JP2013014872A - Composite spinneret and method for producing composite fiber - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a sea-island type composite spinneret preventing island component polymers from merging with each other while increasing hole packing density of island component extrusion holes, to form various fiber cross-sectional shapes, especially modified cross sections, with high accuracy, allowing dimensional stability of the various fiber cross-sectional shapes to be maintained at a high level.SOLUTION: A composite spinneret for extruding a composite polymer stream composed of an island component polymer and a sea component polymer, includes: one or more distribution plates in which distribution holes and distribution grooves for distributing each polymer component are formed; and a lowermost layer distribution plate located on a downstream side in a polymer spinning passage direction of the distribution plates, in which a plurality of island component extrusion holes and a plurality of sea component extrusion holes are formed. The composite spinneret has a plurality of hole groups comprising: the sea component extrusion holes arranged on a virtual circumferential line C1 having a radius R1, centering the island component extrusion holes; the sea component extrusion holes arranged on a virtual circumferential line C2 having a radius R2; and the island component extrusion holes arranged on a virtual circumferential line C4 having a radius R4, in which the hole groups are arranged according to a prescribed arrangement.

Description

  The present invention relates to a composite die and a method for producing a composite fiber.

  Fibers using thermoplastic polymers such as polyester and polyamide are excellent in mechanical properties and dimensional stability, so their uses have diversified and many fibers with various functionalities have been developed.

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

  This composite fiber includes a core-sheath type, a side-by-side type, and a sea-island type fiber obtained by using a composite base, and an alloy type obtained by melt-kneading polymers with each other, and a sea-island type fiber. In the core-sheath type, the sheath component coats the core component, so that it is possible to impart sensibility effects such as texture and bulkiness that cannot be achieved with a single fiber, and mechanical properties such as strength, elastic modulus, and wear resistance. Become. Further, in the side-by-side type, it is possible to express crimpability, which is impossible with a single fiber, and to impart stretchability and the like.

  And in the sea-island type, by eluting the easily-eluting component (sea component) after melt spinning, only the difficult-to-elute component (island component) remains, and it is possible to obtain ultrafine fibers with a single fiber diameter of nano-order. It becomes possible. When it becomes such an extra fine fiber, in the use for clothing, a soft touch and fineness that cannot be obtained with ordinary fibers are expressed, and it can be applied to artificial leather, new touch textiles, etc., and the fiber spacing becomes dense. Therefore, it can be developed as a high-density woven fabric for sports clothing that requires windproof and water repellency. In industrial material applications, it can be applied to high-performance filters, etc., because the specific surface area is increased and dust collection is improved, and precision equipment is used by wiping off dirt by inserting ultrafine fibers into fine grooves. It can also be applied to wiping cloths, precision polishing cloths, and the like.

  In addition, generally the method of manufacturing a composite fiber with a composite nozzle | cap | die is called a composite spinning method, and the method of manufacturing by melt kneading of polymers is called a polymer alloy method. Although the polymer alloy method can be used to produce the ultrafine fibers as described above, the control of the fiber diameter is limited, and it is difficult to obtain uniform and homogeneous ultrafine fibers. On the other hand, the composite spinning method precisely controls the composite polymer flow with a composite die, and in particular, it can form a highly accurate yarn cross-sectional form uniformly and homogeneously in the running direction of the yarn, compared with the polymer alloy method. The superiority is considered high. As a matter of course, the composite die technique in this composite spinning method is extremely important for stably determining the cross-sectional shape of the yarn, and various proposals have been made conventionally.

  For example, Patent Document 1 discloses a composite base as shown in FIG. (B) of FIG. 12 is a plan view of the composite base of Patent Document 1, and (a) of FIG. 12 is a partially enlarged plan view of (b). In the figure, black circle 1 indicates an island component discharge hole for discharging an island component polymer, white circle 4 indicates a sea component discharge hole for discharging a sea component polymer, 5 indicates a lowermost layer distribution plate, and 8 indicates a distribution groove. Hereinafter, in each drawing, when a member corresponding to the already-explained drawing exists, the description may be omitted by using the same reference numerals. In Patent Document 1, a plurality of distribution plates are stacked, and a lowermost layer distribution plate 5 provided with distribution grooves 8, island component discharge holes 1, and sea component discharge holes 4 is disposed in the lowermost layer of the distribution plate. After distributing the island component polymer, which is difficult to elute, and the sea component polymer, which is easy to elute, to a large number in advance, both polymers are discharged from the island component discharge hole 1 and the sea component discharge hole 4 of the lowermost layer distribution plate 5 In addition, it is described that a sea-island type composite fiber can be manufactured by combining immediately after discharge. Further, it is described that by using this composite die, 61 uniformly distributed composite fibers having an island shape of a hexagonal cross section (honeycomb shape) can be manufactured. This composite base is generally called a distribution plate type base.

  However, in the composite base of Patent Document 1, in order to arrange the island component discharge holes 1 and the sea component discharge holes 4 on the same surface of the lowermost layer distribution plate 5, it is not possible to arrange many island component discharge holes 1 and fill the holes. The density cannot be increased, and as a result, nano-order ultrafine fibers may not be obtained. In particular, since a plurality of sea component discharge holes 4 are arranged around one island component discharge hole 1 in order to prevent the island component polymers from joining together, the lowermost layer distribution plate 5 has an island component discharge. Since the sea component discharge holes 4 having a larger number of holes than the holes 1 are arranged, the places where the island component discharge holes 1 are arranged are limited, and the number of island component discharge holes 1 may not be increased. As described in the examples, the obtained fiber is 0.06 denier (trial calculation of fiber diameter: about φ2.5 μm), the fiber diameter is micron size, and it has not reached the nano order. Therefore, if a large number of island component discharge holes 1 are arranged, the composite die becomes large, and there are cases where productivity and operability are unfavorable in a multi-spindle spinning facility in the fiber field. Further, according to the knowledge of the present inventors, by arranging the sea component discharge holes 4 so as to form hexagons around the island component discharge holes 1 as a hole group arrangement pattern, the island shape is six. Although it has a square cross section, no other hole group arrangement pattern is presented, and there may be cases where sea-island type composite fibers having various island shapes cannot be obtained.

  Moreover, FIG. 9, FIG. 10 is disclosed as a hole arrangement | positioning pattern different from patent document 1. FIG. 9 and 10 are partially enlarged plan views of the composite base of Patent Document 5. FIG. According to the knowledge of the present inventors, Patent Document 5 is a pattern in which sea component discharge holes 4 are arranged in three or four equal arrangements around the island component discharge holes 1. Although it is likely that a sea-island type composite fiber having a polygonal shape will be obtained, in reality, the island component polymers may be merged with each other, and this is particularly noticeable when the ratio of the island component polymers is increased.

  Moreover, in patent document 2, the composite nozzle | cap | die as shown in FIG. 13 is disclosed. FIG. 13 is a schematic cross-sectional view of the composite base of Patent Document 2. In the figure, 10 is a discharge plate, 42 is a base discharge hole, 43 is a multilayer plate, 44 is a divided plate, and 45 is an array plate. Patent Document 2 is configured by laminating a multilayer plate 43, a division plate 44, an array plate 45, and a discharge plate 10 in order. The sea component polymer and the island component polymer that flowed in from the upstream side are multilayered and partially divided. By rearranging and repeating the division, it is possible to produce a sea-island type composite fiber by changing to a sea-island composite flow having a large number of island components and finally discharging from the nozzle discharge hole 42. Is described. The ultrafine fiber obtained by dissolving the island component polymer is not disturbed in the sea-island structure even during long-time spinning, the island shape is circular and the thickness is uniform, and the fiber diameter can reach nano order. It is described.

  However, since the island shape of the ultrafine fiber obtained by using the composite die of Patent Document 2 is limited to a circular shape or an elliptical shape similar to the circular shape, an ultrafine fiber having a complex shape, for example, a polygonal island shape, is used. You may not get it. Further, in Patent Document 2, the actual number of islands ((maximum number of islands−minimum number of islands) / average number of islands × 100 [%]) is within ± 20% of the theoretical number of islands. In some cases, it is not possible to control the number of islands with high precision. In addition, the types of sea component polymers that can be used are limited to polyethylene and polystyrene, and there are cases where a wide variety of polymers (polymers having different molecular structures such as polyester, polyamide, polyphenylene sulfide, and polyolefin) cannot be used.

  Moreover, in patent document 3, the composite nozzle | cap | die as shown in FIG. 14 is disclosed. FIG. 14 is a schematic cross-sectional view of the composite die of Patent Document 3. In the figure, 30 is a pipe, 31 is a sea component polymer introduction flow path, 32 is an island component polymer introduction flow path, 33 is an upper base plate, 34 is a middle base plate, 35 is a lower base plate, and 40 is a sea component polymer distribution chamber. , 41 indicate pipe insertion holes, respectively. Patent Document 3 is generally known as a pipe-type base, and includes an upper base plate 33 provided with a sea component polymer introduction channel 31, an island component polymer introduction channel 32, and a pipe 30, and an outer diameter of the pipe 30. And a lower base plate 35 provided with a base discharge hole 42 and a middle base plate 34 provided with a pipe insertion hole 41 having the same or larger diameter. Therefore, the easily eluted component sea component polymer is guided from the ocean component polymer introduction channel 31 to the ocean component polymer distribution chamber 40 and fills the outer periphery of the pipe 30, whereas the hardly eluted component island component polymer is: After being guided from the island component polymer introduction flow path 32 to the pipe 30 and discharged from the pipe 30, the polymers of both components merge to form a sea-island composite cross section, and then through the pipe insertion hole 41 and from the die discharge hole 42. It is described that a composite polymer can be discharged to produce a sea-island type composite fiber.

