibers making up the aggregate are
Select 5cm of one fiber and cut it into 5mm
A cross section perpendicular to the length of the fiber for each interval
(total of 10) measured using a microscope, each
At least 50% of the cross section has at least two different species
at least one of each of the fiber-formable polymeric phases.
A part of the fiber is exposed on the circumferential surface of the fiber.
At least two blocks combined in Dubai Side
This block has a lock inside these cross sections.
At least 2 areas with uneven size (area)
There are two cross sections. This cross section
The situation in which the size of the bumps is uneven can be explained by the actual situation described later.
The fiber obtained in Example was measured.
The photograph is shown in Figure 19. According to the invention, therefore, fiber-forming polymerization
A filamentous fiber consisting of a body, (1) This fiber has a non-circular cross section and
The maximum distance (D) between the two circumscribed parallel lines and the two circumscribed parallel lines
Anomaly coefficient expressed as a ratio to the minimum spacing between row lines (d)
(D/d) is at least 1.1; (2) The fiber runs irregularly along its length.
It has a regular periodic change in the size of its cross-sectional area.
the law of nature, (3) Select 3cm at any point on the fiber.
and calculate the size of the cross-sectional area for each 1 mm interval.
was measured by microscopic observation, and 30 cross sections were
Average value of the product ((F)) and its 30 cross-sectional areas
Find the standard deviation (σ(F)) of
Measure the fiber internal cross-sectional area coefficient of variation [CV (F)]
If set, The coefficient of variation of the fiber internal cross-sectional area [CV (F)] is
has a value ranging from 0.05 to 1.0, (4) Select an arbitrary 5 cm of the fiber and
perpendicular to the length direction of the fiber at intervals of 5 mm.
Measure the cross sections of the corners (10 pieces in total) using a microscope.
If at least 50% of each cross section is at least
Two different fiber-forming polymeric phases each
at least a portion of each other around the fibers.
side-by-side with the surface exposed.
have at least two blocks with
and the size (area) of the block is different.
At least something exists. A novel filament fiber characterized by
will be provided as well. Composite fiber aggregate of the present invention and the above filament
As a fiber-forming polymer that forms fibers
In this case, thermoplastic fiber-forming polymers such as the following are used.
Preferably used. (i) Polyolefin or polyvinyl polymerization
body; For example, polyethylene, polypropylene, poly
Butylene, polystyrene, polyvinyl chloride, poly
Polyvinyl acetate, polyacrylonitrile, polya
Acrylic acid ester or their mutual copolymerization
body. (ii) polyamide; For example, polyε-caprolactam, polyhexa
Methylene adipamide, polyhexamethylene seba
Kamid. (iii) polyester; For example, phthalic acid, isophthalic acid, terephthalic acid
acid, diphenyldicarboxylic acid, naphthalene dicarboxylic acid
Aromatic dicarboxylic acids such as rubonic acid; adipine
acids, sebacic acid, decanedicarboxylic acid, etc.
Aliphatic dicarboxylic acid; or hexahydrotereph
Dibasic acid formation of alicyclic dicarboxylic acids such as tarlic acid
minutes, ethylene glycol, propylene glycol
Cole, trimethylene glycol, tetramethylene
lene glycol, decamethylene glycol, di
Ethylene glycol, 2,2-dimethylpropane
diol, hexahydroxylylene glycol
aliphatic compounds such as alcohol, xylylene glycol, and fats.
Cyclic - or aromatic - glycol or polyester
Polyoxyalkylenes such as tylene glycol
Polyester containing glycol as a glycol component
is advantageous. These dibasic acid components or
One or more of each recalled ingredient
It may also be a combination of copolymerized polyesters.
A particularly preferred example is polyethylene terephthalate.
rate, polytetramethylene terephthalate,
Polytrimethylene terephthalate, US Patent No.
No. 3763109, No. 3023192, No. 3651014 and
The polyester resin described in No. 3766146
Lastomer et al. (iv) other polymers; In addition to the polymers (i) to (iii) mentioned above, various bis
Polycarbonate using phenol; poly
Acetal; various polyurethanes, polyethylene fluoride
Ren, copolymerized polyfluorinated ethylene. Additionally, polymers increase plasticity and melt viscosity.
Even if plasticizers, viscosity increasers, etc. are added to
good. In addition, the polymer usually contains fiber additives.
Used as light stabilizers, pigments, heat stabilizers,
A fuel agent, a lubricant, a dissipating agent, etc. may be added. Furthermore, polymers are not necessarily limited to linear polymers;
Partially cross-linked three-dimensional as long as it does not impair thermoplasticity
It may also be a polymer having a similar structure. Composite fiber aggregate of the present invention and the above filament
The fiber is made of at least one of the above polymers.
It is also manufactured using two types. The composite fiber aggregate of the present invention preferably has the above-mentioned
at least two different fiber-formable polymers of
the phases differ in their apparent melting points by at least 3°C (However, the apparent melting point refers to the
each polymerization if each consists of a single polymer.
melting point of the body, and at least one of them
the polymer phase is made of at least two different polymers;
If so, the mixing weight ratio of the different polymers (combined
The total is 1) multiplied by the melting point (℃) of each polymer.
) consisting of at least two different polymers, such as
ing. Two different polymers are, for example, polyethylene
Combination of terephthalate and polypropylene
It means two different types of polymers that are completely different in type.
For example, the same polymers with different degrees of polymerization
combinations of coalescence (for example, intrinsic viscosities of 0.96 and 0.49)
combination of polyethylene terephthalate, etc.),
or polymers of the same type with different end groups (e.g.
combination of polyamides with different terminal amino groups),
or linear polymers and partially branched homogeneous polymers
(For example, polyethylene terephthalate and branching agent
Partial copolymerization of pentaerythritol as
combination with polyethylene terephthalate) etc.
