CA1135917A - Spinneret assembly for use in production of multi- ingredient multi-core composite filaments - Google Patents

Abstract

ABSTRACT OF THE DISCLOSURE This invention provides an improvement in a spinneret assembly. The assembly comprises superposed rigid, first, second, third and fourth plate members. The first and second plate members partition off a first and second polymer chamber, respectively, from a second and third polymer chamber, respec-tively. The third plate member partitions off the third polymer chamber from one or more funnel-shaped fourth polymer chambers bored in the fourth plate member. The third plate member has a plurality of holes which are exposed to each fourth polymer chamber. The fourth plate member has at the lowermost ends of each fourth polymer chamber an orifice. The third plate member further has bored therein one or more slits, each slit being, on the under surface of the third plate member, of a multi-arm shape having at least three radially extending arms, each of which intervenes between at least two holes of the holes bored in the third plate member. The four plate members form a plurality of series of linked polymer passages, each series having at least one joining point at which two polymer streams join together. At least one of the polymer passages upstream of the joining point has at least one cross section that is narrower than any cross section of the polymer passage downstream of the joining point but up-stream of the succeeding joining point, if any, or said at least one polymer passage upstream of the joining point having a length longer than that of the polymer passage downstream of the joining point but upstream of the succeeding joining point, if any. The assembly produces multi-ingredient multi-core composite filaments each comprised of at least three polymer phases, and avoids defects in conventional assemblies which produce filaments which are not uniform in thickness and cross section and wherein the number of core polymer ingredients in each filament is limited, etc.

Description

: ~3S~

This invention relates to a spinneret assembly to be itted in a spinning pack for the production of multi-; ingredient, multi-core composite filaments, each of which is comprised of at least three ~)olymer phases.
~his application is a divisional of co-pending Application Serial Number 335,223, filed September 6, 1979.
Multi-ingredient, multi-core filaments are composed of a plurality o~ core polymer ingredients and an ; intervening polymer ingredient, both the core and intervening ingredients extending over the entire length of the filaments. Each filament possesses a substantially uniform cross-section, wherein a plurality-of the core polymer ingredients are dispersed in or partitioned off by the intervening polymer ingredient. Such multi-ingredient, multi-core filaments are particularl~ useful for the production of extremely fine filaments. That is, ex*remel~
fine filaments can be obtained therefrom b~ separating the respective ingredients from each other or removing the intervening ingredient therefrom.
Many proposals have been heretofore made for the production of multi-ingredient, multi-core filaments, each of which is comprised of at least three polymer l3~3~

phases. However, conventional spinning appara-t~lses fGr the production of such multi-ingredient, multi-core filarnenls have some of the following defects.
(1) The resulting composite filaments are not uniform in thickness and/or in cross sectlon.

(2) The nurnber of core polymer ingredients in each composite filaMent is limi-ted.

(3) It is troublesome to assem~le the parts into a spinning pack or disassemble the spinn;ng pack, and furthermore, it is difficult -to maintain a high precision af-ter the repeated disassembling and assembling.

(4) Troubles occur during the operation of the spinning pack, for example, the polymer ingredients are contaminated with each other, or a specified polymer ingredient e~hibits an unusually ~ong dwell time in the spinning pack.

SUMtlARY OF TE~E INVENTION
It is the main object of the present invention to provide a spinneret assembly to be fitted in a spinning 20 pack for the production of multi-ingredient, multi-core composite filaments, which assembly does not have the above-mentioned defects.
Other objects and advantages o~ the present invention will be apparent from the ~ollowing description.
In one aspect o~ the present invention, there is provided a splnneret assembly to be fitted in a spinning pack for the pcoduction of multi-ingredient t multi-core composite ~ilaments, each being comprised of at least ' ... . . . . .

.. : . .. .. . .. . . . ...... . . . ... . . .

~3~i9~

three polymer phases A, B and C, the said spinneret assembly having means whereby either the cores in the composite fila-~ ments issuing from the spinneret as.sembly are not all identical .~ or, if the cores are identical, the'y' consist of a multi-divided stream of one of the polymers A and B interspersed by a stream of the other of the polymers A and B, which assembly comprises superposed rigid first, second, third and fourth plate members;
said first plate member partitioning of~ a first polymer chamber, through whi'ch:'a stream of the polymer A
flows/ from a second or third polymer chamber, through which a stream of the polymer B or C flows, respectively;
said second plate member partitioning off the : second polymer chamber from the third polymer chamber;
said third plate member partitioning off the third polymer chamber from one or more funnel-shaped fourth polymer chambers bored in the fourth plate member, through which combined streams of the polymers A, B and C flow, and said third plate member having bored therein a plurality of holes, the lowermost ends of which are exposed to the or each funnel-shaped fourth polymer chamber;
said fourth plate member having at the lowermost end of the or each funnel-shaped fourth polymer chamber an orifice through which a combined stream of the polymers A, ~ and C flows;

.. : .,., , ~ . . . -~lL1359: ILr~;

said third plate member ~urther haviny bored therein one or more slits through which.streams of the polymer C flow from the third polymer chamber to the funnel-shaped fourth polymer chamber, the or each slit being, on the under surface of the third plate member, of a multi-arm shape having at least three radially extending arms, each of which . intervenes between at least two holes of the holes bored in -the third plate member, said first, second, third and fourth plate members forming a plurality of series of linked polymer passages, each.`series having at least one joining point at which two , polymer streams joi.n together, at least one of the polymer passages upstream of the joining point having at least one cross section that is narrower than any cross section of the polymer passage downstream of the joining point but upstream of the succeeding joining point, if any, or said at least one polymer passage upstream of the joining point having a length longer than that of the polymer passage downstream of the joining point but upstream of the succeeding joining point, if any.
In a further embodiment of the invention, at least some of the polymer passages are formed through a member for connecting holes in the first plate member with corresponding holes in the second plate member, the member having bored therein slits extending from some or all of said polymer passages to the second polymer chamber, whereby at least two , .
`, .. . . ..

s~
_ 5 ,--types of core :incJ:redients are fo:rlrled in eclch mu],ti-core compos i te f i l ~rnen t .
.~ In a still fu-r-ther embodiment of the inven-tion, the second pla-te member further has bored the:cein two or more holes, through whi.ch streams of one of the polymers A and B flow, immediately upstream of each joining point at which said one of the pol.ymers A and B joins wi-th the other of the pol.ymers A and B, whereby one of' the polymers A and B is permi-tted to ~: join in multi-divided streams wlth a stream of -the other of the polymers A and B.
In anothe:r embodiment, the plura1,ity of ho1.es bored ir the third plate rnember permit a-t least two streams selected from (a) a stream of the polymer A or a combined stream of the polyrners A and C, (b) a stream of -the polymer B or a combined stream of the polymers B and C, and (c) a combined stream of -the polymers A and B or a combined stream of the polymers A, B and C, to independently flow into the or each funnel-shaped fourth polymer chamber.
In still another embodj.lnent, the thi:rd plate member partitions off the third polymer charnber from two or more fourth polymer chambers and has hored the.rein two or mo:re groups of holes, whereby the respec-tive groups of holes permit at least -two streams selected from (a), (b) and (c) above : -to flow into different funnel-shaped four-th polymer chambers.

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35i'r~1~

BR~E:F DEJ,SCRI1''.1'10N O:F TIIE DRAW[NG5 The features of t}le present invent;on will now be described in detail wi-th refere:nce to -the accornpanying drawings, in which:
FIG. lA is a vertical sec-t:i.onal view oE a par-t ~ of a preferred embodimen-t of the spinneret assembly of t]le inven-tion;
,i FIG. lB is a transverse cross-sectional view of a part of the spinneret assembly sectioned along -the line P-P' indicated in FIG. l;
FIG. 2 is a vert:ical sectional view of a p.:ipe 3 in FIG. lA, which view illustrates the state in which the pipe 3 is supported by a plate member l~a;
FIGS. 3A, 3B and 3C are schemati.c views illus-trating -the lowermost portions of -three modified embodi.rnents of the pipe 3 illustrated ln F'IG. lA;
FIGS. ~A and 4B are ver-tical sectional and plan views of a part of a plate mernber 15c in FIG. lA, which part illustr~tes the configuration of a cylindrical ho].e in the plate member;
FIG. 5 is a vertical sectional view of a part of another emhodiment of the spinneret assembly of the invention;
FIG. 6A is a vertical sectional view of a part of still another embodiment of the splnneret assern~ly of '.