  However, the major problem of the pipe-type base of Patent Document 3 is that the pipe thickness is added to produce one island, so that the area per pipe increases. In addition, since the pipe 30 is press-fitted into the upper base plate 33 and fixed by welding for manufacturing the base, a welding allowance is required, and further, a hole for inserting the pipe 30 is provided. The gap between pipes cannot be reduced due to problems. For this reason, the pipes 30 cannot be densely arranged per unit area, and it may be difficult to produce ultra-fine fibers having a fiber diameter of nano-order. In addition, since the cylindrical pipe 30 is used, the island shape obtained is limited to a circular shape or an elliptical shape similar to the circular shape. Therefore, a sea-island type composite fiber having a complex shape, for example, a polygonal island shape. May not be able to get.

  In addition, in order to obtain a desired fiber form, it is necessary to make a plurality of composite die prototypes and repeat the spinning evaluation several times. However, since the structure of this composite die is very complex, In this respect, there is a problem that the equipment cost is excessive. Further, since the sea component polymer introduction flow path 31 is disposed on the outer periphery of the pipe group in which the pipes 30 are densely disposed, it is difficult to sufficiently supply the sea component polymer to the center of the pipe group. In particular, the island component polymers discharged from the pipe 30 at the center of the pipe group may merge. In particular, if the pipes 30 are arranged more densely in order to increase the hole packing density, the above problem becomes more prominent. According to the knowledge of the present inventors, it may be structurally difficult to freely dispose the sea component polymer introduction channel 31 in the pipe group of the pipe 30. This is because, for example, in order to arrange in the pipe group, it is necessary to bend the pipe 30 in the middle and to provide the sea component polymer introduction channel 31, so that the structure of the base is very complicated. Therefore, there is a problem that the equipment cost becomes excessive.

  Further, as an example similar to a pipe-type base, a composite base of Patent Document 4 as shown in FIG. 15 is disclosed. FIG. 15 is a schematic cross-sectional view of the composite die of Patent Document 4. In the figure, 25 is a discharge hole, 27 is a radial groove, and 28 is a concentric groove. Patent Document 4 discloses that the distribution of the sea component polymer is improved by forming the radial grooves 27 around the island component discharge holes 1 and the concentric grooves 28 around the discharge holes 25, and the sea component polymer ratio is small. Even so, it is described that a sea-island type composite fiber that suppresses merging of island components can be obtained. Further, according to the knowledge of the present inventors, since the hole is formed by machining without using the pipe, the problem of using the pipe at the time of manufacturing the die as in Patent Document 3 can be avoided. Compared with Patent Document 3, the hole packing density can be somewhat increased.

  However, since the grooves are formed around the island component discharge holes 1 and the discharge holes 25, the pitch between the holes is increased, the hole filling density cannot be sufficiently increased, and the fiber diameter is ultrafine with nano order. It may be difficult to produce the fiber. As described in the examples, the minimum diameter of the obtained fiber is 1 μm, so that it cannot reach the nano-order. In addition, since complicated grooving is performed on the base, it takes time, labor, and expense to manufacture the base, and there is a problem that the equipment cost is excessive in this respect as well.

JP 7-26420 A JP 2000-110028 A JP 2007-100343 A JP 2006-183153 A JP 2008-38275 A

  As described above, while increasing the hole packing density of the island component discharge holes, it is possible to prevent the island component polymers from joining together at a high island component ratio (= low sea component ratio), and to obtain an unusually shaped ultrafine fiber. Although eagerly desired, as described above, various problems remain, which has hindered the production of sea-island type composite fibers. Therefore, solving this problem has important industrial significance. Therefore, the purpose of the present invention is to prevent the island component polymer from joining together while expanding the hole packing density of the discharge holes of the island component polymer in the distribution plate type die for producing the sea-island type composite fiber. Various fiber cross-sectional forms, in particular, irregular shaped cross-sections can be formed with high accuracy, and a composite base capable of maintaining high dimensional stability of the cross-sectional form, and a composite fiber manufacturing method for performing melt spinning by a composite spinning machine using the composite base Is to provide.

In order to solve the above problems, the composite base of the present invention has the following configuration. That is, according to the present invention, a composite base for discharging a composite polymer flow composed of an island component polymer and a sea component polymer, wherein distribution holes and distribution grooves for distributing each polymer component are formed. Consists of one or more distribution plates and a lowermost layer distribution plate that is located downstream of the distribution plate in the polymer spinning path direction and has a plurality of island component discharge holes and a plurality of sea component discharge holes The sea component discharge hole disposed on a virtual circumference line C1 having a radius R1 centered on the island component discharge hole, and the sea component discharge hole disposed on a virtual circumference line C2 having a radius R2. There are a plurality of hole groups composed of the island component discharge holes arranged on the virtual circumferential line C4 having the radius R4, satisfying the following expression (1), and satisfying the following conditions (1) to (2): A composite base with either arrangement is provided.
(1) R2 ≧ R4 ≧ √3 × R1 Formula (1)
(2) Condition a. C1: Three sea component discharge holes are equally distributed at a central angle of 120 degrees
C2: Three sea component discharge holes are equally distributed at a central angle of 120 degrees
C4: Six island component discharge holes are equally divided at a central angle of 60 degrees
θ3: The phase angle between the discharge holes arranged at C1 and C2 is 60 degrees.
θ5: The phase angle between the discharge holes arranged at C1 and C4 is 30 degrees. C1: Three sea component discharge holes are equally distributed at a central angle of 120 degrees
C2: Three sea component discharge holes are equally distributed at a central angle of 120 degrees
C4: Three island component discharge holes are equally distributed at a central angle of 120 degrees
θ3: The phase angle between the discharge holes arranged at C1 and C2 is 60 degrees.
θ5: The phase angle between the discharge holes arranged at C1 and C4 is 0 degree. C1: Six sea component discharge holes are equally distributed at a central angle of 60 degrees
C2: Six sea component discharge holes are equally distributed at a central angle of 60 degrees
C4: Six island component discharge holes are equally divided at a central angle of 60 degrees
θ3: The phase angle between the discharge holes arranged at C1 and C2 is 0 degree
θ5: The phase angle between the discharge holes arranged at C1 and C4 is 30 degrees. Condition d. C1: Four sea component discharge holes are equally divided at a central angle of 90 degrees
C2: Eight sea component discharge holes are arranged
C4: Four island component discharge holes are equally divided at a central angle of 90 degrees
θ3: The phase angle between the discharge holes arranged at C1 and C2 is 26.6 degrees.
θ5: The phase angle between the discharge holes arranged at C1 and C4 is 0 degree. According to a preferred embodiment of the present invention, either of the above conditions (2) b and d is satisfied, and the island component discharge holes Are divided into n pieces (n is a natural number of 3 and 4; the same shall apply hereinafter) on the virtual circumferential line C7 of radius R7, satisfy the following expression (3), and satisfy the following condition (4): (3) R7 ≦ R1 · cos (180 / n [degree])
(4) C7: n island component discharge holes are equally arranged at a central angle of 360 / n degrees θ6: phase angle between discharge holes arranged at C7 and C1 is 180 / n degrees According to the embodiment, a composite base that satisfies Expression (5) is provided when the number of ejection holes is n = 4.
(5) R7 ≦ R1 / 2
Moreover, according to the preferable form of this invention, the composite nozzle | cap | die with which the hole filling density of the said island component discharge hole is 0.5 hole / mm < ² > or more is provided.

  Moreover, according to another embodiment of the present invention, there is provided a method for producing a composite fiber in which the above-mentioned composite die is melt-spun with an island component polymer ratio of 50% or more.

  In the present invention, the “distribution hole” means a hole in which a hole is formed by a combination of a plurality of distribution plates and serves to distribute the polymer in the direction of the polymer spinning path.

  In the present invention, the “distribution groove” means that a groove is formed by a combination of a plurality of distribution plates and plays a role of distributing the polymer in a direction perpendicular to the polymer spinning path direction. Here, the distribution groove may be an elongated hole (slit), or an elongated groove may be dug.

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

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

  In the present invention, the “virtual circumferential line C1 having a radius R1” refers to a virtual circumferential line C1 having a radius R1 as the distance between the center points of the sea component discharge hole closest to the reference island component discharge hole. .

  In the present invention, the “virtual circumferential line C2 having a radius R2” means a virtual circumferential line C2 having a radius R2 as the distance between the center points of the sea component ejection hole that is second closest to the reference island component ejection hole. Say.

  In the present invention, the “virtual circumferential line C4 having a radius R4” refers to a virtual circumferential line C4 having a radius R4 as the distance between the center points of the island component ejection holes closest to the reference island component ejection hole. .

  In the present invention, the “virtual circumferential line C7 of radius R7” is a virtual polygon formed by line segments connecting the centers of n island component discharge holes, and the center of gravity of the virtual polygon is defined as a virtual center O. A virtual circumferential line C7 having a radius R7 as the distance between the center points of the center O and the island component discharge holes forming the virtual polygon.

  In the present invention, the phase angle θ6 between the discharge holes arranged at C7 and C1 is a line segment connecting the virtual center O and the center point of the sea component discharge holes arranged on the virtual circumference line C1. The angle at which the virtual center O intersects with a line segment connecting the center points of the island component discharge holes arranged on the virtual circumferential line C7.