You should taste it and understand it. In addition, for example
Melting point, specific gravity, hardness, crystallinity, solvent resistance, dyeability
A combination of two types of polymers with different
In terms of form, heat shrinkage rate, degree of orientation, strength, elongation, and eccentricity
Combinations of two types of polymers with different optical properties are also included.
It should be understood that More specifically, an example
If at least two different polymers are both
To explain the case where it is an ester, these
Polyester has physical properties and chemistry such as
be different in at least one of the properties of
Can be done. (b) Physical properties (i) Color; Identifiable with the naked eye (ii) Melting point; difference of 3°C or more (iii) Boiling water shrinkage rate; air drying after 10 minutes immersion in boiling water
Difference of 3% or more (iv) Specific gravity: 0.03g/cm³difference of more than (v) Crystallinity; X-ray wide-angle measurement difference of 15% or more (vi) Intrinsic viscosity [η]; O-chlorophenol solution
In-liquid measurement or phenol/
Tetrachloroethane (=
1/1) 0.05 or more when measured in solution
difference above (vii) Melt viscosity at die temperature; 500 poise or more
difference (viii) Aggregate strength; difference of 0.5g/de or more (ix) Aggregate elongation; difference of 10% or more (x) Elastic recovery rate at 50% elongation; difference of 10% or more (b) Chemical properties (i) Staining property; visible to the naked eye under an optical microscope at 400x magnification
more than discernible (ii) Chemical etching;
(lukali solution) soaked at 60℃ for 2 hours.
After pickling, a scanning microscope with 1000x magnification was used.
More than visible to the naked eye with a microscope etc. Differences in these physical properties and chemical
Among the differences in properties, especially color, melting point, boiling water shrinkage
rate, crystallinity, intrinsic viscosity [η], aggregate strength,
It is a good idea to take advantage of the difference in coalescence elongation. at least two different polymers within the fiber
The phase aligns the filament at right angles along its fiber axis.
For example, a cross section cut in the direction of
or observe the above cross section with a microscope.
In addition, the above cross section was treated with ion etching to make the surface
Make scratches and examine the surface roughness using an electron microscope (e.g.
For those who wish to observe at a magnification of approximately 1000x)
can be easily identified. As mentioned above, according to the production method of the present invention,
Polymers used in melt spinning processes, such as polyester
Tylene terephthalate, polyε-caprolacta
polyhexamethylene adivamide, polyethylene
polypropylene, polystyrene, polytetra
Polymers such as methylene terephthalate are used advantageously.
Not only is it used in
Polycarbonate, which was considered difficult to
Polymers such as polyester elastomers
It can also be easily turned into fibers without any hindrance.
I can do that. For example, if the degree of polymerization is very high,
Since the melt viscosity is very different, conventionally
At the very least, it was difficult to produce synthetic fibers.
Composite fibers made from two different polymers can also be produced.
can. The composite fiber polymer of the present invention comprises at least two types of
Different polymer phases coalesce side-by-side
It has at least two blocks and follows
As already described in the explanation of the manufacturing method,
Two different polymerizations where the two blocks are non-adhesive
If it consists of body phase, it should be partially split.
This causes fine fibers to be spaced apart along the fiber axis between the polymer phases.
may be provided as an aggregate with
Ru. Such partially split conjugate fiber weight of the present invention
According to the invention, the merging consists of 100 pieces of the aggregate.
At least 20% of the randomly sampled
Along the length of those fibers, (a) Observation of a cross section perpendicular to the fiber axis using a microscope
At least two different types of fibers can be formed when
at least a portion of each of the functional polymeric phases is mutually compatible.
When the fiber is exposed to the circumferential surface,
The part that merged with Dubai Side, (b) at least one of the side-by-side
Also, two different fiber-forming polymer phases are present in the
mutually along the length of the fiber at any interface.
The part separated and finely divided into It is provided as having irregularly. The state of parts (a) and (b) will be explained later.
The cross section of the fiber obtained by example
It is shown in the photograph as Fig. 20. Furthermore, the composite fiber aggregate of the present invention comprises at least
Side-by-side, consisting of two different polymer phases
has at least two blocks joined to the id
Therefore, processing that takes advantage of the difference in shrinkage of different polymer phases is possible.
For example, by treating boiling water, each
Provided as fibers with irregular crimps
can be done. According to the present invention, the composite fiber aggregate of the present invention
Furthermore, it can be provided in the form of short fibers. The average fiber length of such short fibers is 200 mm.
Hereinafter, preferably 150 mm or less is suitable.
The composite fiber aggregate of the present invention made into short fibers can be used as is.
It can also be used or mixed with other fibers.
You can also use In this case at least 50
% by weight, preferably at least 60% by weight of the present invention.
If it is a composite fiber assembly, the composite fiber assembly of the present invention
It is possible to express the characteristics of In addition, the short fiber
The fiber itself or mixed with other short fibers can be used as spun yarn.
It is also possible to use it as The composite fiber aggregate of the present invention has a cross-sectional shape, a size
grain size, its distribution and in the direction perpendicular to the fiber axis
Changes in the number, shape and size of blocks within the fiber cross section
The movement is within a certain range, and such a composite fiber collection
Coalescing cannot be obtained by conventional fiber manufacturing methods.
As a collection, it has structural characteristics.
Also, the characteristics could not be obtained from conventionally known methods.
A variety of interesting things are expressed. Distribution and collection of fiber cross-sectional areas of fiber aggregates
The distribution of the number of blocks within a coalescence is shown in the example described later.
Here are some examples of measurements made on the fibers obtained.
They are shown in FIG. 21 and FIG. 22, respectively. In addition, the cross-sectional shape, size, distribution, fiber axis direction
The range of variation in the fiber cross section along the
The composite material of the present invention is similar to natural silk and wool.
Fiber aggregates add texture and properties to these natural products.
This means that we can provide similar synthetic fibers.