, : . ~1359~q :;
the invention;
: .
FIG. 6B :is a ',ransverse sectional view of a part of the spinneret assembly sectioned along the line P-P' indicated in FIG. 6A;
~, 5 FIG. 7A is an enlarged vertical sectional view : ~, of one embodi.-nent of a connecting member 17 illustrated in FIG. 6A;
j~ .
~ FIG. 7B is a transverse sectional view of the .;
connecting member, sectioned along the line Q-Q' indicated ,lO in FIG. 7A;
FIG. 8A is an enlarged vertical sectional view of another embodiment of the connecting rnember 17 in "~: FIG. 6A;
3:FIG. 8B is a transverse sectional view of the lS connecting member sectioned along the line Q-Q' indicated in FIG. 8A;
FIGS. 9 and lO are vertical~sectional views of parts of other embodiments of the spinneret assembly of the invention;
; ; 20 ; FI~. llA~is a vertical sectional view of a : modified~embod1ment of the connect1ng member 17 illustrated:
in FIG. 6A;
FIG. lls is a transverse sect1onal view of the connecting;member~sectioned along the llne Q-Q' indicated in FIG. llA;
FIGS. 1;2, 13~, 14A,~14B and 14C~are similar~
transverse sectional views of other modified embodiments: ~: -of the~connect1ng~member~;l7~11lustrated 1n FIG 6A;

113S9~7 , .

.` - 8 -E'IGS. 15A through 15L are closs-sectiorlal views of composite filaments obtained by using the spin~leret assemblies illustra-ted in FIGS. 1 and 6;

,, FIG. 16A is a vertical sec.ional view of a part of still another embocliment of the spinneret assembly of c~ the invention;

. FIG. 16B is a transverse sectional view of a part of the spinneret assembly sectioned along the line ~, ;~ P-P' indicated in FIG. 16A;

~; 10 FIG. 16C is an enlar~ed view of a part of the section of the spinneret assembly illustrated in F'IG. 16B;
z~ E'IG. 17A is a vertical sectional view of a part of still another emhodiment of the spinneret assembly of ; the invention;
FIG.:17B is a transverse sectlonal view of a part of the spinneret assembly sectioned along the line P-P' indicated in FIG. 17A;
FIG.~17C is an enlarged view of a part of the sect1on of the splnneret assembly lllustrated in FTG. 17B;
FIGS. 18 and 19 are cross-sections of the composite filaments obtained by uslng two examples of the spinneret assembly of the invention;

FIGS~. OA through 20E;are cross sections of the core~ingredlents of~the composite filaments obtained by ;25 using the;spinneret~assembly~of;the invention;
FIG~.~21 is a vertical~sectional~vLeW of a:part o~ still another embodlment~of the spinneret assembly of the inve~ntion;~

~ ~13553 ~7 .- _ 9 ~
F~G. 22~ is an enlarged vertical sectional vie~
of an upper part of a modified embodiment of -the spinneret assembly, illustrated in FIG. 21;
FIG. 22B is a plan view of the upper part o~ the spinneret assembly illustrated in FIG. 22A;
. FIG. 22C is a plan view of a pi.pe ~4 illustra~ed in FIG. ~2A;
. FIG. 23A is an enlarged ver-tical sectional view ; of an upper part of another modified embodiment of the spinneret assembly illustrated in FIG. 21;
FIG. 23B is a plan view of the upper part of -the spinneret assembly illustrated in FIG. 23A, FIG. 23C is a plan view of a pipe 24 illustrated in FIG. 23A;
FIG. 24 is a vertical sectional view of a part of s-till another~embodiment of the spinneret assembly of the inVentlon;
FIG. :25 is~a vertical sectional view of a part of stlll another~embodiment of the spinneret as3~mbly o the lnvenlion; ~
FIGS. 26 and 27 are cross-sectional views of the ~:
composite filaments obtained~by uslng the:spinneret. assem- -blles lllustrated;ln FIGS. 24 and 2~5;~
FIGS. 28A~:through~28I are cross-sectlonal~vlews f ~-arious~composlte filaments obtain~id by using spinneret assemblies illustrated in FIGS.:29~through ~
FIG. 29 is a vertical sectional view of a part or:~tlll anothe~ embrdimen~ of the~spinneret assembly~o~

~.~l 3S9~
.

..~. the inventio`n;
! '' FIGS. 30, 31 ahd 32 are transverse sectional views of a part of the spinneret ~ssembly sectioned alcng . the lines X~X', Y-Y' and Z-Z', respectivelyl indicated in '!, 5 FIG. 29;
~ FIG. 33 is a vertical sectional view of a part of still another embodiment of the spinneret assernbly of the invention;
.~ .
;~ FIGS. 34, 35, 36 and 37 are transverse sectional views of a part of the spinne:ret assembly sectioned along the lines J-J', K K ', M-M' and ~J-N', respectively, indicated in FIG. 33;
FIG. 38 is a vertical sec-tional view of a part of still another embodiment of the spinneret assembly of the inven~iOn;
~: :
PIGS. 39 and 40 are transverse sectional views of the part o~ the spinneret assembly sectioned along the lines U-U' and V-V1, respectively, indicated in FIG. 39;
FIG~ 41;is a transverse sectional view, sectioned simllarly to in FIG. 40, of a part:of a modified embodiment of the:spinneret:assembly~of~the invention;
FIG.~42~is a ve~tical sectional~view of a part of st111 another embodiment~of the spinneret assembly of the invent~ion:;:
FIGS.~43 and i4 are~transverse:s~ectional:vlews `~
of the part of the spinneret-assembly~,. 5ectioned aloDg the lines S-S' and T-T',~respectlve~ly, lndicated ln FIG. 42; -~
FIGS ~ d 46 are t~an~ er e secc~ al v.ews 359~7 ,, .
of a part o~ a modified eMbodiment of the spinneret assembly ~- of the invention, and;
:
FIGS. 47 and 48 are transverse sectional views of a part of another modified embodiment of the spinneret assembly of the invention.
`: FIG. 49 is a diagrammatical, vertical sectional view of the spinneret assembly of the invention, which i illustrates an example of one series of vertically linked ,: ~ polymer passages;
10 FIG. 50 is an enlarged vertical sectional view . ~ .
~: illustrating the circled portion in FIG. 49;
FIGS. 51A, 51B, 51C and 51D are transver~e sectional views of the part of the spinneret assembly, sectioned ~; along the lines W-W', X-X', Y-Y' and Z-Z', respectively, indicated in FIG. 50;

FIG. 52 lS;~ a vertlcal sectional view of a spinning pack having fltte~d therein the~splnneret~assembly of the nventlon, and; ~
PIG.~53~is a~;d~iagrammatical, vertical sectional view of a splnnlng~pack:havin~g~fltted;thereln a splnning assembly not~of the~invention.
DESCRIPTIO~OF THE PREPEP.RED EMBOD~MENTS :
OP~THE INVÆNTION;
Referring~to~PIGS.;~lA and ~ 1B, ~a~splnneret;assembly is ~ strated,::which is~use~ or:~he~producti:on of~multi-ingredient multl-core c~omposlte~fi~laments~each~of whlch is composed of~l6 core~polymer~ ingredlents~and an intervening polymer lngredi~ent,~bath~of~the core~and lntervenlng f ~ "

3~

polymer ingrèdients e.Y,ending over -the en-tir~ len-Jth or each filamen-t. Each filament possesses a substantially uniform cross section wherein ~he 16 core ingredients are i dispersed in the in-tervening ingredient in an islands-in-sea ' 5 configuration as illustra-ted in FIG. 15A. Each of the core ingredients is comprised of a polymer A core and a ~; polymer B sheath and the core A-sheath B ingredients are dispersed in the intervening polymer C ingredient as ' illustrated in FIG. 15A.
In the spinneret assembly illustrated in FIG lA, a polymer A, i.e., one polymer component of each core ingre-dient, is introduced from a polymer chamber I through l relatively wide connecting holes 1, bored in a plate member 14c, into relatively narrow holes 2 bored'in a plate member l~b. Then, each stream of the polymer A
flows through pipe 3. A polymer B, i.e., the other polymer ccmponent of each core ingredient, is introduced through a hole 10, bored in the superposed plate members 14c, 14b and 14a, into a polymer chamber II formed ~etween the plate member l~a and a plate~memher lSc. Then, the polymex B
flows through circular paths formed around the pipes 3 within the~holes 4 bored'in the pIate mem'ber 15c. Upon leaving the outlet of the pipe 3, each~stream of the polymer A joins~with each stream of the polymer B. Each comblned stream or~ the polymers A and~B flows through a connectlng hole'5, hored 1n a plate member 15b, and then through~a pipe~6.~ A polymer C, i~e., the intervening :
~ -ingredient, is introduced through a hole 12, bored in the .
, 1~3~;91~7 ~: - 13 -superposed plate members 14c, l~b, 14a, 15c, 15b and 15a, into a polymer chamber III formed between the plate member 15a and a plate member 16. Then, the polymer C flows through circular paths formed around the pipes 6 within `~ 5 holes 7 bored in the plate memker 16. Upon leaving the outlet of the pipe 6, each combined stream of the polymers A
and B joins with each stream of the polymer C. And, upon entering a funnel-shaped polymer chamber IV bored in a plate member 16', the combined streams of the polyrners A, B and C join together and are extruded through an oriLice 9 to form a single composite filament.
. Referring to FIG. lB which is a transverse cross--3~ -sectional view of a pari of the spinneret assembly, sectioned along the line P-P' indicated in FIG. lA, the lS reference numerals 1, 10 and 12 are holes throuah which the polymers A, B and C are introduced into the spinneret ;~ assembly~ respectively. Approximately half of the number of holes 1 are illustrated in the quater circle and the ~:~ remaining half are not lllustrated (the latter half are present in another quater circle not illustrated). A
plurality of the sets of holes~l, lO and 1~ can be provided in the.plate member 14c~. In other words,~although~only ~; one unlt~for ~he production of a~single composite rilament :
is illustrated ln FIGS. lA and lB so that~:the feature~of the invention bé understood more readily, a plurallty:of such a unit may be provided in one spinneret assembly.
In the spinneret assembly illustrated ln FIG. lA, the relatlvely~wlde holes 1 have a funFtion of~substantially :: : :: : :