  In the present invention, the “center angle” means the center point of the reference island component discharge hole and the center point of two sea component discharge holes adjacent to each other in the circumferential direction arranged on the virtual circumferential lines C1 and C2. Or an angle at which a line segment connecting the center points of two island component discharge holes adjacent in the circumferential direction arranged on the virtual circumferential line C4, or the virtual center O and the virtual circumferential line C7 The angle which the line segment which connects the center point of two island component discharge holes adjacent to the circumferential direction arrange | positioned in FIG.

  In the present invention, the “phase angle” means a line segment connecting the center point of the reference island component discharge hole and the center point of the sea component discharge hole arranged on the virtual circumferential line C1, and the reference island component. The angle at which the line connecting the center point of the discharge hole and the center point of the sea component discharge hole arranged on the virtual circumference C2 intersects, or the center point of the reference island component discharge hole and the virtual circumference C1 A line segment connecting the center point of the sea component discharge hole disposed above, and a line segment connecting the center point of the reference island component discharge hole and the center point of the sea component discharge hole disposed on the virtual circumferential line C2. The angle at which crosses.

  In the present invention, the “hole filling density” refers to a value obtained by dividing the number of island component discharge holes for discharging the island component polymer by the cross-sectional area of the discharge introduction holes. In the scope of claims 2 and 3, the n island component discharge holes arranged on the virtual circumference C7 are defined as one island component hole group, and the number of island component hole groups is represented by the cross-sectional area of the discharge introduction hole. The value obtained by dividing. The larger the pore packing density, the more the composite fiber is composed of a larger number of island component polymer components.

  According to the composite die of the present invention, while expanding the hole filling density of the discharge holes of the island component polymers, the island component polymers are uniformly distributed, and the island component polymers are prevented from merging with each other. Particularly, the irregular cross section can be formed with high accuracy, and the dimensional stability of the cross section can be maintained high.

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

  Hereinafter, embodiments of the composite base of the present invention will be described in detail with reference to the drawings. 5 is a schematic cross-sectional view of the composite base used in the embodiment of the present invention, FIG. 7 is a view taken along the line XX of FIG. 5, and FIG. 1 is a partially enlarged plan view of FIG. 2, 3, 4, 16, 18, and 19 are partially enlarged plan views of a lowermost layer distribution plate used in another embodiment of the present invention, and FIG. 6 is used in the embodiment of the present invention. FIG. 17 is a schematic partial sectional view of a distribution plate and a lowermost layer distribution plate used in the embodiment of the present invention. These are conceptual diagrams for accurately transmitting the main points of the present invention, which are simplified, and the composite base of the present invention is not particularly limited, and the number of holes and grooves and the size ratio thereof are not limited. These can be changed according to the embodiment.

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

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

  Here, the plate thickness of the thin plate is preferably in the range of 0.01 to 0.5 mm, and more preferably in the range of 0.05 to 0.3 mm. By reducing the thickness of the thin plate, there is an advantage that the hole diameter and groove width of the holes that can be processed, the distance between holes, and the pitch between grooves can be reduced, and the hole filling density can be increased. Specifically, the hole diameter DMIN that is the smallest among the island component discharge holes 1 and the thickness BT of the lowermost layer distribution plate 5 in which the minimum holes are formed satisfy the expression (6). The hole filling density can be further increased. Further, when the distribution groove 8 is formed, the groove width is set to DMIN, and the plate thickness BT of the distribution plate 6 satisfies the formula (6), so that the hole filling density is increased as described above. can do.

BT / DMIN ≦ 2 (6)
Here, in the case of BT / DMIN> 2, as described above, it is possible to further increase the hole filling density. However, when it is attempted to minimize the discharge spots of the island component polymer, the equation (6) It is more preferable to satisfy.

  However, if the thickness of the distribution plate 6 and the lowermost layer distribution plate 5 is reduced within the range of 0.01 to 0.5 mm, the strength of the thin plate is reduced and bending tends to occur. The type may be limited (high-viscosity polymer will have a large pressure loss and bend). In that case, a plurality of thin plates may be stacked and metal-bonded to increase the overall thickness and improve the strength. Further, by increasing the thickness of the thin plate, the strength per sheet is improved, so that there is an advantage that the types of polymers that can be used increase. However, if it is too thick, the hole diameter, groove width, and hole-groove pitch that can be processed cannot be reduced, and the hole filling density may not be increased. In that case, the thickness of the distribution plate having a large number of holes may be reduced, and the thickness may be increased as the number of holes decreases.

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

  In addition, the hole diameters of the island component discharge holes 1 arranged in the lowermost layer distribution plate 5 are preferably all equal, and the hole diameters of the sea component discharge holes 4 are preferably all equal. Thereby, since the discharge speed of the island component polymer discharged from the island component discharge hole 1 and the sea component polymer discharged from the sea component discharge hole 4 can be made uniform, an island component cross section with excellent uniformity can be obtained. it can. Moreover, the hole diameters of the island component discharge hole 1 and the sea component discharge hole 4 may be different, and may be appropriately determined depending on the island component / sea component polymer ratio. This is because when the ratio of the island component polymer is increased, the discharge speed of the island component polymer discharged from one island component discharge hole 1 (the discharge speed is the discharge flow rate is the island component discharge hole 1 or the sea component discharge hole). 4), and the diameter of the island component discharge hole 1 having a large amount of polymer discharge so that the discharge speed of the sea component polymer discharged from one sea component discharge hole 4 is approximately equal. It is preferable to reduce the diameter of the sea component discharge hole 4 with a large polymer discharge amount or a small polymer discharge amount. Thereby, the cross-sectional form of the island component obtained can be remarkably stabilized and the form can be accurately maintained. The diameters of the island component discharge holes 1 and the sea component discharge holes 4 are preferably in the range of 0.01 to 0.5 mm, and more preferably in the range of 0.05 to 0.3 mm. .

  First, while increasing the hole packing density of the composite die 18, which is the most important point of the present invention, it is possible to prevent merging of polymers of island components with each other and to form various fiber cross-sectional forms, particularly deformed cross-sections with high accuracy. The principle will be described. Here, in order to increase the hole packing density, the interval between the island component discharge holes 1 must be as close as possible, but in this case, the island component polymers merge between adjacent island component discharge holes. . Therefore, in order to prevent the island component polymers from joining each other, for example, as shown in FIG. 12, the island component discharge hole 1 is surrounded by a sea component discharge hole 4 for discharging the sea component polymer. And the confluence | merging of adjacent island component polymers can be suppressed, and the fiber from which an island component becomes a hexagonal cross section can be obtained. However, on the other hand, the distance between the island component discharge holes becomes too large to increase the hole filling density. In other words, there is a trade-off relationship between the hole packing density and the prevention of merging of the island component polymers.

  Here, the merging of the island component polymers when the cross-sectional shape of the island component is round is mainly generated on the line connecting the centers of the adjacent island component discharge holes 1, but the irregular shape having a plurality of edge (corner) portions. In some cases, it occurs not only on the line connecting the gravity centers of the island component discharge holes 1 but also between adjacent edge portions. In view of production efficiency, it is preferable to increase the island component polymer ratio as much as possible and reduce the sea component polymer ratio, but in this case, the occurrence of merging of the island component polymers becomes more remarkable.

  Therefore, it is an extremely important technique to increase the hole packing density, suppress the merging of the island component polymers, and produce a fiber having a highly accurate fiber cross-sectional form. Accordingly, the present inventors have conducted extensive studies on the above-mentioned problem, which was not considered in the conventional technology, and as a result, have found a new technology of the present invention.

  That is, the lowermost layer distribution plate 5 according to the embodiment of the present invention has a sea component discharge hole 4 and a virtual circumference C2 having a radius R2 on a virtual circumference C1 having a radius R1 with the island component discharge hole 1 as a center. The sea component discharge hole 4 and the island component discharge hole 1 on the imaginary circumferential line C4 having the radius R4 form one hole group, and a plurality of these hole groups are arranged, satisfying the formula (1), and It arrange | positions so that it may become either of conditions (i)-(ii) of (2). Here, conditions (a) and (b) are the arrangement patterns of the island component discharge holes 1 and the sea component discharge holes 4 in which the island component is a triangular cross section, the condition c is a hexagonal cross section, and the condition D is a quadrilateral cross section. Show.