Wear. Thus, the composite fiber aggregate of the present invention can be used for fabrics,
In addition to knitting, all kinds of non-woven fabrics etc.
It can be used as a material for textile products. The composite fiber aggregate of the present invention has a fiber cross section and length.
Moderate irregularity in direction and imparted during fiber forming
by anisotropic cooling effect, often by heat treatment
It exhibits a high degree of crimp, and this property is unique to fibers.
It can be applied to increase the intertwining of fibers.
Ru. The composite fiber aggregate of the present invention further has a configuration after molding.
Parallel array sheets that maintain columns, and orthogonal sheets
Orthogonal non-woven fabrics bonded together using electricity and air
Randomized random structure non-woven fabric, artificial leather
It can also be easily applied to The present invention will be described below with reference to Examples. but
However, the following examples will facilitate understanding of the invention.
This invention is described in order to explain the invention in no way.
It is not a restriction. Example 1 6-Nylon (melting point 488°K, intrinsic viscosity [η]=
1.3) chips and polypropylene (melting point 438°K,
Using melt index 15) chips,
A fiber aggregate was molded using the apparatus shown in Fig. 4.
That is, the 6-nylon chips were put into an extruder A with an inner diameter of 30 mm.
in the temperature range of 200 to 300℃ while continuously supplying a fixed amount.
kneaded and melted in the
g of the molten polymer is sent to the mixer section 6~, and at the same time,
Connect the polypropylene tip to extruder B with an inner diameter of 30 mm.
Temperature range from 240 to 310℃ with continuous quantitative supply
The gear pump 4b mixes and melts the mixture at a rate of 14 per minute.
g of the molten polymer is sent to the mixer section 6, and
The 6-
Mix the molten polymer of nylon and the polypropylene.
Then, using an I-type die, the size is 160
It has a band-shaped molding area of mm x 5 mm, and has a 32 mesh flat area.
Discharged from spinneret 9 consisting of one piece of woven wire mesh
I set it. At that time, the cooling near the surface of the forming area is
As shown in the figure, the gas injection nozzle is located directly below the spinneret.
The cooling device 11~ having a wind speed of 9 m/sec
Aim the air at the molding area where the polymer will be discharged.
37,000 denier composite under the molding conditions shown in Table 1.
A fiber aggregate was obtained. The main physical properties of the composite fiber aggregate are shown in Table 2.
It is as expected. Example 2 Mixer section 6 has Kenix type static mixer
Insert 16 spinnerets and spinnerets 9 to 50 meshes
160mm x 5mm made of one plain woven wire mesh.
Table 1 was prepared using an apparatus as shown in Fig. 4 having a molding area.
The composite fiber aggregate was spun under the fiber forming conditions of
Ta. Fiber cross-section micrograph of the obtained composite fiber aggregate
The true color is shown in Figure 7-a, and this is cold stretched to about 3 times.
After that, the fiber aggregate was heat-treated in boiling water for 10 minutes.
Fiber cross-section micrographs are shown in Figures 7-b and 7-c.
It is. From these photos, we can see that the different weights in the fiber cross section are
At the interface of the lamellar mixed state of the coalesced phase, the fiber aggregate
It was found that the body was easily split. Figure 7-
In b, the partially split part and the still split part are shown.
It is clear that there is a mixture of untextured parts.
That's it. Furthermore, it is clear from Figures 7-a, -b and -c.
The fiber aggregate obtained in this example was constructed as follows.
More than 95% of each fiber has a non-
It is obvious at first glance that it is circular. Example 3 As a spinneret, 12 mesh, 30 mesh and
Laminated three pieces of plain woven wire mesh in the order of 45 and 45 mesh.
8 in the die in Figure 4 in parallel.
20 rows, then state in series on each individual row
Using a device like the one shown in Figure 4, which has six sensors arranged in
Polyethylene terephthalate (melting point 540°K,
Chips with intrinsic viscosity [η] = 0.71) and polypropylene
Ren (melting point 438°K, melt index 15)
Fiber molding is carried out under the conditions shown in Table 1.
Ta. Fiber cutting of the fiber aggregate obtained in Examples 1 and 2
On the surface, the interface between the polymer phases has a smooth curve.
However, the fiber obtained in this example
The interface of the polymer phase is somewhat stiff in the cross section of the fiber.
It turned out that it was. Furthermore, stretching was performed under the conditions shown in Table 1.
I was able to Example 4 The inside of the die in Figure 4 is 2cm long and 5cm wide.
cm, thickness 200μ, and is shown in Figure 6-b.
Approximately 800 plates with concave areas are stacked together.
Place it in a holder, set it up as a mixer, and put it into practice.
The same polyethylene terephthalene used in Example 3
Lamellar melt of polypropylene and polypropylene polymer
Mix in a structural shape and use as a partition member to improve the opening area ratio.
[(-)/] is 0.294 (generally, the aperture ratio
29.4%) of 70 mesh plain weave wire mesh.
under the fiber forming conditions shown in Table 1, at a speed of 20 m/min.
The composite fiber aggregate was collected at a temperature of 1. Microscope of fiber cross section of the obtained composite fiber aggregate
Statistically calculate the average fineness of the composite fiber from the photo.
When I turned it on, it was 0.9 de. Furthermore, the above micrograph
The average number of blocks within the composite fiber assembly from
When [(B)] was actually measured, it was 4.0 pieces/book. Ma
In addition, in the above micrograph, the cross section of the fiber is
Single polymer phase, not do-by-side
One fiber with a rectangular shape is composed of
It was not possible. The composite fibers obtained in this example are 13 to 13 in FIG.
It can be easily stretched on a heating plate as shown in
I understood. Example 5 The mixer section 6~ in Figure 4 has a Kenics type state.
Insert 6 Tsuku mixers (outer diameter 14φ, length 21mm)
Then, there is a Kenics-type static mark on the inside of the die.