:
~L3591r7 uniformly di`stributing the polymer A therein The pipes 3 also have a distributing function to some extent, and accordingly, the plate member 14c having bored therein the . holes 1 may be omitted It is convenient, however, to ; S provide such a plate member 14c because, flrst, the lowermost . constricted portions of the holes 1 have an enhanced .,; .
,i function of the polymer distribution and, secondly, a ~; composite filament having core ingredients di.fferent from .~ each other in the cross section or thickness can be produced , ~
~' 10 by ~-arying the cross sec-tions of the constricted portions ` of the holes from each other.
The plate member 14b having bored therein the relatively narrow holes 2 which connect the holes 1 with the pipes 3 may also be omitted. :It is convenient, however, to provide such:a plate member 14b because the plate member l4b prevents tbe pipes 3 from upwardly slipping out. It is also possible to bore in the pla:te member 14b holes 2 having a diameter slightly~larger than the inner diameter of pipe~s;6 an~ to insert into each of the holes a : 20 pipe (not illustrated)~having the~same inner diameter~as : that of the pipe ~3.
The~plate Inernber~lSb having bored therein the holes S,;which fur~ction slmi~larly to the holes 2 bored ln the plate member~l4, may also be~omltted. ~It 1s convenient, however, to provlde such a plate member lSb~ because, first, the lower~constricted portion of~each hole~5 enhances : the~distrlbution~of polymer~streams~as well as preveDts the plpe 6 from upwardly~sllpplng out, and secondly,~

l3~3~

multi-core composite filaments each having an increased number of core ingredients can be advantageously produced.
The cross sections or the runnel-shaped polymer chamber IV and of the oritice 9 are preferably circular, but may be of any other configurations such as, for `~; example, polygonal and multi-armed (e.g., T and Y letter-- -shaped).
~, The lengths of the upper pipe 3 and the lo~er pipe 6 are not particularly limited. The lowermost of the 1~ lO upper pipe 3 may end within he hole 4, at the boundary ;;~ between the hole 4 and the hole 5 or within the upper part of the hole S. Similarly, the lowermost of the lower pipe ~! 6 may end within the hole 7, at the boundary becween the hole 4 and the poiymer chamber IV or within the upper part of the polymer chamber IV.
The number of the core ingredients in each of the composte f1laments produced by us~ing the spinneret assembly 3~ illustrated in FIGs. lA and lB may be varied within the range of from 2~to approximately 10,000, preferably from 2 : 20 to approxlma~e1y~1,000, and m~ore preferably from 4 to approximate1y 200.~
Referr1ng~to PIG. 2 illustrating the state in wh1cn each p1pe~3 is~supported ~y the plate member~l4a, the ~ipe~
3 has a~1arger~outer diameter~1n the upper portion thereof ~ `
2~5 so that;the~p1pe~can be'prevented~from slipping out from the~;plate~member ~14a due~ to~the d1fference~in the Ihermal expansi~on~coeff1cient between the pipe 3 and the plate~
member~l4a or~due~to the thermal d1stortion~of~the plpe 3.

31 ~35~1~
., ~ `

Upward slipping out of -the pipe 3 can be prevented by the plate member 14b (not illustrated in FIG. 2) having bored therein the holes 2, ~hich plate rnember is superposed on ; the plate member lAa. The fitting of the pipe 3 to tne plate member 14a may ~e effec-ted in various ways such as, for example, screwing, clamping, brazing, fusion ~eldiny or adhesion. Alternatively, the pipe 3 may be integrated with the pla-te member 14a ~,' .
The fitting of the pipe 6 to the plate member l5a may be effected in ways similar to those mentioned above .,~ .
-f in reference to the pipe 3.
In Fig. 1, the circular paths formed around the pipes 3 within the holes 4 and those formed around the pipes 6 within the holes 7 are preferably comple-tely circular. ~owever, they do not have to be completely circular but may be varied depending upon the cross section of the respective pipes and holes. The cross sections of the pipes and the holes may be circular, elliptic, triangular or polygonal. The configurations of these cross sections may be~finned or~projectlonal. ~ ~
Instead of `forming the circular path around the pipe 3 and/or 6 within the hole 4 and/or 7 as illustrated in Fig. l~ it is~possible to use;a sl;ender-pipe, which extends~ downward ,rom the plate member 14a and/or 15a and~
ends w1thin~ the polymer chamber II and/or III, and further us~e a thick pipe,~whlch extends upward from the hole 4 and/or 7 of the~pl~ate member lSc and/or~16 so that the~

uppermost portion~of the~thick pipe surrounds the lowermost i9~

portion o~ the slender pipe to form a circular path there-between. Alternati.vely, it lS also possible to use a thick pipe, which e~tends do~.inward frorn the plate rnember 14a and~or 15a and ends within the polymer chamber II and/or

5 III, and further use a slender pipe, which e~tends upward from the hole a and/or 7 of the plate rnember 15c and/or 16 ., -so that the lowermost portion of the thick pipe surrounds the uppermost portion or the slender pipe to form a circular -path therebetween.
The spinneret assembly ill~strated in FIGs. lA and lB is suitable particularly for the produc-tion of a rnulti--core composite filament, the core ingredients of which are of a core-sheath configuration. However, the core-sheath configuration is not necessarily concentric, ~ut may be eccentric . The core-sheath configuration may be varied depending upon the relative position of the pipe 3 to the hole 4. The eccentricity of the core-sheath configuration can be enhanced to various extents by inclining the direction in which the polymer A issues rrom the pipe 3. For t.his purpose, pipes having ouLlet portions as illustrated in FIGS 3A, 3B and 3C may be used.
In order to uniformly co1nbine the two polymer streams A and B and thus produce composite filaments having an enchanced uniformity in thickness and in cross--section, at least one 'of the two polymer passages upstream of the joininy point, through which passages two polymer streams A and B flow, respectively, must have at least one cross section that is narrower than any cross section of ' :' _.

i ... .

~"3S~lL

the polymer passage do~nstream of the joining poirlt r,ut : upstream of the succeeding joining poirlt or must have a `~ length longer than that of the polyMer passage downstream of the joining point b~lt upstream of the succeediny joining point. For exarnple, in the spinneret assembly illustrated in FIG. lA, at least either -the lowerrnos-c constric-ted portion of hole 1, pipe 3, or t:he circular path formed around the lowermost portion of the pipe 3 wi.tnin l-he hole ` 4 must have a cross section that is narrower than any - 10 cross section of the pipe 6 and than any cross section of the orifice 9, or the length frorn the inlet end of the holes 1 to the lowermost end of the pipe 3 must be longer than the length from the lowermost end of the pipe 3 to the lowermost end of the pipe 6 and than the length from the lowermost end of the pipe 6 to the outlet end of the orifice 9. Similarly, at ].east one of the two polymer passages upstream of the joining point, through -~hich passages a combined stream of the polymers A and B and a . .
stream of the polymer C flow, respectively, must have at 20 at least one cross section that is narrower than any cross section of the polymer passage downstream of the joining point, or must have a length longer than that of the polymer passage downstream of the joining point. That is, at least either the pipe 6 or the circular path formed 25 around the lowermost portion of the pipé 6 within the hole 7 must have a cross section narrower than that of the orifice 9, or the length from the lowermost end of the g pipe 3 to the lowermost end of the pipe 6 must be longer .. ..