As a first pattern, as shown in FIG. 1, when a certain island component discharge hole 1 is used as a reference and the sea component discharge hole 4a is adjacent to the reference island component discharge hole 1 at the shortest center distance. A virtual circumferential line having a radius R1 as a line segment connecting the reference island component discharge hole 1 and the center point of the sea component discharge hole 4a is defined as C1, and the sea component discharge hole 4 is disposed on the virtual circumferential line C1. Then, when the sea component discharge holes 4b adjacent to each other at the second shortest center distance are used, a virtual circumferential line having a radius R2 as a line segment connecting the reference island component discharge hole 1 and the center of the sea component discharge hole 4b. When the sea component discharge hole 4 is arranged on the virtual circumferential line C2 and the island component discharge hole 1a adjacent to the reference island component discharge hole 1 at the shortest center distance is defined as C2. A virtual circumferential line C4 having a radius R4 that is a line segment connecting the centers of the island component discharge holes 1 and 1a. A virtual circumferential line C4 is arranged in a region sandwiched between the virtual circumferential line C1 and the virtual circumferential line C2, and satisfies the formula (1), and each virtual circumferential line C1, C2, and On C4, it arrange | positions so that it may become the condition (a) of (2). Here, Equation (1) is calculated by rounding off the fourth decimal place.
(1) R2 ≧ R4 ≧ √3 × R1 Formula (1)
(2) Condition a. C1: Three sea component discharge holes are equally distributed at a central angle of 120 degrees
C2: Three sea component discharge holes are equally distributed at a central angle of 120 degrees
C4: Six island component discharge holes are equally divided at a central angle of 60 degrees
θ3: The phase angle between the discharge holes arranged at C1 and C2 is 60 degrees.
θ5: The phase angle between the discharge holes arranged at C1 and C4 is 30 degrees. C1: Three sea component discharge holes are equally distributed at a central angle of 120 degrees
C2: Three sea component discharge holes are equally distributed at a central angle of 120 degrees
C4: Three island component discharge holes are equally distributed at a central angle of 120 degrees
θ3: The phase angle between the discharge holes arranged at C1 and C2 is 60 degrees.
θ5: The phase angle between the discharge holes arranged at C1 and C4 is 30 degrees. C1: Six sea component discharge holes are equally distributed at a central angle of 60 degrees
C2: Six sea component discharge holes are equally distributed at a central angle of 60 degrees
C4: Six island component discharge holes are equally divided at a central angle of 60 degrees
θ3: The phase angle between the discharge holes arranged at C1 and C2 is 0 degree
θ5: The phase angle between the discharge holes arranged at C1 and C4 is 30 degrees. Condition d. C1: Four sea component discharge holes are equally divided at a central angle of 90 degrees
C2: Eight sea component discharge holes are arranged
C4: Four island component discharge holes are equally divided at a central angle of 90 degrees
θ3: The phase angle between the discharge holes arranged at C1 and C2 is 26.6 degrees.
θ5: The phase angle between the discharge holes arranged at C1 and C4 is 0 degree. As a result, the island component polymers between the reference island component discharge hole 1 and the island component discharge hole 1a that are most likely to be joined together are , And a straight portion having a deformed cross section (triangular cross section) is formed by the arrangement of the sea component discharge holes 4a on the virtual circumference line C1, and the arrangement of the sea component discharge holes 4b on the virtual circumference line C2 By forming an edge part by this, it is possible to obtain a fiber having a uniform island component and a highly accurate cross section (triangular cross section).

  Explaining the principle of the present invention along the flow form of the polymer, both the island component polymer and the sea component polymer are simultaneously discharged toward the discharge introduction hole 11 on the downstream side of the lowermost layer distribution plate 5, As each polymer widens in a direction perpendicular to the direction of the polymer spinning path, the polymer flows along the direction of the polymer spinning path, and the two polymers merge to form a composite polymer stream. At that time, in order to prevent the island component polymers discharged from the reference island component discharge hole 1 and the island component discharge hole 1a from joining together, a sea component polymer that physically divides the island component polymer is interposed. The sea component polymer discharged from the sea component discharge hole 4a on the virtual circumference C1 plays this role.

  And another important role of the sea component discharge hole 4a on the virtual circumferential line C1 is to form an island component having an irregular cross section. This partially suppresses the widening of the island component polymer discharged from the reference island component discharge hole 1, that is, in order to obtain a form in which the island component has a triangular cross section, the three sea component discharge holes 4a are provided. By equally dividing at a central angle of 120 degrees, widening of the island component polymer is suppressed from three locations. And the island component which flows out from between the holes of the sea component discharge hole 4a by arranging the sea component discharge holes 4b on the virtual circumference C2 equally at a central angle of 120 degrees with a phase angle of 60 degrees. The polymer is suppressed by the sea component polymer discharged from the sea component discharge hole 4b. Since the sea component discharge hole 4a and the sea component discharge hole 4b have a phase difference and are disposed on the virtual circumferential line C1 and the virtual circumferential line C2 having different radii, the sea disposed on the inner peripheral side The component discharge hole 4a forms a side of a triangular cross section, and the sea component discharge hole 4b arranged on the outer peripheral side has a role of forming an edge (corner) portion of the triangular cross section.

  In addition, the island component polymer discharged from the reference island component discharge hole 1 and the island component polymer discharged from the island component discharge hole 1a on the virtual circumferential line C4 also have a role of suppressing merging. ing.

  In order to obtain a fiber having a large island filling density and an island component having an irregular cross section, the radius R4 of the virtual circumferential line C4 is decreased, and the reference island component discharge hole 1 and the island component discharge hole 1a are separated. In this case, the present inventors have found that there is a distance at which the island component polymers discharged from the respective holes widen and the island component polymers join together. This is because the space between the virtual circumference line C1 and the virtual circumference line C2 forms a space that sufficiently widens the island component polymer discharged from the island component discharge hole 1, and allows the island component polymers to merge. The key is the arrangement of holes that can be suppressed. That is, it suffices to determine that the radius R4 that is the distance between the center points of the island component discharge holes 1a adjacent to the reference island component discharge hole 1 satisfies Expression (1).

  Here, in the case of R4> R2 in the formula (1), the island component discharge hole 1 serving as a reference and the island component discharge holes 1 arranged on the virtual circumferential line C4 cannot be brought close to each other. As a result, the island packing density cannot be increased. Further, in the case of R4 <√3 × R1 in the formula (1), the island component discharged from the reference island component discharge hole 1 and the island component discharge hole 1 arranged on the virtual circumferential line C4. There may be a case where merging of polymers occurs. The feature of this arrangement is that the number of islands can be increased and the island packing density can be increased, but the island component polymer ratio cannot be increased to 50% or more. It is suitable to obtain a composite fiber.

  Next, as another arrangement pattern in which the island component has a triangular cross section, as shown in FIG. This is because three sea component discharge holes 4 are equally arranged at a central angle of 120 degrees on the virtual circumference C1 around the reference island component discharge hole 1, and on the outer circumference of the virtual circumference C4. Three island component discharge holes 1 are equally divided at a central angle of 120 degrees with a phase angle of 0 degrees, and a phase angle of 60 degrees on a virtual circumferential line C2 on the outer periphery of the three island component discharge holes 1 The component discharge holes 4 are equally arranged at a central angle of 120 degrees. By adopting such an arrangement, the island component polymer ratio can be increased, and even at a high island ratio of 70% or more, there is no merging of the island component polymers, and a fiber having a uniform triangular cross section is obtained. be able to.

  Further, as shown in FIG. 3, the arrangement pattern in which the island component has a hexagonal cross section is arranged in the condition (2). In the arrangement of (2) c, six sea component discharge holes 4 are equally arranged at a central angle of 60 degrees on a virtual circumferential line C1 around the reference island component discharge hole 1, and the outer periphery of the sea component discharge hole 1 is virtual. Six island component discharge holes 1 are equally distributed at a central angle of 60 degrees with a phase angle of 30 degrees on the circumferential line C4, and a phase angle of 30 degrees on the virtual circumferential line C2 on the outer periphery thereof. Then, the six sea component discharge holes 4 are equally arranged at a central angle of 60 degrees. By adopting such an arrangement, it is possible to increase the hole filling density and the island component polymer ratio, and even at a high island ratio of 70% or more, the island component polymers do not merge with each other, and the island component is uniform. A fiber having a hexagonal cross section can be obtained.

  Further, as shown in FIG. 4, as the arrangement pattern in which the island component has a quadrangular cross section, there is an arrangement in the condition (2). In the arrangement of the condition (2), the four sea component discharge holes 4 are equally divided at a central angle of 90 degrees on the virtual circumference C1 around the reference island component discharge hole 1, and Four island component discharge holes 1 are equally arranged at a central angle of 90 degrees on the virtual circumferential line C4 with a phase angle of 0 degree, and a phase angle of 22.5 is placed on the virtual circumferential line C2 of the outer periphery. The eight sea component discharge holes 4 are arranged at a certain degree. By adopting such an arrangement, it is possible to increase the hole packing density and the island component polymer ratio, and to obtain a fiber having a rectangular cross section with a uniform island component even at a high island ratio of 70% or more. Can do.

  Next, the principle of forming a cross-sectional shape with a high degree of profile and achieving this with a high hole packing density will be described. Here, according to the knowledge of the present inventors, not only on the line connecting the centroids of the adjacent island component discharge holes 1 but also between the edges (corners) of the island component cross section, as the cross-sectional shape has a high degree of irregularity. It becomes easy for the island component polymers to merge. Also, a plurality of island component discharge holes 1 are arranged in a dense manner so as to have a desired shape, and island polymers discharged from the island component discharge holes 1 are merged to form a highly irregular cross-sectional shape. However, according to the knowledge of the present inventors, since a plurality of island component discharge holes 1 are necessary to form a cross-sectional form of one island component, the number of holes that can be arranged in the composite die is reduced. Has a limitation, and as a result, the hole packing density cannot be increased, and there is a limit in forming a cross-sectional shape of hundreds or thousands of island components.

Therefore, as the cross-sectional shape of the island component increases, the island component polymers are more likely to merge with each other, and the degree of difficulty is further increased in order to achieve this under high production efficiency. Therefore, the present inventors have intensively studied the above-mentioned problem that has not been considered in the conventional technique, and as a result, have found a new technique of the present invention.