Arrange the kissers in 16 rows in parallel, and in each of those rows
As shown in Figure 5, there are 4 Kenix type statics.
Adopts a mixing system in which kissers are arranged in series to reduce heavy
Fiber forming area consisting of various partition members for the combined melt
The device shown in Figure 4 is a rectangle of 390 mm x 20 mm.
It was used. As a specific partition member, this implementation
In the example, one piece of 30 mesh plain weave wire mesh is used, and
The polymer is the same polyethylene as used in Example 3.
Terephthalate and polypropylene were used. First, we investigated the mixing state of two types of polymers.
In order to ensure that the fiber molding area
A rectangular polymer receiving box (stainless steel) without a mesh
(response material) and place the mixed polymer in it.
After pulling, the receiving box is cooled in water.
and quickly solidify while leaving the polymer mixture intact.
turned into The polymer mixed sample was placed on the mouth surface.
It is cut along parallel planes and photographed using a microscope.
FIG. 24. From the multiple micrographs, the
Effective average cord length [(c)] and difference per unit area
Find the boundary line length [(p)・(p)] of the polymer phase.
Then, the boundary line length becomes 0.42mm and 373mm, respectively.
is sufficiently longer than the average length of the partition member.
be understood. Next, one piece of 30-mesh plain-woven wire mesh was added to the molten polymer.
When used as a partition member for a mixed molten phase, the
When spinning under the same fiberizing conditions, the average single yarn density was
225,000 denier fiber made of 10 de neel fiber
A fiber aggregate was obtained. Average blots within the aggregate in these fiber cross sections
The number of blocks [(B)] is 5.5 pieces/piece, and the polymer mixture
From the effective average code length [(c)] that indicates the
Theoretical average block number calculated by the formula in the text
[(B)] is 5.0 pieces/book, and [(B)] and [(B)
]
It can be seen that they match well. Obtained above
Composite fiber aggregates made of composite fibers are
More than 95% of the cross-sectional shapes are non-circular.
There are two polymer phases arranged in a lamellar structure on the side.
Figure 10 shows that they are arranged in a by-side pattern.
This is clear from the micrograph. Black part of fiber cross section
Minutes are dyed polyethylene terephthalate parts
It's a minute. The composite fiber aggregate can be used as a cartridge heater.
With 3 built-in heating rods with an outer diameter of approximately 5 cm,
Stretching with alternating arrangement of two rods that are not heated
Rod surface temperature range from 80 to 120° in zone
When stretched approximately 3.5 times with
Compounds shown in Table 2 that can be used as raw materials
A composite fiber aggregate was obtained. Furthermore, the composite fiber aggregate obtained by drawing
Easy to process by mechanically massaging the product as it is.
I was able to split the fibers into Figure 20 shows the mechanical massaging process.
At the boundary of the
The cross-sectional form was changed in the length direction of the fiber at 5 mm intervals.
This is a microscopic photo showing the change. In positions 1 to 4, the product
Extremely unsplit and in position 5-10
It is clear that the fibers are actively split.
Ru. In addition, in Figure 20, the length of the fiber is 5 cm.
In this case, the number of blocks did not change at all, and the fibers were split.
Each block of fibers corresponds to which block of unsplit fibers.
Easily trace whether it was made from Tsuku
Can be done. (In Figure 20, each block has
They are numbered 1 to 6 and displayed. ) Example 6 Types of polymers and methods of melt mixing different polymer phases
The formula, fiber forming conditions, etc. are the same as in Example 5.
It is a member that simply partitions the polymer mixture state.
By changing only a certain discharge surface base material (spinneret base material),
Changes in the shape of the resulting composite fiber aggregate and fiber
I investigated the change in the number of blocks in the cross section. Book
In the embodiment, the partition member shown in FIG.
One piece of 45-mesh plain-woven wire mesh shown in the schematic diagram in a.
It was used. The mixed state of the polymers is shown in Figure 24.
The composite fiber aggregate obtained was
The surface photograph is shown as a micrograph in Figure 11.
Ru. The average number of blocks within an aggregate is determined by the number of fiber cross sections.
According to the actual measurement from the photo, it is 3.3 pieces/piece, and the polymer
From the effective average code length [(c)] showing the mixed state of
It agrees well with the calculated theoretical average block number.
Ru. Also, there are many fiber cross-sectional photographs such as those shown in Figure 11.
, the number of blocks within the composite fiber assembly
Figure 22-a shows the bar graph obtained by examining the cloth.
be. From this graph, we can see that one of the features of the present invention is
Variation coefficient of the number of blocks within a set within a certain range
When I calculated [CV(AB)], it was 0.34. The composite fiber
If you look at Figure 11, which is a cross-sectional photograph of the fibers in the aggregate,
The cross-sectional shape of more than 90% of the fibers in the aggregate is non-circular.
There are different polymer phases in the fiber cross section.
More than 95% of the
You can see at a glance that it's on top. Here, from the undrawn composite fiber aggregate, any
Select one fiber and run it along the length of the fiber.
Cut it over a length of 5 cm at 5 mm intervals.
The 19th study tracked the changes in the fiber cross section.
It is a diagram. Micrographs of fiber cross sections at each of 10 locations
Then, cut out only the fiber cross section and arrange it again.
Figure 19 shows the crucifixion. From this diagram
As is easily understood, among the individual fibers,
Over the length of 5cm, the size of the block is slightly different.
The number of blocks is changing, but the number of blocks is not changing.
It's worth noting that. The shape of the block is
Some parts change in a similar way, and some parts change in a non-similar way.
You can see that Furthermore, the composite fiber aggregate was stretched in the same manner as in Example 5.
Heat the drawn composite fiber aggregate at 170℃
When processed, a run as shown in Figure 26 was obtained.
A composite fiber aggregate with a dam high crimp structure was obtained.