~ 1~3~9~

; than the le~gth from the lowermost end ol~ the pipe 6 to the outlet end of the orifice 9. By satisfying these re~uisites, any polymer stream can be uniformly distributed at the joining point, and thus, composite filaments having an enhanced uniformity in -thickness and in cross-section can ~e produced. I~ these requisites are not satisfied, a complicated spinneret assernbly, which has extra ordinarily large, very precise and difficult to rnaintain, ~ill be necessary for obtaining the desired uniform composite filaments.
It is more preferable that ~oth of the polymer passages upstrearn of the joining poinr. have at least one cross section that is narrower than any cross sec-tion of the polymer passage downstream of the joining point but upstream of the succeeding joining point, if any, or both of the polymer passages upstream of the joining point have a length longer than that o~ the polymer passage downstream of the joining point but upsiream of the succeeding joining point, if any.
In order to completely prevent any of the core ingredients, which are disposed in close proximity to the outer periphery in the cross section of each composite filament, from being exposed on the surface of each filament, it is preferable that -the polymer passages, through which polymer streams forming the above-mentioned peripherally : disposed core ingredients flow, are provided at least at a portion of each polymer passage with relatively narrow cross sections, as compared with those provided in the ,, , . : . : , , . ,, .. , . ~ " . . . ... , . -~l135'~

pol~mer passages thro~gh which pol~rmer s~re~rns ~Form:ing th-centrally disposed core ingredients flow. Instead of providing the relatively narrow cross sectiGns, it is possible to permit relati-~ely large amounts of the r~ol~-,-er C (i.e., the intervening ingredient) to flo~J ',hrougn the circular paths formed around the end portions of t~Ae 2i pes through which polymer streams forming the bo~,e-r~entionea peripnerally disposed core ingredients rlo-~.
The core ingredients in a composite lilament rnav be difEerent in thickness from each orher. Such a compos_t~
filament can be produced by ~Ising a spinneret assembly wherein the narrowest cross section of one series o~
polymer p2ssages, through which a stream of a core-~orrninc polymer ingredient flows, is different in size from the narrc,l"est cross section of at least one of the o~her series of polymer passages, through which a s-ream of a core-forming polymer ingredient flows.
The core ingredients of a composi'ce lilament may different in thickness from those of another composite filament. Such composite filaments can be produced ~y using a spinneret assembly wherein the narrowest cross sections of the respective series of polymer rassages, through which the polymer streams forming the core ingre-dients of one cornposite filament flow, are different in size from the narrowest'cross sections of the polymer passage series through which the polymer streams forming the core ingredients of at least one other composite filament flow.

~. .

., , . . : . .... , -, 31L~;~5~
- 2~ -Refer~^ing to FIGs. 4A and 4B, which illus-trate a modified configuration of the hole 4 in FIG. lA, the uppermost portlon of the hole 4 is constricted. This modification serves to make the distribution of the poly;ner stream B more uniform, and thus, to mak~ the cross section and thickness of the combined slream OL the PO1YmerS
A and B more uniform. Furthermore, this rnodification serves to support the pipe 3 (not shown), to be inserted in the hole 4 at the constricted portion thereof, and thus, to minimize undesirable bending of the pipe 3. The constricted portion may be provided in another por-tion of the hole 4, although it is preferable to provide it in the uppermost portion of the hole as illustrated in FI~S. 4A
and 4B. It is preferable that, ~hen -the lowermost portion of the hole is constric-ted, each opening of the constricted portion (through which opening a stream of the polymer B
i flows) not be positioned in close proximity to any opening of the constricted portion of the adjacent hole 4, so as to mitigate or minimize the non-uniEorm distribution of the polymer component B around the core polvmer component A.
The number of openings bored in the constricted portion may be voluntarily varied. Alternatively, -~he hole 4 may be constricted in another way, e.g., the constricted portion may be formed by making the hole diameter thereof smaller than that of the other portion (although this not illustrated in the figures).
A constricted portion similar to those mentioned above may also be provided in the lower hole 7 bored in ` , ~L135i~r7 the plate member ]6. This col-lstricted portion serves to make the cross section and -thickness of the combined ; stream of the sheath polymer C and -the core polymeLs A
plus B more uniform, whet]ler the core ingredient of the polymer phases A plus B is of a core-sheath con~iguration or a side-by-side configllration.
Instead or forming a circular path arourld ~he pipe 3 within the hole 4 as illustrated in FIG. lA, a circular path, through which a stream of the polymer B flo~s, may be formed around a pipe 3a, extending upward from the plate member 15a, within a hole 4a bored in the plate member 14a as illustrated in FIG. 5.
Referring to FIGS. 6A and 6B ~hich illustrate another embodiment oE the spinneret assem~ly of the present invention, a rigid connecting member 17 sandwiched ~etween plate members 14 and 15C is provided. The connecting member 17 has bored therein a plurality of vertical holes 3' connec-ted with holes 1 and holes 4' , bored in the plate members 14 and 15c, respectively. The connecting memher 17 further has bored therein a plurality of slits 3", each of which is e~posed to a polymer chamber II at one end thereof and to the holes 3' at the other end thereof. Streams or a polymer A are introduced Lorm a polymer c~-amber I through relatively wide connecting holes 1 into the holes 3'. Streams of a polymer B are introduced from the polymer chamber II through the slits 3" into the ho]es 3'. In each hole 3' , the polymer stream A and tne polymer stream s join together to rorm a combined stream ' . . 7.._..

. : . .

~L3S~

of a side-b~-s.ide configurar.ion. Edch combined stredm of the polymers A and B flows t7nrough the hole 4, ,ind t}~en, through a pipe 6. A stream of a polymer C, introduced ., .
j from a hole 12 into a 2olymer chamber III, is c7ivided into circular patlls formed around the pipes 6 within holes 7 bored in the plate member 16a. Upon leaving the outlet o~
1_he pipe 6, each cornbined stream of the polymers A ~nd B
joins with each st:ream of the polymer C. ~pon entering a funnel-shaped polymer chamber IV, the combined strealTIs of the polymers A, B and C join to~ether and are extruded through an orifice 9 to form a single composite filamen-t.
The lowermost constricted portion of each or the holes ~' bored in the plate member 15c has a function similar to that o~ the hole 5 illustra-ted in FIG. lA.

The above-mentioned embodiment of the spinneret assembly provided with the connecting member 17 is particu-larly suitable for the production of multi-core composite ~ilaments, each core ingredient ~ieing of a side-by-side _ ,~.
or bi-metal confiquration. However, such a spinneret 20 assembly may be used for the production or multi-core composite filaments, each core ingredient being o~ a core-sheath configuration, by using the connecting member 17, each vertical hole 3' bored therein being connected to a plurality of radially extending slits 3" bored in the 25 connecting member 17. 'The number of core ingredients in : each.of the multi-core composi-te Iilaments produced by using the spinneret assembly with the above-mentioned connecting member 17 may be varied within the range of .~ -from 2 to 2~ or more, prefe.rably from 2 to ~0. When the : core lngredients are disposed on one circular line in the !' , cross section of each composite filament, the number of the core-ingredients is preferably within the range of ;.5 L rom 2 to lO. When the core ingredients are disposed so -that a part of the core ingred:ients is surrounded by ~.he remaining part of the core ingreZients in the cross section of each composite filament, the number o~ the core in~re-dients is preferably within the range of from 5 to 20.

! 10 Details of the CGnneCt~ng member 17 will he apQarent from FIGS. 7A, 7B, 8A and 8B. These figures illustrate two embodiments of the connecting member 17 suitable for the production of multi-core composite filaments, each of which is composed of Eour core polymex ingredienls dispersed in one intervening polymer ingredient C, each of the core polymer ingredients being of a side-by-side configuration and comprised of the polymers A and B.
The connecting member 17 ,~ay be in a monobloc body or in an assembly of two or more ~ar-cs, although -the former is preferable. Alternatively, the connecting member may be integrated with either the plate member 14 (in FIG. 6A) or the plate member 15c (in FIGS. 6, 7A
and 8A). The cross sectional shape and size o~ each hole 3' and l or each slit 3" may be varied to produce multi-core composite filaments, the core ingredients of which have various cross sectional shapes and sizes, and various combined configurations. The cross-sectional shape of each slit 3" may be, for example, circular, squarer rectangular i9~

or wavy rec~àngular. The angle of each slit 3" to t~,e hole 3' may also be varied in difLerent manners from those illustrated in F'IGS. 7B and 8s~ In general, t~o polymers A and B are difrerent from each other in viscosity and surface active proper-ty, and consequently, the interface of the combined two polyrner strealns is not complecely flat but curved.
It is preferable to constrict each hole 4' a-t at least one portion of the hole 9', for example, at the lowermost portion thereof, as ill~lstrated in FIGS. 6, 7A
and 8A, in order to effect a uniform distribution of polymer streams.
As one modification of the spinneret assemblies i11ustrated in FIGS. lA and lB, and FIGS. 6A and 6B, a spinneret ass2mbly provided with the two mechanisms of joining together the polymér streams A and B, illustrated in FIG. lA and FIG. 2A, may also used. By this modification, unique three polymer ingredient, multi-core composite filaments can be obtalned, a part of the core ingredients of each composite filament being of a core-sheath configu-ration and the remaining part of the core ingredients being of a side-by-s~de configura-tion.
Other modifications o~ the spinneret assemblies illustrated in FIGS~ lA and IB, and ~IGS. 6A and 6B, will now be described. One modification is illustrated in FIG. 9, in which a part of the polymer streams B flowing through the ho:Les 4 bored in the plate member 15C join ~ with the polymer stream A, and the other part of the :
..... = _.................................... , 3$91rb~

polymer streams B do not join with the poly;ner st~ream A.
Another modification is illus~rated ln FIG. lO, in -~hich a part of the polymer streams A Elowing through the holes 1 join with the polymer stream B and the other part of the polymer streams A do not join with the polymer stream B.
lternatively, these two modifications may be combined, although such combination is no-t illustrated. Furthermore, ~, the mechanisms of joining together -the -t~o polymer streams A and B as illustrated in FIGS. 9 and 10, may be replaced by the mechanïsm of joining together the two polymer streams A and Z as illustrated in FIG. 6A. By using these modified spinneret assemblies, unique mul-ti-core composit~
filaments can be obtained, a part of the core ingredients of each composite filament being comprised of a poly.ner A
or B, or a core mixture of polymers A and B, and ,he other part of the core ingredients being comprised of core-sheath type cores of polymers A and B, and/or side-by-side type cores of polymers A and 3.
Some modifications of the connecting member, other than those illustrated in FIGS. 7A, 7B, 8A and 8B, will be described with reference -to FIGs. llA through 14C.
Referring to FIGS. llA and llB, the connecting member has bored therein four holes 3', which connect with the con-fronting four holes 1 kored in the ~late member 14, and one central hole 3', which has no confronting hole 1 bored in the plate mem~er 14. The central.hole 3' connects with : the polymer chamber II through four radially extending slits 3". By using this modified connecting member, .~