  That is, as shown in FIG. 18, the lowermost layer distribution plate 5 of another embodiment of the present invention satisfies either of the conditions (2) and (d) of (2), and the reference island component discharge hole 1 is the virtual center. The island component discharge holes 1 on the virtual circumferential line C4 are virtually divided into n pieces (n is a natural number of 3 and 4; the same shall apply hereinafter) on the virtual circumferential line C7 having a radius R7 with O as the center. With the group center P as the center, it is divided into n pieces on a virtual circumferential line C7 having a radius R7. Here, the arrangement pattern of the island component discharge holes 1 and the sea component discharge holes 4 in which the island component is a Y-shaped cross section when n is three and the cross section is cross when n is four is shown. The smaller the number of n, the higher the profile shape can be obtained.

First, as a pattern with three n, as shown in FIG. 18, the distance between the center points of the virtual island O and the three island component discharge holes 1b, 1c, 1d on the virtual circumference C7, and The distance between the center points of the three island component discharge holes 1 adjacent to the virtual group center P is set as a radius R7, the expression (3) is satisfied, and the conditions (4) are satisfied. Here, equation (3) is calculated by rounding off the fourth decimal place.
(3) R7 ≦ R1 · cos (180 / n [degree])
(4) C7: n island component discharge holes are equally arranged at a central angle of 360 / n degrees. Θ6: The phase angle between the discharge holes arranged at C7 and C1 is 180 / n degrees. An imaginary circumference in which the island components polymer discharged from the three island component discharge holes 1b, 1c, and 1d on the line C7 are merged to form a dent on the corner of the triangular cross section and are most likely to be merged. By preventing merging of island component polymers between the group of island component discharge holes 1 on the line C7 and the group of island component discharge holes 1 on the virtual circumferential line C4, the island components are uniform, The fiber which becomes a high profile cross-section (Y-shaped cross section) form can be obtained.

  Explaining the principle of the present invention along the flow form of the polymer, both the island component polymer and the sea component polymer are simultaneously discharged toward the discharge introduction hole 11 on the downstream side of the lowermost layer distribution plate 5, As each polymer widens in a direction perpendicular to the direction of the polymer spinning path, the polymer flows along the direction of the polymer spinning path, and the two polymers merge to form a composite polymer stream. At that time, the island component polymers discharged from the hole group of the island component discharge holes 1b, 1c, and 1d around the virtual center O and the hole group of the three island component discharge holes 1 around the virtual group center P It is effective to intervene the sea component polymer that physically divides the island component polymer, and this role is discharged from the sea component discharge hole 4 on the virtual circumferential line C1. The sea component polymer plays.

  Another important point of the present invention is that the island component polymers discharged from the three island component discharge holes 1b, 1c, and 1d merge to form an irregular cross section of one island component. . When the island component polymers discharged from the three island component discharge holes 1b, 1c, and 1d merge, a triangular cross section having the respective island component discharge holes 1 as the apexes is formed. At that time, the sea component polymer is discharged from the sea component discharge holes 4 between the island component discharge holes 1b and 1c, between the island component discharge holes 1c and 1d, and between the island component discharge holes 1d and 1b. And by allowing a part of the sea component polymer to enter between the joining island component polymers, a dent can be formed on the corner of the triangular cross section, and as a result, a cross-sectional form having a high degree of irregularity (Y-shaped cross section) Can be formed. That is, as the discharge hole arrangement for achieving this, the island component discharge holes 1a, 1b, and 1c arranged on the virtual circumferential line C7 around the virtual center O are used as the sea component discharge on the virtual circumferential line C1. Three island component discharges having a phase angle of 30 degrees with the hole 4 and equally arranged at a central angle of 120 degrees and centered on a virtual group center P on a virtual circumferential line C7 having a radius R7 The holes 1 are equally arranged at a central angle of 120 degrees with a phase angle of 30 degrees with the sea component discharge holes 4 on the virtual circumferential line C1.

  Here, in the case of R7> R1 · cos (60 [degrees]) in the expression (3) (in the case of n = 3), the island arranged on the virtual circumferential line C7 with the virtual center O as the center The island component polymer discharged from the component discharge hole 1 and the island component polymer discharged from the island component discharge hole 1 disposed on the virtual circumferential line C7 centered on the virtual group center P may occur. is there. Further, if R7 in the formula (3) is reduced, the merging of the island component polymers as described above can be suppressed, but on the other hand, the degree of irregularity of the cross-sectional shape of the obtained island component is reduced. R7 may be determined according to the above. Here, as a lower limit for reducing R7, when the radius r of the island component discharge hole 1 is set, it is preferable that R7 ≧ √3 · r. Y-shaped cross-section yarn can be obtained.

  As a feature of the hole arrangement pattern that becomes the Y-shaped cross-section yarn, the island component polymer ratio can be increased, and even at a high island ratio of 70% or more, there is no merging of the island component polymers, and the island component is uniform. A fiber having a cross section can be obtained. Furthermore, since a large number of islands can be arranged and the island packing density can be increased, it is suitable for obtaining a composite fiber called nanofiber, which has a fiber diameter of nanosize.

Next, as an arrangement in which the island component has a cross-section, as shown in FIG. This is because the four island component discharge holes 1 arranged on the virtual circumference line C7 having the radius R7 with the virtual center O as the center are 45 degrees with the sea component discharge hole 4 on the virtual circumference line C1. And having four island component discharge holes 1 arranged on a virtual circumferential line C7 having a radius R7 centered on the virtual group center P, and equally divided at a central angle of 90 degrees. It has an upper sea component discharge hole 4 and a phase angle of 45 degrees, and is equally divided at a central angle of 90 degrees. The feature of the hole arrangement pattern serving as the cross-section thread is that the island component is ejected on the virtual circumferential line C7 centered on the virtual center O so as to satisfy Expression (5), which is a condition narrower than Expression (3). The sea component discharge hole 4 on the virtual circumferential line C1 is arranged between the hole group of the hole 1 and the hole group of the island component discharge hole 1 on the virtual circumference line C7 centered on the virtual group center P. That is.
(5) R7 ≦ R1 / 2 Formula (5)
The lower limit for reducing R7 is preferably R7 ≧ 1.5 · √2 · r when the radius r of the island component discharge hole 1 is set. With such an arrangement, the hole group of the four island component discharge holes 1 on the virtual circumferential line C7 centered on the virtual center O and the virtual circumferential line C7 centered on the virtual group center P The island component polymers discharged from the group of four island component discharge holes 1 are prevented from joining each other, and in particular, when the island component polymer ratio is 50% or more, a fiber having a high profile (cross section) is obtained. be able to.

  As described above, as the number of n increases to 3 and 4, the range of the radius R7 of the virtual circumferential line C7 becomes narrower than the radius R1 of the virtual circumferential line C1. In addition, the present inventors have found a range of R7 that can achieve a cross-sectional form with a high degree of irregularity at a high island component polymer ratio while preventing the island component polymers from joining together.

  Further, as shown in FIG. 17, in the plurality of stacked distribution plates 6, the number of distribution holes 7 formed in the distribution plate 6 is configured to increase toward the downstream side in the polymer spinning path direction. The distribution plate 6 in which the distribution holes 7 for guiding the polymer in the direction of the polymer spinning path are formed, and the distribution plate 6 in which the distribution grooves 8 for guiding the polymer in the direction perpendicular to the direction of the polymer spinning path are formed. Distributing grooves 8 are formed so as to communicate alternately with the distribution holes 7 positioned upstream in the polymer spinning path direction and the distribution holes 7 positioned downstream in the polymer spinning path direction. ing.

  Therefore, a single distribution groove 8 that communicates with a single distribution hole 7 at a position downstream in the polymer spinning path direction is formed, and a plurality of distribution grooves 8 that communicate with the end of the distribution groove 8 (in FIG. 17). A flow path for a tournament-type polymer constituting the two distribution holes 7 is formed.

  In this tournament type polymer flow path, the path length from the distribution hole 7 of the distribution plate 6 located at the upper end of the polymer spinning path direction or the distribution groove 8 to the island component discharge hole 1 of the lowermost distribution plate 5 is as follows. Are equal. In each of the stacked distribution plates 6, each distribution plate 6 has a structure in which the hole diameter of the distribution hole 7, the groove width, the groove depth, and the groove length of the distribution groove 8 are equal. In this case, as the number of tournament flow paths decreases toward the upstream side in the direction of the polymer spinning path, the flow rate of the polymer passing through the distribution grooves 8 and the distribution holes 7 sequentially increases, and the flow path pressure loss increases. Accordingly, it is preferable to increase the diameter of the distribution hole 7, the width of the distribution groove 8, and the depth of the distribution groove in order to suppress the increase in flow path pressure loss. Also, as shown in FIG. 17, a two-branch tournament type polymer flow path in which one distribution groove 8 communicates with two distribution holes 7 on the downstream side in the polymer spinning path direction is preferable. However, this is not a limitation. When the distribution groove 8 communicates with two or more distribution holes 7 (in the case of a tournament type flow path having two or more branches), the distribution holes 7 on the downstream side are distributed from the distribution holes 7 on the upstream side in the polymer spinning path direction. It is preferable that the flow path pressure loss of the flow path of each polymer is equalized by equalizing the groove length, groove width, and groove depth of the distribution groove 8 that reaches the center. Further, disposing the distribution hole 7 at the end of the distribution groove 8 eliminates the abnormal retention of the polymer, has the advantage of high polymer distribution and precise control.