Ta. Other features of this embodiment are shown in Tables 1 and 2.
As shown. Example 7 Types of polymers and methods of melt mixing different polymer phases
The formula, fiber forming conditions, stretching conditions, etc. are as shown in the example.
5 and Example 6, simply adding the polymer
Discharge with a large aperture ratio that separates and cuts the mixed state
A composite fiber aggregate was obtained by changing only the surface base material. 12
A piece of mesh plain-woven wire mesh is used as a partition member.
Fiber cross section of the undrawn composite fiber aggregate obtained by
The photo is as shown in Figure 12, with an average single yarn denier.
Even thick fibers such as 106de have a coagulation length of less than 1cm.
The thinning phenomenon of fiber formation is completed within a very short range.
I found out that This solidification length [f] is stable
It is cooled with dry ice in the state where it is formed into fibers.
While blowing a large amount of low-temperature air,
stop the extrusion of the molten polymer,
A sun that freezes many thinned fibers in an instant.
Collect the sample and observe its many thinned parts under a microscope.
I was able to measure it. Example 8 Types of polymers and methods of melt mixing different polymer phases
The formula, fiber forming conditions, stretching conditions, etc. are as shown in the example.
5 and Example 6, simply adding the polymer
Change only the discharge surface base material that separates the mixing state and cuts it.
As a result, a composite fiber aggregate was obtained. In this example, as shown in the schematic diagram of Fig. 1-b,
One piece of level woven wire mesh with 40 mesh
It was used as a partition member for the polymer phase melt. Fiber cross section of the obtained undrawn composite fiber aggregate
can be understood from the micrograph in FIG. partition
Polymer mixture state before cutting by cutting member
is common to Examples 5 to 10, and the 24th example
This can be understood from the micrograph shown in the figure.
When using this partition member, the fiber cross section
The irregularity coefficient (D/d) becomes larger than 2, and the aggregate
The internal block number variation coefficient [CV(AB)] is as large as 0.45.
There is a tendency to Other characteristics and fiber properties are shown in Tables 1 and 2.
As shown in the table. Example 9 Types of polymers and methods of melt mixing different polymer phases
The formula, fiber forming conditions, stretching conditions, etc. are as shown in the example.
5 to Example 8, just different.
Discharge surface that partitions and cuts the molten mixture of polymer phase
A composite fiber aggregate was obtained by changing only the base material. Main implementation
In the example, the schematic diagram of Fig. 1-d is used as a partition member.
One etching plate shown was used. like this
Etched plates are made by photo-curing the surface of stainless steel plates.
After applying the adhesive resin, print the original negative film over it.
Avoid chemical etching by overlapping layers and irradiating them with light.
After curing the resin on the surface layer of the part, remove the uncured part.
Wash off the water and then erode the stainless steel material.
The chemical etching process shown in Figure 1-d is performed.
A mesh-like perforated plate with numerous patterns was used.
After that, wash away the photocured portion remaining on the surface layer.
It can be easily manufactured by the following method. A feature of this method is that any desired
A mesh-like perforated plate with an uneven shape can be manufactured at low cost.
This is a point that can be built. In this example, FIG.
- The ABC triangle of d is a regular triangle with a side length of 0.5 mm.
It is square. The undrawn composite fiber aggregate obtained in this example
A cross-sectional photograph of the fiber is shown in FIG. It is clear from this figure
The cross-sectional shape of 95% or more of the fibers in the aggregate
The shape is non-circular, and more than 90% of the fibers in the aggregate
Polymer phases with different cross-sections allow for side-by-side
You can see that it has an id-shaped block shape.
Ru. In the fiber cross section of the composite fiber aggregate obtained,
The average number of blocks within the aggregate [(B)] is estimated in advance.
It agrees well with the theoretical average number of blocks [(B)]
are doing. The composite fiber aggregates were prepared in Examples 5 to 8.
It was possible to stretch it in the same way. Other characteristics and fiber properties are shown in Tables 1 and 2.
As shown in the table. Example 10 Types of polymers and methods of melt mixing different polymer phases
The formula, fiber forming conditions, stretching conditions, etc. are as shown in the example.
5 to Example 9, but only with different
Discharge to separate and cut the molten mixture of polymer phase
A composite fiber aggregate was obtained by changing only the surface base material. Real truth
In the example, the schematic diagram of FIG. 1-c is used as the partition member.
Usually used for 70 mesh plain weave wire mesh as shown in
40 mesh specially woven using fine wire
One piece each of plain woven wire mesh and 30 mesh plain woven wire mesh
are stacked on top of each other in the bias direction and specially sintered.
A sintered wire mesh was used. The resulting composite
The fiber cross section of the fiber aggregate can be seen using a cross-sectional microscope in Figure 15.
As shown in the photo, the deformity factor (D/d) is
The block number variation coefficient [CV(A
B)] is slightly large at 0.54, and the fluctuation in the number of blocks is large.
There is a tendency to be harsh. After stretching the composite fiber aggregate
However, this anomaly coefficient, the variation coefficient of the number of blocks within an aggregate,
The number etc. tends to be large in this embodiment. Other characteristics and fiber properties are shown in Tables 1 and 2.
As shown in the table. Example 11 Polyethylene tereph on the A side of two 30φ extruders
of tallate (melting point 540°K, intrinsic viscosity [η] = 0.71)
Chips and polypropylene (melting point 438°K, melt
35 parts and 15 parts weight of chips with index 15) respectively.
Mixed and supplied in a quantitative ratio, microbubbles are produced by an extruder.
The blended melt is extruded, and from the extruder on the B side,
Polypropylene (melting point 438°K, melt index
Extrude the chips in step 15) at a rate of 50 parts, and
In the mixer section 6~ and the die inside 8~, those A
The polymer melt phases of and B were mixed. Figure 25
indicates the mixed morphology of the polymer phases of A and B.