5~

multi-core composite fila~ents can be ol~tained, each of which has a cross-section such that a core ingredient of a polymer B is surrounded by four lngredients, each being of a side-by-side configuration and comprised of polymers A
and B. As a further rnodified em~odirnent of -the spinneret assembly illustrated in FIG. llA, an additional hole 1 may be bored in the plate rnember 14, which hole confronts the - central hole 3' of the connecting member. This modification results in multi-core composite filaments, each of which has a cross-section such that a core-sheath core ingredient is surrounded by four side-by-side core ingredients.
Referring to FIGS. 12 and 13, the functions of the connecting members illustrated therein will be readily understood without an e~planation thereof. Furtnermore, referring to FIGS. l~A, 14B and 14C, the connecting members illustrated therein are characterized in that a part of tne holes 3' bored therein are not connected to the polymer chamber II, so that the resulting composite filaments have a part of the core ingredients which is comprised of a polymer A, and another part which is of a side-by-side configuration and is comprised of polymers A and B.
The cross-sections of eY~amples of the multi-core composite filaments obtained by using spinneret assemblies illustrated in FIGS. lA and lB, and FIGS. 6A and 6B, are shown in FIGS. 15A through 15L.
In another embodiment of the spinnere-t assembly of the invention, the plate member partitioning off the polymer chamber III from one or more funnel-shaped polymer .

" .~ """, ' . ' `,, - 2~3 -charnbers IV ~as bored therein a plurali~y of lloles, the lowermost ends of which holes are e~posed to the or each funnel-shaped polymer chamber IV, and furthermore, which holes are characterized as permitting at least two str-ams selected from (a) a cornbined s-tream of the polymers A and C, (b) a combined stream of the polymers B and C, and (c) a combined s.ream of the polymers A, B and C, to independ-ently flow into the or each funnel-shaped polymer chamher IV. Two spinneret assernblies illustrated in FIGS. 16A, 16B and 16C, and FIGS. 17A, 17B and 17C, are examples or the above-mentioned embodimen-t. Each of the rnulti-core composite Eilaments obtained by using the spinneret assembly illustrated in FIGS. 16A, 16B and 16C have sixteen core ingredients, ten of which are comprised of the polymer A
and surround the other six core ingredients comprised of the polymer B in the cross sec,ion of each composite filament. Each of the multi-core composite filaments obtained by using the spinneret assembly illustrated in FIGS. 17A, 17B and 17C also ha~e si~teen core lngredients, eight of which are comprised of the polymer A and the other eight o~ which are comprised of the polymer B, these sixteen core ingredients belng randomly disposed in the cross-section of each composite filament.
Other preferable composite filaments obtained by ~5 using spinneret assemblies similar to those illustra-ted in FLGS. 16A through 17C are as fol-lows. One such composite filament has four or five core ingredients, one to three of which, particularly two of which, are comprised of the ~ . . .

1135~r7 polymer A an`d the othel-s the polymer B. Another of such composite filaments has five to seven core ingredients, one of which is disposed approximately in the center of .he cross section of the filament and the others are disposed around the center core ingredient, and one to four of which is comprised of ~he polymer A and the ot]-lers the polymer B. The core ingredients in each composite filament may be different from each other in cross-sectional configuration and/or thickness. Such different core composite filaments result in fine filarnents having a sil~-like hand and feel. Still another preferable composite filament has 15 to 150 core ingredients, and is particularly suitable for high quality woven or knitted fabrics and artificial leathers.

In still another embodiment of the spinneret assembly of the invention, a plate member R partitioning off the polymer chamber I from the polymer chamber II further has bored therein two or more lloles, through which streams of one of the polymers A and B flow, immediately upstream of each joining point at which said one of the polymers A
and B joins with the other of the polymers A and B, whereby one or the polymers A and B iS permitted to join in multi--divided streams with a stream of the other of the polymers A and B.

FIGS. 18 and 19 illustrate the cross-sections of two examples of the multi-core composite filaments obtained by using spinneret assemblies according to the above--mentioned embodiment. As illustrated in ~IGS. 18 and 19, ` ~l3~91~
` - .

each of .he core ingredients is comprised of the polymers A
and B and the in-tervening ingredien-t is comprised of the polymer C. However, one of the core ingredient polyme~s may be -the same as the intervening ingredient polymer.
For reasons of expediency, the 'ollowing explanation is presented for the case where each composite rilamen~ is comprised of the three polymers A, B and C. Referring to FIGS. 18 and 19, each core ingredient is characterized as having a cross-section such that sagrnents of the polymer A
'10 are partitioned off by the polymer B. In FIG. 19, the ;polymer B is shown as six radially extending lines.
Se~-eral other examples of the cross-section of the core ingredient are illustrated in FIGS. 20A throuyh 20E. The periphery of each cross section of tne core ingredients illustrated in FIGS. 18 ,hrough 20E is circular. It should be noted, however, that, as the relative amount of the core ingredient polymer -to the amount of the intervening ingredient polymer lncreases, the periphery of each cross-section gradually changes from a circle to a polygon.
Referr1ng to FIG. 21 illustrating a spinneret assembly suitable for the production of multi-core composite filaments similar to those illustrated in FIGS. 18 through 20E, the plate membe~r 14b has bored therein a plural1ty of holes 21 connecting the polymer chamber I with the holes 23.
Two or more holes 21 bo'red in the plate member 14b confront each joinlng point, 1.e., the uppermost end 22 of the ~
pipe 24. The polymer A flows through the holes 21 toward each joining point 22, where the polymer streams A join : .
'~: :
.: . .

~L~IL3S9~7 ,:
with a polymèr stream B flowed from the polymer cham~er II
through the circular path formed around the pipe 24 within the hole 23. The so forrned combined stream of the polymers A
and B flows through the pipe 24 and then through the pipe 27. The number of the holes 21 confrotlting each joining point, i.e., the number of the polymer A segments . in each core ingredient, is preferably in the range of from 3 to 10.
;~ Some modifications may be made on -the spinneret assembly, illustrated in FIG. 21, as follows. The plate member 14b having a concavity, in the bottom OL which the holes 21 are bored, may be composed of two rnembers, i.e., i 3~ a thin plate member having holes 21 bored therein and thick plate member, superposed on the thin plaie member, ~ ~ 15 which thlck plate~member has a large hole bored therein.
i ~ The plate rnember 14a may be omitted. This is because the ~ -gap (illustrated in FIG. 22A by a reference numeral 23') ;between the under surface of the~plate member lib and the uppermost end of~the~pipe 23 has a functl~on;of controlling the stream of the polymer B, whi~h~function is approximately similar~to tha~t or~the~narrow circular path formed around the pipe 23. ~
FIGS~ 22A, 22B and 22C~and FIGS.~23A, 23B and 23C
illustrate modi}ied mechanlsms by~which~the two polymer streams~A and B~join to~ether,~wherein FIGS 22A and 23A
are~enlarged vertlcal sectional~views, FIGS. 22B and 23B
are plan~views~and~FIGS.~22C~and 23C are plan vie~s of~the pipes 24. Refer~ing to FIG. 22A,; the pipe 24 is positioned ` ~3~i91~

so that the uppermost end of the pipe 24 is in close proximity to the under surface of the plate rnember 14b.
Referring to FIG. 23A, the pipe 24 is positioned so that the uppermost end of the pipe 24 is in contact ~ith the under surface of the plate member 14b. In the 3~0dified mechanism illustrated in FIGS. 23A, 23B and 23C, the pipe 24 has four radially extending slits 28 bored in the uppermost end portion thereof, through which strearns of the polymer B flow into the pipe 24.
Although the number oE the holes 21 bored in the pla-te member 14b, illustrated in FIGS. Z2A thro-lsh 23C, through which streams of the polymer A flow into the pipe 24, is four, the number of the holes 21 may preferably be varied in the range of from 2 to 10. When the multi-core composite filaments~ each core ingredient of which is comprised of core polymer A segments having a large area i~ and an~intervening~polymer B segTnent having a small area, are desired, it is convenient that the under ~urface of the plate member 14b or the uppermost end of the pipe 24 be provided with guide members (not shown) forming radially extending slits or grooves through which streams of ihe polymer are introduced into the proxlmity of the central a~is of the pipe 24.