  Here, as a structure for equalizing the flow path pressure loss of the other polymer flow paths, a plurality of polymer flow paths inside the distribution plate 6 formed by the distribution holes 7 and the distribution grooves 8 can be used. It is mentioned that the diameter of the distribution hole 6 in the path having a relatively long polymer flow path from the upper end to the lowermost layer distribution plate 5 is larger than the diameter of the distribution hole 6 in the relatively short path. This makes it possible to equalize the flow path pressure loss. Further, as a structure for equalizing the flow path pressure loss of the other polymer flow paths, the hole diameter of the island component discharge hole 1 of the upper layer plate 2 is set to the flow path pressure loss difference in each flow path of the upstream distribution plate 6. The structure which adjusts so that it may become equal is mentioned. Specifically, by increasing the diameter of the island component discharge hole 1 communicating with the flow path having a large flow path pressure loss and reducing the island component discharge hole 1 communicating with the upstream flow path having a small flow path pressure loss, It is possible to equalize the flow path pressure loss.

  Next, each member common to the composite base 18 of the embodiment of the present invention shown in FIG. 1, FIG. 2, FIG. 3, FIG. 4, FIG. Explained.

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

  Moreover, the island component discharge hole 1 in the present invention is not limited to a round cross section in the direction perpendicular to the polymer spinning path direction, and may have a non-round cross section or a hollow cross section. In this case, it is preferable that the shape of the island component discharge holes 1 arranged in the lowermost layer distribution plate 5 is the same. In the case of a shape other than the round cross section, it is easy to obtain a fiber having a deformed cross section by making the island component discharge holes 1 similar in advance so that the island component has a desired shape. In addition, in the irregular cross-section fiber of the island component, it becomes easier to form corners more sharply. (It is easy to reduce the radius of curvature.) However, when the island component discharge hole 1 has a cross-sectional shape other than a round shape, a round cross-sectional distribution hole 7 is arranged in communication with the island component discharge hole 1 immediately above the circular cross-section. It is preferable to discharge the polymer through the island component discharge holes 1 having a cross-sectional shape other than the round shape after securing the polymer meterability through the distribution holes 7.

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

  Further, the reduction hole 12 in the present invention can reduce the size of the composite base 18 by setting the reduction angle α of the flow path from the discharge introduction hole 11 to the base discharge hole 42 in the range of 50 to 90 °, and Instability phenomena such as draw resonance of the composite polymer stream can be suppressed, and the composite polymer stream can be supplied stably.

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

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

  Further, one distribution plate 6 of the present invention may be provided with a distribution hole 7 on the upstream side of the distribution plate 6 and a distribution groove 8 (downstream side) in communication therewith. The distribution groove 8 may be disposed on the upstream side of the distribution plate 6, and the distribution hole 7 (downstream side) may be disposed in communication therewith. In this way, the polymer can be distributed by communicating the distribution hole 7 and the distribution groove 8 and repeating this one or more times.

  Here, the hole filling density of the island component discharge holes 1 of the lowermost layer distribution plate 5 is increased, that is, the sea component discharge holes 4 on the reference island component discharge holes 1 and the virtual circumferential line C1, or the virtual circumference. The distance between the island component discharge hole 1 on the line C4 and the sea component discharge hole 4 on the virtual circumference line C2, or the island component discharge hole 1 on the virtual circumference line C7 and the sea on the virtual circumference line C1. In order to reduce the distance from the component discharge hole 4, the distribution plate 6 and the lowermost layer distribution plate 5 of the present invention have a laminated structure of thin plates. The distribution holes 7 arranged in the distribution plate 6 distribute the polymer mainly in the polymer spinning path direction, and the distribution groove 8 distributes the polymer mainly in the direction perpendicular to the polymer spinning path direction. By alternately laminating the distribution plate 6 provided with the distribution holes 7 and the distribution plate 6 provided with the distribution grooves 8, the polymer can be distributed freely and easily in the fiber cross-sectional direction. By utilizing this, the island component discharge hole 1 and the sea component discharge hole 4 can be arranged in a very narrow region.

  Next, a method for producing a composite fiber common to the composite base 18 of the embodiment of the present invention shown in FIGS. 1, 2, 3, 4, 5, 6, 18, and 19 will be described in detail. To do.

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

  Moreover, it is preferable to control the discharge rate ratio of the polymer of each component discharged from the island component discharge hole 1 and the sea component discharge hole 4 of the present invention by the discharge amount, the hole diameter, and the number of holes. The range of the discharge speed is as follows. When the discharge speed Va of the island component polymer per single hole and the discharge speed of the sea component polymer are Vb, the ratio (Va / Vb or Vb / Va) is 0.05-20. More preferably, it is in the range of 0.1 to 10, and in this range, the polymer discharged from the lowermost layer distribution plate 5 is formed as a laminar flow through the discharge introduction hole 11 and the reduced hole 12. Therefore, the cross-sectional shape is remarkably stable, and the shape can be maintained with high accuracy.

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

  Next, as a manufacturing method of the distribution plate 6 and the lowermost layer distribution plate 5 of the present invention, a pattern is transferred to a thin plate, which is usually used for processing of electric / electronic parts, and fine processing is performed by chemical processing. Etching is preferred. Here, etching is a processing method that applies a chemical reaction and corrosive action of chemicals such as an etchant to etch a thin plate (dissolution processing / chemical cutting), and masks the required processing shape (necessary) The target processed shape can be obtained with very high accuracy by removing the unnecessary portion with a corrosive agent such as an etching solution. Since this processing method does not require consideration for distortion of the workpiece, the lower limit of the thickness of the workpiece is not limited as compared with the other processing methods described above, and the present invention refers to an extremely thin metal plate. The junction groove 8, the distribution hole 7, the island component discharge hole 1, and the sea component discharge hole 4 can be formed. In addition, since the distribution plate 6 and the lowermost layer distribution plate 5 manufactured by etching can be reduced in thickness per sheet, the effect on the total thickness of the composite base 18 even if a plurality of sheets are stacked. There is almost no need to newly install another pack member in accordance with the composite fiber having a desired cross-sectional shape. In other words, if only the distribution plate 6 and the lowermost layer distribution plate 5 are exchanged, the cross-sectional shape can be changed. Further, as another manufacturing method, it is possible to use a lathe, machining, press, laser processing, or the like, which is a drill processing or metal precision processing used in conventional base manufacturing. However, since these processes are limited in the lower limit of the thickness of the processed plate from the viewpoint of suppressing distortion of the workpiece, the thickness of the distribution plate 6 is applicable to the composite die of the present invention in which a plurality of distribution plates are laminated. Need to be considered.

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

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

  The sea-island type composite fibers obtained by the composite base of the present invention are two or more different polymers as shown in FIGS. 8 (a), (b), (c), FIGS. 20 (a), (b). In the cross section perpendicular to the fiber axis direction, the sea-island structure (the sea-island structure referred to here is a plurality of island portions composed of the island component polymer 13 and the sea portion composed of the sea component polymer 20). Structure) is formed. In that case, the cross-sectional shape of the island portion is not limited, and the cross-sectional shape of the island portion may be configured by one island component discharge hole 1 as shown in FIG. 1 or FIG. As shown in FIGS. 18 and 19, a cross-sectional shape may be configured by an island component discharge portion 21 in which a plurality of island component discharge holes 1 are gathered. By arranging the holes as shown in FIGS. 1 and 2, a sea-island type composite fiber having a triangular cross section as shown in FIG. 8A can be obtained. Further, by arranging the island component discharge holes 1 and the sea component discharge holes 4 as shown in FIG. 3, a hexagonal cross section as shown in FIG. 8 (b) is obtained, and as shown in FIG. By adopting the hole arrangement, a sea-island type composite fiber having a square cross section as shown in FIG. 8C can be obtained. Further, the hole arrangement as shown in FIG. 18 results in a Y-shaped cross section as shown in FIG. 20A, and the hole arrangement as shown in FIG. 19 results in FIG. 20B. A sea-island type composite fiber having a cross section as shown can be obtained.

  Further, regarding the number of islands obtained using the composite base of the present invention, it is theoretically possible to produce an infinite number of islands within the range allowed by the space, but the practically feasible range is 2 to 2. 10,000 islands is a preferred range. The range for obtaining the superiority of the composite die of the present invention is more preferably 100 to 10,000 islands.

Moreover, in this invention, it is preferable that a hole filling density is 0.5 hole / mm < ² > or more. If the hole filling density is 0.5 hole / mm ² or more, the difference from the conventional composite die technology becomes more clear. In the range studied by the present inventors, the hole filling density could be implemented if it was in the range of 0.5 to 20 holes / mm ² . From the viewpoint of the hole filling density, a range in which the superiority of the composite die of the present invention is obtained is preferably 1 to 20 holes / mm ² .

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

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

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

  Hereinafter, the effects of the composite die of the present embodiment will be specifically described with reference to examples. In Examples 1, 2, 3, and 4 and Comparative Examples 1, 2, 3, and 4, the island component discharge part is configured by one island component discharge hole, and the sea component discharge part is configured by one sea component discharge hole. A sea-island type composite fiber is spun using the lowermost layer distribution plate. In Examples 5 and 6, and Comparative Examples 5, 6, and 7, the island component discharge portion is composed of a plurality of island component discharge holes. Sea-island type composite fibers were spun using a lower layer distribution plate, and whether or not the island component polymers were merged was determined as follows.