This is a stereomicroscope photo, and the scale at the bottom of the photo is
One scale corresponds to a length of 1 mm, and the part that looks black is
of polyethylene terephthalate and polypropylene
The white part shows the A polymer phase in a micro-mixed state.
indicates the B polymer phase consisting only of polypropylene.
It is something. Melting of different polymer phases as shown in FIG.
Filter the mixture using one piece of 45 mesh plain weave wire mesh.
When cut, as shown in Figure 16, the sasa
Different polymer phases are blotted side by side.
A composite fiber aggregate with a cross-sectional shape of
Obtained. According to FIG. 16, the A polymer phase
Liethylene terephthalate and polypropylene
It is clear that they are mixed in a microblend.
Ru. The A polymer phase and the B polymer phase are macroblocks.
It is clear that they are mixed in a lenticular pattern. A,
Average number of blocks in the aggregate consisting of the polymer phase of B
is in good agreement with the theoretical average block number, and the actual
Compared to Example 6, each of the different polymer phases
Even in a microblended state, the present invention
There is no problem with the macro blend control technology.
It shows. Other characteristics and fiber properties are shown in Table 1 and
As shown in Table 2. Examples 12 to 14 Similarly, from Example 12 to Example 14, the partition part
The discharge surface base material (spinneret) used as material is
One piece of mesh plain woven wire mesh, as shown in Figure 4.
kenix to be inserted into the mixer section 6~
Varying the number of elements in the static mixer
It was carried out with different changes. For example, in Example 12, 10 elements
Polyethylene terephthalate (melting point
540°K, intrinsic viscosity [η] = 1.00) and 6-nylon
(melting point 488°K, intrinsic viscosity [η] = 1.3) was melt-mixed.
Under the fiber forming conditions shown in Table 1,
The composite fiber aggregate was spun. In Example 13, 13 elements are used to create a point.
Liethylene terephthalate (melting point 540°K, intrinsic viscosity
degree [η] = 1.00) and polyester elastomer
(Du Pont, Hytrel 4056, grade, fusion)
Point 441°K) was melted and mixed to form the mixture shown in Table 1.
The composite fiber aggregate is spun under the following fiber forming conditions.
did. In Example 14, 16 elements are used to create a point.
Liethylene terephthalate (melting point 540°K, intrinsic viscosity
degree [η] = 1.00) 80 parts and polybutylene terephthalene
(melting point 499°K, intrinsic viscosity [η] = 1.15)
Melt-mix and form the fibers shown in Table 1.
The composite fiber aggregate was spun under the following conditions. Both Example 13 and Example 14 are made of polyester.
It is composed of a ter-based polymer phase. In Example 14, the weights of the A polymer phase and the B polymer phase
Even if the ratio changes greatly, the macrobranch of the present invention
This shows that the control technology progresses well.
Ru. Furthermore, the composites obtained from Example 12 to Example 14
Place the synthetic fiber aggregate vertically as shown in Figure 4.
Stretched using a heating plate with a width of 600 mm and a width of 600 mm.
did. Other characteristics and fiber properties are shown in Tables 1 and 2.
As shown in the table. Example 15 Using the same polymer phase as in Example 13, the
The mixer section 6 of such a device is
Insert 20 pieces of Itzuku mixer to create very thin lamellae.
Prepare a structural polymer mixture melt and use it as a partition member
Use one piece of 80 mesh plain weave wire mesh as the first
The fibers were spun under the fiber forming conditions shown in the table, and
Example using a heating plate as shown in
The composite fiber aggregate was drawn under the same conditions as in 13.
I got it. The undrawn composite fiber aggregate has an average single fiber density of
Fiber cross section despite being very thin at 0.9de
The average number of blocks in the aggregate [(B)] is
The number of blocks is close to the expected theoretical average number of blocks.
Ta. Other characteristics and fiber properties are shown in Tables 1 and 2.
As shown in the table. Example 16 The same polyethylene terephthalene used in Example 14
(70 parts) and polybutylene terephthalate (30 parts)
Mixer section) using the device shown in Figure 4.
6 to 13 elements of the Kenics type static mixer.
1-c as a partition member.
Special sintered gold of 40 mesh and 30 mesh
A net (same as the partition member used in Example 10)
Using, shown in Table 1 and Table 2
It was spun under fiber forming conditions and further stretched. stretched
Aggregation of the composite fiber aggregates at 0.5de intervals
A bar graph showing the internal fineness distribution is shown in Figure 21.
Therefore, the cross-sectional area variation coefficient [CV(A)] within the aggregate is constant.
The aggregate has a fineness distribution such that
I understand that. In addition, the drawn composite fiber collection
Take out any single composite fiber from the union, and
Cross-sectional area at every 1 mm interval in the length direction of the fiber
Figure 18 shows the actual changes in
The selected fibers have an average fineness of the aggregate
It is slightly thinner, and the cross-sectional area fluctuates around 2.3de.
You can see that This selected fiber fabric
The filament internal cross-sectional area coefficient of variation [CV(F)] is 0.16.
Yes, based on the average value of CV(F) of the aggregate 0.30
By chance, one with a slightly smaller variation in cross-sectional area was selected.
I know it was released. The stretched film obtained in this example
When the composite fiber is heat treated at 170℃, it has a yield of 14.5/I
It had a number of crimps. This heat treated composite
A long fiber web is produced from a fiber aggregate.
Now you can make futon cotton with good bulk. In addition, this heat-treated composite fiber aggregate is approximately 50mm thick.
I cut it into strips, made it into a short sleeve, and then ran it through a card machine.
However, futon cotton with good bulk was created. In this way, the composite fiber aggregate of the present invention can be used as it is.
It can also be used as a filler for long fibers, and can also be used as a filler for long fibers.
After that, it can also be used as a filler for short fibers.