.
The advantages of the spinneret assemblies illustrated in FIGS. 21 through 23C are summar]zed as follows.
(1) C03nposite filaments each~having a great many fine core lngredients can be readily produced. For example, the composite filament illustrated in FIG. 18 can be 359~7 regarded as having 28~i.e., 7x4) fine core polymer A
ingredients. That is, 28 fine filamnets can be obtained therefrom by disso-lving out the polymers B and C. If a :~' composlte filament having 2a core ingredients is produced `~j 5 by using a conventional spinneret assembly, the spinneret assembly used must be provided with 28 pipes per filament.
~; In contrast, the spinneret assembly of the invention must ~ be provided only with seven pipes per filament. The `~ smaller the nwnber of pipes, the more reduced the pressure ; 10 drop in polymer streams flowing through the forest of the pipes. Thus, the composite fllament or the core ingredients ~ produced by using the spinneret assembly of the invention i are uniform in thickness and cross section.
The spinneret assembly of the lnVention is par.i-cularly advan-tageous in the case where the assembly is provided with ten or more pipes per filament. Furthermore, the spinneret assembly of the invention is smaIl in size per fllament. ~ ;
Similarly, the composi~e filament illustrated in FIG. 19 can be converted into 96(i.e., 6x16) flne polymer A
filaments~by'dissolving out the~polymers B and C therefrom.
If the polymer B lS the same as the polymer C, the dls olu-tion thereof can be effected in~a slngle step.
(2) Flne compcsite filaments, each comprlsed of two polymer ingredients" can be obtained. For example, flne ccmposlte~fllaments~comprlsed;of polymers A~and B can be easily obta1ned~by~dlssolvi~ng~out only~the lntervening pclymer C ingredlen;t from the composlte filament illustrated ~359~

in FIG. 18 or 19. If the polymer A possesses little or no affinity for the polymer B, the fine composite filament can be readily divided.
(3) Fine filaments of a special shaped cross section, such as a wedge shaped sectlon, a cross shaped section and an oblong shaped section, can be ob-tained, for example, by removing the polymers C and either A or B from the corr,posi.e filaments illustrated in Figs. 18 through 20E. Fine filaments of such a special shaped section cannot be produced by a conventional spinneret assern~ly. Furthern-lore, when one of the core-forming polymers is a polyblend, fine polyblend filaments can be obtained. Such fine polyblend filaments have many applications, such as, for example, anti-static fine filaments.

i:
In still another embodiment of -the spinneret assembly of the inventlon, a plate member S partitions off the polymer chamber III from two or more funnel-shaped polymer chambers IV and has bored ~herein two or more groups of h~oles; the lowermost ends of the holes in each group being exposed to each funnel-shaped polymer chamber IV and;~furthermore, the respective groups of holes~permitting at least ~two , streams selected from ~a) a comblned stream of~the polyMers A

; and C,~(b~)~a comblned stream of -che polymers B~and C, and (c) a combined stream of the polymers A, B and C, to inde pendently flow lnto different ~funnel-shaped polymer chambers IV. The two spinneret assemblies illustrated in;~FIGS. 24 and-25 are~examples of the above-mentioned embodiment. ~

R~ rring~to~ . 24, the s~inneret -ssemb~ly comprises : ~3~91'7 ~~ - 35 -' units Y, by~which multl-core com~osite filarnen~s each comprised of core polymex B ingredients and an intervening Z~ ~ polymer C ingredient are produced, and units Z, by which multi-core composite filaments each comprised of core polymer A ingredients and an inLervening polymer C inyredient are produced. These multi-core composite filaments are -formed in a state such that the composite filaments of one ~ type intervene between the composite filarnents o-f the i~ other type, or surround the composite filamen-ts of the other type. Thus, the two type composite filaments are obtained in a state wherein they are mixed to the desired e~tent. Therefore, by chemically or physically removing the intervening polymer C ingredients from the composite filaments, a bundle of fine filamellts can be obtained which is comprised of small bundles of fine polymer A
:
filaments and sma;ll bundles of fine polymer B filaments, the two type bundles being mixed with each other to the desir~ed extent.
Referrlng~to FIG. 25 illustrat1ng a modification of ~20 the sp1nneret assembly in FIG.~24, the polymer A introduced 3~through a hole~29~into the polymer chamber I flows into holes~I bored~1n~the plate member l4c and~ the polymer B
introduced through a hole 30 into the`polymer chamber II
flows into~ holes~ 10 bored in the plate;member l4c. The two polymer cihambers I~and II are partitioned off from each other by a pàrt1t1on wall 31. :~ The plate member~14a llustrated~in FIG. 25 corresponds to a combinat1on of the two~plate members~14a and~lSa 1l1ustrated in FIG. 24. As 3591~7 compared with the spinneret assembly illustr2ted in FIG. 24, ~- the spinneret assembly illustrated in FIG. 25 is advantaseo~s in that the cost of its equipment in less, but fine filaments finally obtained by using the spinneret ass2mbly in FIG. 2 are somewhat poor in filament distri~ution.
The cross sections of two examples of the bundles of composite filaments obtained by using the spinneret assemblies illustrated in FIGS. 24 and 25 are illustrated in FIGS. 26 and 27. In these two composite filament bundles, the composit~ filaments of a Z type comprised of the polymers A and C intervene between the composite filaments of a Y type comprised of the polymers B and C as illustrated in FIG. 26, or the ~ormer type cornposite filaments surround the latter type composite filaments as illustrated in FIG. 27. By removing or separating the intervening poIymer C ingredients from the respective bundles oe the composite filaments, a mixture of the two type flne filament bundles is obtained in the desired mixed state. Such desired mixed state cannot be obtained by conventional doubling and twisting procedures wherein two type fine filament bundles separately prepared are doubled and twisted.
The above-mentioned mixture of the two type flne fllament bundles; can be used in various ways. For example, 25~ special textile products are obtained by a comblnation of a non-shrinkable~polymer A and~a shrinkable polymer~B, a ; combination of two polymers A and B different in~dye- ;
-receptive properties~ or reslstance to attack by chemlcals,~

:

. ~ , .

or a combination of a colored polymer A and a non--colored polymer s. Also, various raised textile products of different softness, hand, feel and denseness can be obtained.
Furthermore, silk-like, wool-like and suede-like textile 5 products can also be o~tained.
In another embodiment of the spinneret assembly of the invention, the plate member S, which par,itions off `, the polymer chamber III from one or more funnel-shaped , polymer chambers IV and has bored therein a plurali-ty of holes, the lowermost ends of the holes being exposed to the or each funnel-shaped polymer chamber IV, is character-ized as further having bored therein one or more slits through which streams of the polymer C flow ~rom the polymer chamber III to the funnel-shaped polymer chamber IU, the or each slit being, on the under surface of the plate member S,~ of a multi-arm shape having at least three radially extending arms, each of which intervenes between at l ast two holes~of the holes bored in the plate member S.
Spinneret assemblies illustrated in FIGS. 29 through 32, FIGS. 33 hrough 37, FIGS. 38 through 41 and FIGS. 42 through 48 are~four~examples of the above-meDtioned embodi-ment of the invention.
Referring to~FlGS. 29 through 32, the spinneret assembly illustra-ted therein is~sultable ror~the production of multi-core composite filam;ents each of which has a cross sectlon~as ll~lustrated~ln FIG.~28s. ~The ~olymer C
introduced through~a~hole 12 into the polymer chamber III
lows through~slits 32, bored in a projecting part 31 of 3~i9~

the plate member, in-to tile funnel-shaped polymer chamber IV where the stream of the polymer C joins wi-th two polymer ; streams A and two polymer streams B, flowing -through the holes 33 and 34, respectively.
. 5 Referrlng to FIGS. 33 thxough 37, the spinneret assembly illustrated therein is approximately similar to that in FIGS. 29 th.rough 32, wherein two polymer streams A
flowing through holes 37 and, then, through holes 38, and two polymer stream B flowing through holes 40 and, then, through holes 41, join together with a stream of the polymer C issuing rrom a slit 35. The cross shaped slit, ~: through which the polymer C flows from the polymer chamber III to the funnel shaped chamber IV, is comprised of a wide in-troductory part 36 and a narrow part 35.
Referring to FIGS. 38 through 40, the spinneret assembly illustrated therein is approximately similar to that in FIGS. 33 .hrough 37, wherein a polymer C stream flows through a hole 73, a bore 66 and, then, a hole 66, and then, ~olns with two polymer A streams lssuing from 20 holes 65 and wlth two polyme~ B streams lssuing from :`
holes 72. FIG. 441 illustrates a part;of a modiried embodi-ment of the Splnneret assembly ln FIGS 38 through ~ao, said part corresponding to FIG. 40.~ In this rnodified spinneret assembly, t~he polymer C flows through four~radially extending .
holes 85, rnstead;of~one hole 73 in FIG.-40.
Referr1n~g~to FIGS:.~ 42 through 44, the~spinneret ~ :
assembly illustrated:therein~is a modification of the spinneret assembly ln FIGS. 29 through 32 and lS suitable :: :