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

(2) Multifilament fiber diameter and fiber diameter variation (CV%)
The resulting multifilament composed of ultrafine fibers was embedded with an epoxy resin, frozen with a Reichert FC-4E cryosectioning system, and cut with a Reichert-Nissei ultracut N (ultra microtome) equipped with a diamond knife. The cut surface was photographed at a magnification of 5000 times with a VE-7800 scanning electron microscope (SEM) manufactured by Keyence Corporation. 150 ultra-fine fibers randomly selected from the obtained photos are extracted, all circumscribed circle diameters (fiber diameters) are measured using image processing software (WINROOF), and the average fiber diameter and fiber diameter standard are measured. Deviation was determined. Here, the circumscribed circle refers to the broken line 14 in FIGS. 8A, 20A, and 20B. From these results, the fiber diameter CV% (coefficient of variation) was calculated based on the following formula. All of the above values are measured for each of the three photographs, averaged at the three positions, measured in nm to the first decimal place, and rounded off to the nearest decimal place.

Fiber diameter variation (CV%) = (fiber diameter standard deviation / average fiber diameter) × 100
(3) Deformity and irregularity variation (CV%)
The cross section of the multifilament is photographed by the same method as the fiber diameter and fiber diameter variation described above, and the diameter of the perfect circle circumscribing the cut surface is defined as the circumscribed circle diameter (fiber diameter) from the image. Using the diameter of the circle as the inscribed circle diameter, the degree of irregularity = the circumscribed circle diameter ÷ the inscribed circle diameter was obtained up to the third decimal point, and the figure rounded to the third decimal place was obtained as the irregularity. Here, the inscribed circle refers to the broken line 19 in FIGS. 8A, 20A, and 20B. This extraordinary degree was measured for 150 ultrafine fibers randomly extracted in the same image, and from the average value and standard deviation, irregularity degree variation (CV% (coefficient of variation)) was calculated based on the following formula. Calculated. About this irregularity variation, the second decimal place is rounded off.

Variation in irregularities (CV%) = (standard deviation of irregularities / average value of irregularities) x 100 (%)
(4) Evaluation of cross-sectional shape of ultrafine fiber Using the same method as the fiber diameter and fiber diameter variation described above, a cross section of a multifilament is photographed, and a line segment having two end points in the cross-sectional outline is straight from the image. The number of parts that are The cross section of 150 multifilaments randomly extracted from the target image in the same image was evaluated. About 150 multifilaments, the number of straight portions was counted, and the total sum was divided by the number of multifilaments to calculate the number of straight portions per multifilament, and rounded off to the second decimal place.
Further, a line extended as 22 in FIG. 8A is drawn from the straight line portion existing in the outline of the cross section. The number of intersections of two adjacent lines is counted, the angle is measured, the total of the angles is calculated by dividing by the number of intersections, and the value rounded to the nearest decimal point is 1 The angle of book intersection. The same operation was performed on 150 multifilaments, and the simple number average was taken as the angle of intersection.

(5) Fineness The sea-island type composite fiber is made into a circular knitting, and 99% or more of the readily soluble component is dissolved and removed by immersing it in a 3% by weight aqueous solution of sodium hydroxide (80 ° C. bath ratio 1: 100), and then unraveling. Then, a multifilament made of ultrafine fibers was extracted, the weight of 1 m was measured, and the fineness was calculated by multiplying by 10,000. This was repeated 10 times, and the value obtained by rounding off the second decimal place of the simple average value was defined as the fineness.

(6) Polymer melt viscosity The chip-like polymer was adjusted to a moisture content of 200 ppm or less by a vacuum dryer, and the melt speed was measured stepwise by a Capillograph 1B manufactured by Toyo Seiki Co., Ltd. The measurement temperature is the same as the spinning temperature, and the melt viscosity of 1216 s ⁻¹ is described in the examples or comparative examples. By the way, it took 5 minutes from putting the sample into the heating furnace to starting the measurement, and the measurement was performed in a nitrogen atmosphere.
[Example 1]
Polyethylene terephthalate (PET melt viscosity: 120 Pa · s) with an intrinsic viscosity (IV) of 0.63 dl / g as an island component, and 5.0 mol% of 5-sodium sulfoisophthalic acid with an IV of 0.58 dl / g as a sea component polymer Copolymerized PET (copolymerized PET melt viscosity: 140 Pa · s) is melted separately at 290 ° C., weighed, and flowed into a spin pack incorporating the composite die of this embodiment shown in FIG. A sea-island composite polymer stream was discharged from the hole. In the lowermost layer distribution plate, 1000 island component discharge holes are perforated at regular intervals for one discharge introduction hole for the island component polymer. The sea-island ratio is 50/50, and the discharged composite polymer stream is cooled and solidified, then applied with oil, wound at a spinning speed of 1500 m / min, and unstretched with 150 dtex-15 filament (single hole discharge rate 2.25 g / min) Fiber was collected. The wound unstretched fiber is stretched 3.0 times between rollers heated to 90 ° C. and 130 ° C. to obtain a sea-island type composite fiber of 50 dtex-15 filaments, and 99% or more of sea components are dissolved by the method described above. 15,000 multifilaments were collected.

Here, in the composite base used in Example 1, the distribution plate in which the distribution holes are perforated and the distribution plate in which the distribution grooves are perforated are alternately laminated, and the lowermost layer as shown in FIG. Distribution plates are stacked. The distribution plate is perforated with a thickness of 0.1 mm, a hole diameter of 0.2 mm, a groove width of 0.3 mm, a groove depth of 0.1 mm, and a minimum hole pitch of 0.4 mm. And the thickness 0.1mm of the lowermost layer distribution plate, the hole diameter 0.2mm of the island component discharge hole, and the sea component discharge hole, the radius R1 of the virtual circumferential line C1 is 0.4mm, and the virtual circumferential line C2 The radius R2 is 0.8 mm, the radius R4 of the virtual circumference C4 is 0.693 mm, and the holes are drilled so as to satisfy the condition (2). As shown in Table 1, the island component has a triangular cross-section (three straight portions at an intersection angle of 60 °), the island component polymers do not merge with each other, the fiber diameter variation is 4.6%, the degree of deformity is 1.9, and the shape is irregular. The variation was 4.5%, and the fiber diameter of this multifilament was 537 nm.
[Example 2]
As shown in FIG. 2, the island component polymer is formed using the same composite die as in Example 1 except that the arrangement of the island component discharge holes and the sea component discharge holes of the lowermost layer distribution plate is changed to the condition (2). The ratio was larger than that of Example 1 (sea / island ratio was 20/80). Otherwise, spinning was performed under the same polymer, equivalent fineness and spinning conditions as in Example 1, and 13,500 multifilaments were collected.

Here, the composite base used in Example 2 has an island component discharge hole and a sea component discharge hole having a hole diameter of 0.2 mm, a radius R1 of the virtual circumferential line C1 of 0.4 mm, and a virtual circumferential line. A hole is drilled with a radius R2 of C2 of 0.8 mm and a radius R4 of the virtual circumferential line C4 of 0.8 mm. As shown in Table 1, the island component has a triangular cross-section (three straight portions at an intersection angle of 60 °), the island component polymers do not merge with each other, the fiber diameter variation is 5.9%, the degree of deformity is 1.84, and the shape is irregular. The degree of dispersion was 6.3%, and the fiber diameter of this multifilament was 955 nm.
[Example 3]
As shown in FIG. 3, the same composite base as in Example 1 was used except that the arrangement of the island component discharge holes and the sea component discharge holes of the lowermost layer distribution plate was changed to the condition (2), and the sea island ratio 15000 multifilaments were collected by spinning under the same polymer, the same fineness, and the same spinning conditions as in Example 1 except that the ratio was 20/80.

Here, the composite base used in Example 3 has an island component discharge hole and a sea component discharge hole with a hole diameter of 0.2 mm, a radius R1 of the virtual circumferential line C1 of 0.4 mm, and a virtual circumferential line. The C2 radius R2 is 0.8 mm, and the virtual circumference C4 has a radius R4 of 0.693 mm. As shown in Table 1, the island component has a hexagonal cross section (six straight-line portions at an intersection angle of 120 °), there is no merging of the island component polymers, the fiber diameter variation is 5.9%, the degree of deformity is 1.23, The irregularity variation was 3.9%, and the fiber diameter of this multifilament was 488 nm.
[Example 4]
As shown in FIG. 4, the same composite base as in Example 1 was used except that the arrangement of the island component discharge holes and the sea component discharge holes in the lowermost layer distribution plate was changed to the condition (2). The sample was spun under the same polymer, the same fineness, and the same spinning conditions as in Example 1 except that the ratio was changed to 30/70, and 13,000 multifilaments were collected.

Here, the composite base used in Example 4 has an island component discharge hole and a sea component discharge hole with a hole diameter of 0.2 mm, a radius R1 of the virtual circumferential line C1 of 0.4 mm, and a virtual circumferential line. The C2 has a radius R2 of 0.894 mm, and the imaginary circumferential line C4 has a radius R4 of 0.8 mm. As shown in Table 1, the island component has a square cross section (angle of 90 ° at the four straight portions), there is no merging of the island component polymers, the fiber diameter variation is 5.3%, the degree of deformity is 1.71, and the shape is irregular. The degree of variation was 5.6%, and the fiber diameter of this multifilament was 868 nm.
[Example 5]
As shown in FIG. 18, the same composite base as in Example 1 was used except that the arrangement of the island component discharge holes and the sea component discharge holes of the lowermost layer distribution plate was changed, the sea island polymer ratio was 30/70, and the total fineness was 110 dtex. 11,000 multifilaments were collected by spinning under the same polymer and spinning conditions as in Example 1, except for changing to.