I understand. Other characteristics and fiber properties are shown in Table 1 and
As shown in Table 2. Example 17 Inside the die 8~ of the device as shown in Figure 4, Figure 6-b
A stacked plate mixer such as the one above was inserted. recess
The size of the plate is 5 cm wide and 1 cm high.
cm, thickness 0.6mm, and the depth of the recess is 0.37mm
It is. Obtained by stacking 270 of these plates.
Polyethylene terephthalate using mixer
(melting point 540°K, intrinsic viscosity [η] = 1.00) and 5-Nat
2% by weight of lium sulfoisophthalic acid was copolymerized.
polyethylene terephthalate (melting point
520°K, intrinsic viscosity [η] = 0.49) were mixed in a layer,
The resulting molten mixture of different polymer phases was
Divided and cut with one piece of plain woven wire mesh, inside the assembly.
Molding composite fiber aggregate with average block number close to 2
did. Here, 5-sodium sulfoisophthalic acid is
The polymer phase being copolymerized is easily cationic.
The composite fiber assembly can be dyed with dyeable dyes.
It is easy to analyze the number of blocks in the fiber cross section of the body.
Ta. Example 18 and Example 19 A stacked plate mixer similar to Example 17 was used.
Polyethylene terephthalate
(melting point 540°K, intrinsic viscosity [η] = 1.00) and polypropylene
Pyrene (melting point 438°K, melt index 15)
Mix in layers and make 50 mesh plain weave of the mixed melt.
Cut using a partition member made of wire mesh and shown in Table 1.
The fiber was spun under the same fiber forming conditions. The layered mixed melt obtained in this example was
Sampled and solidified using the same method as in 5.
After that, the layered mixed resin body is placed in a spinneret and flat.
When we cut the surface along the row plane and observed the surface, we found that
As shown in the micrograph in Figure 23-a.
Ta. Slightly bend this solidified mixed resin body.
Apply force to separate the interface of the lamellar polymer phase.
When I let go and looked deep inside, I found the 23rd
As shown in Figure b, each polymer phase looks like a distorted curve.
It turned out that it was like a surface layer. In Example 18, the lamellar structure of the layered mixed melt was
Place the wire mesh in a direction parallel to the boundary line so that the mesh overlaps.
Example 19
Next, we will explain the boundaries and barriers of the lamellar structure of a layered mixed melt.
Flatten the wire mesh in the direction of the wire so that the mesh overlaps.
It is attached with a woven wire mesh fixed as a base. The undrawn composite fiber aggregate obtained in Example 18
A cross-sectional photograph of the fiber is shown in Figure 8, which was obtained in Example 19.
The fiber cross-section photograph of the undrawn composite fiber aggregate is shown in No. 9.
It is a diagram. From these figures 8 and 9, the polymer phase
Discharge that separates and cuts even if the mixture state is the same
Due to the arrangement of the surface substrate, the position of the interface of the polymer phase is
Where the fiber is placed in the cross section changes.
I understand very well. In addition, we can use a stacked plate mixer to
The blended mixture is prepared using a Kenics type stand.
Mix into a macro blend using a take mixer.
The coefficient of variation of the number of blocks within the aggregate is
[CV(AB)] becomes smaller, in other words, the block
The distribution of the number of blocks becomes sharp, and the number of blocks becomes the same.
There is a notable trend that the same things are coming together.
Ru. This confirms that the unstretched composite obtained in Example 19
Bars showing the distribution of the number of blocks within the fiber aggregate
It is best understood by the graph in Figure 22-b.
Ru. FIG. 22-a, which is a bar graph of Example 6;
A comparison with Figure 22-b further shows that this
I can understand it well. In addition, the irregularity coefficient defined by the following formula in the text
deviation rate α(i,j)=(D/d)i−(D/d)j/(D/
d) j×100 and cross-sectional area deviation rate β(i,j)=Si−Sj/Sj×100 When we specifically collect 10 items such as in Example 19, we get α(i, j); 3.1, 28.7, 18.0, 6.4, 6.4, 28.1,
13.8, 8.9, 15.9, 3.2 β (i, j); 21.0, 27.8, 15.0, 9.5, 8.7,
17.4, 4.5, 35.2, 50.0, 21.0 Most of them are α(i, j)>2 β(i,
j)>5, etc. Other characteristics and fiber properties are shown in Tables 1 and 2.
As shown in the table. Comparative example 1 A stationary mixer is installed in the mixer section 6~ of the device as shown in Fig. 4.
The same equipment as in Example 1 was used except that the combiner was not used.
was carried out using the same polymer system and similar fiber forming conditions.
When applied, in the fiber forming area of spinneret 9~
Melt polymerization of 6-nylon and polypropylene
The body is discharged as a biased flow without being mixed, and the cooling device
Experimented with various conditions for the cooling air jetted from 11.
However, the 6-nylon part that discharges uneven flow is supercooled.
On the other hand, the polypropylene part with uneven flow discharge is optimal.
It doesn't cool down to a viscosity and becomes nothing more than a plastic-like substance.
It didn't work. Comparative example 2 In Example 2, 50 mesh monoprene wire mesh
In addition to one piece, a 100μ effective diameter with a thickness of 2cm is placed inside the die.
Except for inserting the sintered metal body, everything else is the same as in Example 1.
Spun with similar polymer under similar fiber forming conditions.
did. Fiber cross-sectional photograph of the obtained undrawn fiber aggregate
Cut the sample into 7μ thick pieces with a microtome and cut into 6-inch pieces.
When I dyed the iron part, I found that
Liethylene terephthalate polymer phase and 6-nylo
The interface between the polymer phases is too jumbled.
It was not possible to identify individual blocks.