l~L359~r7 - 39 ~
for the pro~uction of multi-core composite filaments, each of which has a cross section as illustrated in E'IG. 28G.
` This modified spinneret assembly is characterized in that four radially extending grooves 42 are provided in the upper periphery of the funnel-shaped polyrner chamber IV, through which grooves a portion of the polymer C flow into the polymer chamber IV. This portion of the polymer C
forms wedge shaped areas intervening in the polymer segments A and B as illustrated in FIG. 28G.
FIGS. 45 and 46 are transverse cross sections illustrating a part of a modified spinneret assembly which is approximately similar to that illustrated in FIGS. 42 through 44 and is suitable for the production of multi-core composite filaments each having a cross section as illus-trated in FIG. 28I. FIGS. 47 and 48 are also transverse cross sections illustrating a part of another modified spinneret assembly which is approximately similar to that in FIGS. 42 through 44 and is suitable for the production of multi-core composite fi~aments each having a cross section as illustrated in FIG. 28H. Vertical cross sections of these modified~ splnneret assemblies are approximately similar to that shown in FIG. 42~and, hence, are not illustrated herein.
Several examples of the multi-core composite filaments ~ : :
obtained by using the s'pinneret assemblies of the type similar to those illustrated in~FIGS. 29 through 48 are illustrated in cross section in FIGS. 28A through 28I.
These composite fllaments are comprlsed of a plurality of ~: -. : . .
: :

~1;35~
-- ~o --segments of -three polymers A, B and C. When the Cegments of three polymers A, B and C are separated from each other by chemical and/or physical means, a mixture of fine filaments or a bundle of fine composite filaments is obtained. That is, when the composite filaments are ,, .
treated with a solvent capable of selectively dissolving the polymer C, the resulting filaments are comprlsed of the polymers A and B. In contrast, when the segments of the polymers A, B and C are mechanically separated from each other, the resulting fine filaments are comprised of the polymer C as well as the polymers A and B. At least a part of the polymer C present in the resulting fine filaments is multi-arm shaped.
` In the cross sections illustrated in FIGS. 28A, 28B
and 28C, the respective polymer C segments are of the same cross-shaped configuration as each other, but the polymer `~ A segments~and the polymer B segments are different from ; each other. The cross sectional conriguration of the polymer C;~segment;may be~any multi-arm shape, other than cross-shaped, as 111ustra-ted in PIGS. 28D, 28E and 28F.
The number of arms~of the multi-arm~shape may be varied, ; pre~erably wlthln~the range of from~3 to 30. It LS also ;~
possible to provide each arm wlth one or more~brancned or~
crossed arms, although this not~lllustrated. Furthermore, 25~ the core polymer A segmbnts and~the core~polymer~B~segments ; are, preferably, symmetrically~d~sposed about the center~
of the cross sectlon of each compos1te filamentj as illus-,; trated not~ln~FIGS.;~288 and 28F~but in;FIGS. 28A, 28C, 28D

: ~ ~ : , - , - ~359~7 ~; - 41 _ and 28E. Th~s is because the composite filament haviny a symmetrical cross section is not liable to be curled and possesses good working proper-ties. The composite filaments " ! obtained by one and the same spinneret assembly may be different from each other in cross section and/or in `j~ thicXness.
In the cross section illustrated in FIG. 28G, a j~ portion of the polymer C seyments are wedge~shaped. Each `~ of the wedge-shaped polymer C segments has a function of, when the composite filament is subjected to a chemical or physical dividing treatment, dividing each core segment OL-the polymer A or B or A+B, located at both sides of each wedge-shaped polymer C segment, into two segments. The cross section illustrated in FIG. 28H is similar to that in FIG. 28G, except that two wedge-shaped polymer C segments intervene within each of the polymer A and B segments.
The cross section lllustrated in FIG. 28I is also sim1lar to that in FIG. 28G, except that a polymer A segment is located at one side of each wedge-shaped polymer C segment and a polymer B segment at the other s1de thereof. This composite filament in FIG. 28I is characterized 1n that, when it is subjected to a chem1cal or physical dividing treatment, the polymer A segment and;the~polymer B seyment located at hoth~sides of each wedge-shaped polymer C
segment are readily separated from each other and the resulting rine fi1aments are a uniform m1xture compris1ng polymer A filaments~ and polymér B filaments.
The multi-core composite f1laments ~ strated with : ~3L359~t7 , ; - 42 -.:
reference to~FIGs. 28A thro~gh 28E further have the following . advantages. First, since the intervening poly~er C ingre-~`- dient is of a multi-arm shape, each arm extending radially, ; the multi-core composite filaments can be produced without undesirable separation of the core and intervening ingre-.~ dients during their manufacture, even when the polymer C
is poor in affinity for the polymers A and B. Secondly, the cross section of each composite filament is symmetrical about the center, and therefore, the composite filament is - 10 not liable to develop crimps and possesses good working ;r properties. Thirdly, the intervening polymer C ingredient having a multi-arm shape cross section can be made thin, and therefore, when the intervening polymer C ingredient is dissolved out from the composite filament, the dissolution loss can be minimized.
FIG. 49 illustrates a typical example of the verti-9~ cally linked polymer passages through which a stream of .he polymer A, a combined stream of the polymers A and B
and a combined stream of the polymers A, B and C flow, respectively. For~a convenience~sake, only one series of the passages are illustrated thereln. The flgure on the right slde o~ FIG.;49 illustrate the cross sections of the polymer streams, sectioned along the lines W-W', X-X', Y-Y' an~d Z-Z', respectively. FIG. 50~1S an enlarged vertlcal~sectlonal~vlew~illustrating the~circled portion in FIG. 49~. FIGS. ~SlA, 51B, 51C and 51D are cross sections, sectloned along the~llnes W-W', X-X'j Y-Y~' and Z-Z', respectively, of FIG. 50.

L3S9~
. . --~ - ~3 -`-:
,.. .
FIG. 52 illustrates a spinning pack having fitted therein the spinneret assembly of the invention. The ~' polymers A, B and C are independently introduced from ....
j~ outlets 90, 91 and 92 through filter assemblies' 93, 94 and ,~ 5 95 into the polymer chambers I, II and III, respectively.
The spinneret assembly of the invention is preferably characterized in that, after at least the plate members <; forming the polymer chambers II and III (i.e., the plate members 14a, 15c, 15b, 15a and 16, more preferably the ~'~ 10 plate members 14c, 14b, 14a, 15c, 15b, 15a, 16 and 16') ',` are assembled into a spinneret assembly unit by using one ,~ or more bolts 96 and 97, the spinneret assembly unit can ; be fitted into the spinning pack.
~I Furthermore, the spinneret assembly of the invention ~; 15 is preferab~y characterized as not;having two or more polymer-introducing passages which open at the side wall of the spinneret assembly. FIG.~53~diagrammatically llustrates a spinning pack having fitted therein a spinneret assernbly having two polymer-int~roduci'ng passages 102 and 103 opening at the side wall of the splnneret assembly.
In this spinnlng;~pack, minor portions of'~the polymer streams A, B and C introduced from introducing passayes 98j~99 and 100,~ re~spectively, bored in the spinnig pack,~
inevltably`penetra~te into~a narrow cylindrical gap I05 between the~outer wall of the~spinnere~ assembly and the inner wall of ~he spinn~ing pack.~ In order~to prevent the polymer~strea~ms A,~;B~;and C, which have penetrated into the ' gap 105, from belng~contamina;ted~wlth each other, O-rlngs 104 ~`~

: ~3~9~
- 4~ _ must be provided within the gap lOS as illustr~ted in a circled, enlarged cross sectional view in the upper right portion of FIG. 53. However; such provision of O-rings inevita~ly forms gaps 106 between the plate members, causing mutual contamina-tion of the polymer streams which flow downward through the vertica]ly linked polymer passages (illustrated in FIG. 49) .
The shape of the spinneret assembly of the invention is not particularly limited. The shape may be columnar or square pillar-shaped, although the former is preferable.
The plate members may be made of various rigid `A materials. The rigid materials used include, for example, stainless steel, such as SUS-32 or -27, iron, titanium, glass, quartz, ceramics, gold, platinum and rigid plastics.
These material may be used alone or in combination.
The polymers, which flow through the spinneret assembly of the invention, may be either in a molten form or in a solution form. The polymers used ln a molten form include, for example, fiber-forming polyesters, polyamides, polyolefins, styrene polymers, polyurethanes and modified vinyl polymers. The polymers used in a solution form include, for example, polyamides, acrylic polymers, vinyl ; ~ polymers, polyvrethanes and cellulose acetate. It is not a requirement that each, of the three polymers A, B and C
25 may be a single polymer; and each may be a polyblend ~-comprised of two or more polymers. It is also possible that the intervening polymer ingredient lS the same as one of the core polymer ingredients.

: j:

35~7 , ., - 45 _ . The multi-ingredient rr~ul-ti-core composite filaMents obtained by using the spinneret assembly of the invention have many applications. For example, the fcllowing filarnents or yarn can be produced from the multi-core composite ~` 5 filaments.
(1) Fine core-sheath type composite filaments.
(2) Fine side-by-side type composite filâments.
(3) Combined filament yarns comprised of different fine filaments.
~i 10 (9) Fine multi-core core-sheath type filaments.
-' ~5) Cornbined filament yarns comprised of bundles of different fine filaments.

(6) A combination of at least two of th~ above--mentioned filamen-ts and yarns.

. ~
-~ 15 The following fabrics can be produced from the above-listed fine filaments and yarns.
Deeply colored fabrics~ These fabrlcs can be manufactured~from~fine core-sheath typ~e composite filaments, the core ingrediénts of~which are prepared~from a pigmented polymer~, or ~rom post-dyed products of the fine core-sheath filaments. Flne side-by-side~type compos~1te~ilaments are not~sultable for thls use because~plgmen~t tends to come of~ from the Eilaments in the step~of~divlding the filaments.
2);~ ~Bu1ky~fabrics, partlcu~1ar1y~raised fabrlcs.
These fabrlcs can~be manufactured~from comDlned~fl1ament yarns comprised~of~ine filaments of dlfferent shrlnkage ` or~rom~flne sldè-by-slde type fl1amen~ts. A1though~slde-by~
slde type~ aments do not~exhiblt~a~great cr~lmp-deve1Opins ; `~
capabl1ity, they~result in den;slfi~ed~ raised fabrics.

: .. ll~S~q - ~6 -(3) ~Fabrics with a moire' fin:ish. The.se fabrics ; are made of fine filaments divided frDm multi-core composite filaments, which have cross sections such that different core ingredients are unevenly distributed therein, or which are comprised of different multi-core composite filaments. The division of the multi-core comp~site filaments may be carried out either prior to or after the , formation of fabrics.
-~ It is expected that the multl-core composite filaments ~ 10 produced by using the spinneret assembly of the invention ; have various applications, other than those wherein they are used as fine filaments. The complicated and unique ,~ - design for the cross-sectional configurations of the multi-core composite filaments will produce their unique uses.

:

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Claims (15)

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:

1. A spinneret assembly to be fitted in a spinning pack for the production of multi-ingredient multi-core composite filaments each being comprised of at least three polymer phases A, B and C, the said spinneret assembly having means whereby either the cores in the composite filaments issuing from the spinneret assembly are not all identical or, if the cores are identical, they consist of a multi-divided stream of one of the polymers A and B interspersed by a stream of the other of the polymers A and B, which assembly comprises superposed rigid first, second, third and fourth plate members;
said first plate member partitioning off a first polymer chamber, through which a stream of the polymer A
flows, from a second or third polymer chamber, through which a stream of the polymer B or C flows, respectively;
said second plate member partitioning off the second polymer chamber from the third polymer chamber;
said third plate member partitioning off the third polymer chamber from one or more funnel-shaped fourth polymer chambers bored in the fourth plate member, through which combined streams of the polymers A, B and C flow, and said third plate member having bored therein a plurality of holes, the lowermost ends of which are exposed to the or each funnel-shaped fourth polymer chamber;
said fourth plate member having at the lowermost end of the or each funnel-shaped fourth polymer chamber an orifice through which a combined stream of the polymers A.

B and C flows;
said third plate member further having bored therein one or more slits through which streams of the polymer C flow from the third polymer chamber to the funnel-shaped fourth polymer chamber, the or each slit being, on the under surface of the third plate member, of a multi-arm shape having at least three radially extending arms, each of which intervenes between at least two holes of the holes bored in the third plate member, said first, second, third and fourth plate members forming a plurality of series of linked polymer passages, each series having at least one joining point at which two polymer streams join together, at least one of the polymer passages upstream of the joining point having at least one cross section that is narrower than any cross section of the polymer passage downstream of the joining point but upstream of the succeeding joining point, if any, or said at least one polymer passage upstream of the joining point having a length longer than that of the polymer passage downstream of the joining point but upstream of the succeeding joining point, if any.

2. A spinneret according to claim 1, wherein at least some of the polymer passages are formed through a member for connecting holes in the first plate member with corresponding holes in the second plate member, the member having bored there-in slits extending from some or all of said polymer passages to the second polymer chamber, whereby at least two types of core ingredients are formed in each multi-core composite filament.

3. A spinneret assembly as claimed in claim 1, wherein said second plate member further has bored therein two or more holes, through which streams of one of the polymers A and B
flow, immediately upstream of each joining point at which said one of the polymers A and B joins with the other of the polymers A and B, whereby one of the polymers A and B is permitted to join in multi-divided streams with a stream of the other of the polymers A and B.

4. A spinneret assembly as claimed in claim 1, wherein said plurality of holes bored in the third plate member, the lowermost ends of which holes are exposed to the or each funnel-shaped fourth polymer chamber, permit at least two streams selected from (a) a stream of the polymer A
or a combined stream of the polymers A and C, (b) a stream of the polymer B or a combined stream of the polymers B and C, and (c) a combined stream of the polymers A and B or a combined stream of the polymers A, B and C, to independently flow into the or each funnel-shaped fourth polymer chamber.

5. A spinneret assembly as claimed in claim 1, wherein said third plate member partitions off the third polymer chamber from two or more funnel-shaped fourth polymer chambers and having bored therein two or more groups of holes, the lowermost ends of the holes in each group being exposed to each funnel-shaped fourth polymer chamber, whereby the respective groups of holes permit at least two streams selected from (a) a stream of the polymer A or a combined stream of the polymers A and C, (b) a stream of the polymer B or a combined stream of the polymers B and C, and (c) a combined stream of the polymers A and B or a combined stream of the polymers A, B and C, to flow into different funnel-shaped fourth polymer chambers.

6. A spinneret assembly according to claim 1 or 2, wherein said slits bored in said connecting member extends from some or all of said polymer passages to the second polymer chamber whereby a narrow path is formed in said connecting member between said polymer passages and the second polymer chamber.

7. A spinneret assembly according to claim 1 or 2, wherein the narrowest cross section of one series of polymer passages, through which a stream of a core-forming polymer ingredient flows, is different in size from the narrowest cross section of at least one of the other series of polymer passages, through which a stream of a core-forming polymer ingredient flows, whereby there are formed composite filaments each having at least two core ingredients which are different n thickness from each other.

8. A spinneret assembly according to claim 1 or 2, wherein the narrowest cross sections of the respective series of polymer passages, through which the polymer streams forming the core ingredients of one composite filament flow, are different in size from the narrowest cross sections of the polymer passage series through which the polymer streams forming the core ingredients of at least one other composite filament flow, whereby there are formed composite filaments, at least two of which are different from each other in the thickness of the respective core ingredients.

9. A spinneret assembly according to claim 1 or 2, wherein both of the polymer passages upstream of the joining point have at least one cross section that is narrower than any cross section of the polymer passage downstream of the joining point but upstream of any succeeding joining point, both of the polymer passages upstream of the joining point having a length longer than that of the polymer passage down-stream of the joining point but upstream of any succeeding joining point.

10. A spinneret assembly according to claim 1 or 2, wherein both of the polymer passages upstream of the joining point have a length longer than that of the polymer passage downstream of the joining point but upstream of any succeed-ing joining point.

11. A spinneret assembly according to claim 3, 4 or 5, wherein said slits bored in said connecting member extend from some or all of said polymer passages to the second polymer chamber whereby a narrow path is formed in said connecting member between said polymer passages and the second polymer chamber.

12. A spinneret assembly according to claim 3, 4 or 5, wherein the narrowest cross section of one series of polymer passages, through which a stream of a core-forming polymer ingredient flows, is different in size from the narrowest cross section of at least one of the other series of polymer passages, through which a stream of a core-forming polymer ingredient flows, whereby there are formed composite filaments each having at least two core ingredients which are different in thickness from each other.

13. A spinneret assembly according to claim 3, 4 or 5, wherein the narrowest cross sections of the respective series of polymer passages, through which the polymer streams forming the core ingredients of one composite filament flow, are different in size from the narrowest cross sections of the polymer passage series through which the polymer streams forming the core ingredients of at least one other composite filament flow, whereby there are formed composite filaments, at least two of which are different from each other in the thickness of the respective core ingredients.

14. A spinneret assembly according to claim 3, 4 or 5, wherein both of the polymer passages upstream of the joining point have at least one cross section that is narrower than any cross section of the polymer passage downstream of the joining point but upstream of any succeeding joining point, both of the polymer passages upstream of the joining point having a length longer than that of the polymer passage downstream of the joining point but upstream of any succeed-ing joining point.

15. A spinneret assembly according to claim 3, 4 or 5, wherein both of the polymer passages upstream of the joining point have a length longer than that of the polymer passage downstream of the joining point but upstream of any succeeding joining point.