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【table】 [Brief explanation of the drawing]

Figures 1-a, b, c and d are schematic diagrams of mesh-like spinnerets used in the process of the present invention. Fig. 1-a shows a partition member made of a plain-woven wire mesh, Fig. 1-b shows a partition member made of a twill-woven wire mesh, and Fig. 1-c shows two types of plain-woven wire meshes stacked in the bias direction and sintered. FIG. 1-d is a schematic diagram showing a partition member of a porous plate which has been etched. FIG. 2 is a schematic cross-sectional view of an arbitrary position in the fiber forming region of the generalized mesh-like spinneret of the present invention. FIGS. 3-a, b, and c are schematic diagrams for explaining the correlation between the formation state of the macroblend molten phase and the size of the pores of the partition member that is the spinneret.
FIG. 4 is a schematic diagram showing an example of an apparatus for manufacturing the fiber assembly of the present invention. FIG. 5 is a schematic diagram showing a cross-section of a die of the invention, which is provided with a static mixer inside the spinneret. Figure 6-a
and b are enlarged schematic diagrams showing an example of a laminated plate-like static mixer according to the present invention. FIG. 7-a is a micrograph of a cross section of the fiber aggregate obtained in Example 2. FIGS. 7-b and 7-c are micrographs of a cross section of a fiber aggregate treated with boiling water after cold stretching. FIG. 8 is a micrograph of a cross section of the fiber aggregate obtained in Example 18. 9th
The figure is a micrograph of a cross section of the fiber aggregate obtained in Example 19. FIG. 10 is a micrograph of a cross section of the fiber aggregate obtained in Example 5. 11th
The figure is a micrograph of a cross section of the fiber aggregate obtained in Example 6. FIG. 12 is a micrograph of a cross section of the fiber aggregate obtained in Example 7. 13th
The figure is a micrograph of a cross section of the fiber aggregate obtained in Example 8. FIG. 14 is a micrograph of a cross section of the fiber aggregate obtained in Example 9. 15th
The figure is a micrograph of a cross section of the fiber aggregate obtained in Example 10. FIG. 16 is a micrograph of a cross section of the fiber aggregate obtained in Example 11. 17th
The figure is an explanatory diagram showing the maximum interval (Di, max) between two parallel lines circumscribing the fiber cross section and the minimum interval (di, min) between two parallel lines circumscribing the fiber cross section. Figure 18 shows
3 is a graph showing the change in cross-sectional area in the longitudinal direction of a single fiber selected from the fiber aggregate obtained in Example 16. FIG. 19 shows one fiber selected from the fiber aggregate obtained in Example 6,
It is an enlarged microscope photograph showing the change in the cross-sectional area of the fiber in the fiber axis direction at regular intervals. Figure 20 shows
One fiber was selected from the fiber aggregate obtained in Example 5, and these are micrographs of a cross section of the fiber in the fiber axial direction at regular intervals and a cross section of the split fiber. FIG. 21 is a fineness distribution diagram for each 0.5 denier section of the fiber aggregate obtained in Example 16.
FIG. 22-a and FIG. 22-b are bar graphs showing the fiber cross-sectional block number distribution of the fiber bundles obtained in Examples 6 and 19, respectively. 23-a and 23-b are micrographs of the layered molten mixtures obtained in Examples 18 and 19. 24th
The figure is a resin cross-sectional micrograph showing the mixed state of the molten polymer phase obtained in Example 5. FIG. 25 is a resin cross-sectional micrograph showing the mixed state of the molten polymer phase obtained in Example 11. Figure 26 shows
3 is an enlarged photograph showing the crimped state of individual fibers of the fiber bundle obtained in Example 6.

Claims (1)

[Scope of Claims] 1. (1) A collection of a large number of fibers, (2) at least 90% of the fibers have a non-circular cross section, and (3) at least 50% of the fibers have a non-circular cross section. (4) at least 50% of the fibers are comprised of at least two different fiber-formable polymeric phases in cross-sections perpendicular to their fiber axes; It has at least two blocks that are joined side by side with at least a portion of each being exposed to the circumferential surface of the fiber, and at least one of the number, shape and size of the blocks is different from that of the individual fibers. (5) For each fiber constituting the aggregate, select 3 cm of any one fiber and measure the size of the cross-sectional area at 1 mm intervals by microscopic observation. Then, the average value of the 30 cross-sectional areas [
(F)] and the standard deviation of its 30 cross-sectional areas [δ
(F)] and measure the fiber internal cross-sectional area variation coefficient [CV(F)] from the following formula: The coefficient of variation of the fiber internal cross-sectional area [CV (F)] is
An assembly of fibers consisting of at least two different fiber-formable polymers, characterized in that the fibers have a value in the range from 0.05 to 1.0. 2 The fiber aggregate has a fiber cross-sectional area coefficient of variation within the aggregate [CV(A)], which is expressed by the following formula: In the formula, (A) is obtained by randomly extracting a subset of 100 fibers from the assembly and measuring the cross-sectional size of each fiber in the cross section at an arbitrary position by microscopic observation. is the average value of the cross-sectional area of the 100 fibers to be determined, and δ(A) is the standard deviation of the cross-sectional area of the 100 fibers; is in the range of 0.05 to 1.5. A collection of fibers. 3 The collection of fibers will be randomly
If you extract a subset of 100 fibers and observe the cross-section of each fiber at an arbitrary position under a microscope, at least 50% of the cross-sections of two randomly selected fibers will be ( 1) Irregularity coefficient deviation rate (α) expressed by the following formula α=(D/d)i−(D/d)j/(D/d)j×10
0 (%) In the formula, (D/d)i is the larger irregularity coefficient,
(D/d)j indicates the smaller irregularity coefficient. and/or (2) Cross-sectional area deviation rate (β) expressed by the following formula β = Si − Sj / Sj × 100 (%) In the formula, Si is the size of the larger cross-sectional area (mm ² ),
Sj is the size of the smaller cross-sectional area (mm ² ), and β is the cross-sectional area deviation rate. The aggregate of fibers according to item 1 or 2, which has different cross-sectional area sizes represented by .