Here, the composite base used in Example 5 has a distribution plate thickness of 0.1 mm, a hole diameter of 0.2 mm, a groove width of 0.3 mm, a groove depth of 0.1 mm, and a minimum hole pitch of 0.4 mm. Is perforated. The thickness of the lowermost distribution plate is 0.1 mm, the diameter of the island component discharge hole and the sea component discharge hole is 0.2 mm, the radius R7 on the virtual circumferential line C7 is 0.22 mm, and the virtual circumferential line They are arranged so that the radius R1 on C1 is 0.44 mm and n = 3 in the conditions of the expressions (3) and (4). As shown in Table 2, the island component has a Y-shaped cross section, there is no merging of the island component polymers, the fiber diameter variation is 5.3%, the irregularity degree 2.3, and the irregularity variation 4.5%. The filament diameter was 870 nm.
[Example 6]
As shown in FIG. 19, the arrangement of the island component discharge holes and the sea component discharge holes of the lowermost layer distribution plate is arranged so that n = 4 in the conditions of equations (3), (4), and (5). Otherwise, the same composite die as in Example 1 was used. In the lowermost layer distribution plate, 600 island component discharge holes are formed at regular intervals for one discharge introduction hole for the island component polymer. The sea-island ratio was 50/50, and the total fineness was 110 dtex. Otherwise, spinning was performed under the same polymer and spinning conditions as in Example 1, and 9000 multifilaments were collected. Here, the composite base used in Example 6 has an island component discharge hole and a sea component discharge hole having a hole diameter of 0.2 mm, a radius R7 of the virtual circumferential line C7 is 0.25 mm, and a virtual circumferential line. C1 radius R1 is perforated at 0.5 mm. As shown in Table 2, the island component has a cross section, there is no merging of the island component polymers, the fiber diameter variation is 5.9%, the irregularity degree 2.4, and the irregularity variation 4.4%. The fiber diameter was 710 nm.
[Comparative Example 1]
As shown in FIG. 9, except that the arrangement of the island component discharge holes and the sea component discharge holes of the lowermost layer distribution plate was changed, the same composite base as in Example 1 was used, and the same polymer, sea island ratio, Multifilaments were collected by spinning at the same fineness and spinning conditions.

Here, in the composite base used in Comparative Example 1, three sea component discharge holes are equally arranged at a central angle of 120 degrees on the virtual circumferential line C1, and three sea component discharges are performed on the virtual circumferential line C2. The holes are equally divided at a central angle of 120 degrees, the three island component discharge holes are equally divided at a central angle of 120 degrees on the virtual circumference C4, and the phase angle between the discharge holes disposed at C1 and C2 Is arranged at 60 degrees and the phase angle between the discharge holes arranged at C1 and C4 is 30 degrees. The diameter of the island component discharge hole and the sea component discharge hole is 0.2 mm, the radius R1 of the virtual circumferential line C1 is 0.4 mm, the radius R2 of the virtual circumferential line C2 is 0.8 mm, and the virtual circumferential line The radius R4 of C4 is perforated at 0.4 mm, and R4 is out of the range of the formula (1). As shown in Table 1, the island component polymer merged, and a multifilament having a triangular cross section could not be obtained.
[Comparative Example 2]
As shown in FIG. 10, the same composite base as in Example 2 was used except that the arrangement pattern of the island component discharge holes and the sea component discharge holes in the lowermost layer distribution plate was changed, and the same polymer and sea island ratio as in Example 2 were used. Multifilaments were collected by spinning at the same fineness and spinning conditions.

Here, in the composite base used in Comparative Example 2, four sea component discharge holes are equally arranged at a central angle of 90 degrees on the virtual circumferential line C1, and eight sea component discharges are performed on the virtual circumferential line C2. The four island component discharge holes are equally divided at a central angle of 90 degrees on the virtual circumferential line C4, and the phase angle between the discharge holes arranged at C1 and C2 is 26.6 degrees. The phase angle between the ejection holes arranged at C4 is arranged at 45 degrees. The diameter of the island component discharge hole and the sea component discharge hole is 0.2 mm, the radius R1 of the virtual circumferential line C1 is 0.4 mm, the radius R2 of the virtual circumferential line C2 is 0.894 mm, and the virtual circumferential line C4 has a radius R4 of 0.566 mm, and R4 is out of the range of equation (1). As shown in Table 1, the island component polymer was merged, the fiber diameter variation was 26%, and the irregularity variation was 27%, and a multifilament having a uniform square cross section could not be obtained.
[Comparative Example 3]
As shown in FIG. 11, except that the arrangement of the island component discharge holes and the sea component discharge holes of the lowermost layer distribution plate was changed, the same composite base as in Example 2 was used, and the same polymer, sea island ratio, Multifilaments were collected by spinning at the same fineness and spinning conditions. Here, the hole arrangement in FIG. 11 is devised by the present inventors so that the island component has a parallelogram-shaped cross section as a deformation pattern of a quadrangular cross section. The diameter of the island component discharge hole and the sea component discharge hole is 0.2 mm, the radius R1 of the virtual circumferential line C1 is 0.4 mm, the radius R2 of the virtual circumferential line C2 is 0.566 mm, and the virtual circumferential line C4 A radius R4 is drilled at 0.8 mm, and R4 is out of the range of the formula (1). As shown in Table 1, the island component polymer merged, and a multifilament having a parallelogram cross section could not be obtained.
[Comparative Example 4]
As shown in FIG. 12, the same composite base as in Example 3 was used except that the arrangement pattern of the island component discharge holes and the sea component discharge holes in the lowermost layer distribution plate was changed, and the same polymer and sea island ratio as in Example 3 were used. Multifilaments were collected by spinning at the same fineness and spinning conditions.

Here, in the composite base used in Comparative Example 4, six sea component discharge holes are equally arranged at a central angle of 60 degrees on the virtual circumferential line C1, and six sea component discharges are performed on the virtual circumferential line C2. The holes are arranged at a central angle of 60 degrees, the six island component discharge holes are equally arranged at a central angle of 60 degrees on the virtual circumference C4, and the phase angle between the discharge holes arranged at C1 and C2 is 30. The phase angle between the ejection holes arranged at C1 and C4 is arranged at 0 degree. The diameter of the island component discharge hole and the sea component discharge hole is 0.2 mm, the radius R1 of the virtual circumferential line C1 is 0.4 mm, the radius R2 of the virtual circumferential line C2 is 0.693 mm, and the virtual circumferential line C4 has a radius R4 of 0.8 mm, and R4 is out of the range of equation (1). As shown in Table 1, the island component has a hexagonal cross section (six straight-line portions at an intersection angle of 120 °), there is no merging of the island component polymers, the fiber diameter variation is 5.9%, the degree of deformity is 1.22, Although the irregularity variation was 4.2%, the fiber diameter was 1.4 μm, and nano-order multifilaments could not be obtained.
[Comparative Example 5 and Comparative Example 6]
Next, using the same composite die as in Example 5 except that the ratio of the radius R1 of the virtual circumference C1 and the radius R7 of the virtual circumference C7 is different, the same polymer, equivalent fineness, and spinning as in Example 5 are used. Comparative examples 5 and 6 will be described as comparative examples in which spinning is performed under conditions and the sea-island ratio is changed. Here, the radius R7 on the virtual circumference C7 where the island component discharge holes and the sea component discharge holes are arranged is 0.33 mm, and the radius R1 of the virtual circumference C1 is 0.44 mm. In Comparative Example 5, the sea-island ratio was 30/70, and in Comparative Example 6, the sea-island ratio was 50/50. As shown in Table 2, when the island component polymer ratio was as high as 50% or 70%, the island component polymers joined together, and a Y-shaped cross-section multifilament could not be obtained.
[Comparative Example 7]
Next, using the same composite die as in Example 6 except that the ratio of the radius R1 of the virtual circumference C1 and the radius R7 of the virtual circumference C7 is different, the same polymer, equivalent fineness, and spinning as in Example 6 are used. Comparative example 7 will be described as a comparative example in which spinning is performed under conditions and the sea-island ratio is changed. Here, the radius R7 on the virtual circumference C7 where the island component discharge holes and the sea component discharge holes are arranged is 0.35 mm, and the radius R1 of the virtual circumference C1 is 0.44 mm. The sea-island composite fiber was manufactured with a sea-island ratio of 50/50. As shown in Table 2, merging of island component polymers occurred, and a multifilament having a cross-section could not be obtained.

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

1 Island component discharge hole 2 Virtual circumference line C1
3 virtual circumference line C4
4 Sea component discharge hole 5 Lowermost layer distribution plate 6 Distribution plate 7 Distribution hole 8 Distribution groove 9 Metering plate 10 Discharge plate 11 Discharge introduction hole 12 Reduction hole 13 Island component polymer (island part)
14 circumscribed circle 15 spinning pack 16 spin block 17 cooling device 18 composite base 19 inscribed circle 20 sea component polymer (sea part)
21 island component discharge part 21 intersection 22 extension line 23 virtual circumference line C2
24 Sea component discharge section 25 Discharge hole 27 Radial groove 28 Concentric upper groove 30 Pipe 31 Sea component polymer introduction flow path 32 Island component polymer introduction flow path 33 Upper mouth plate 34 Middle mouth plate 35 Lower mouth plate 40 Sea component polymer distribution chamber 41 Pipe Insertion hole 42 Base discharge hole α Reduction angle L Running section 43 Multi-layer board 44 Dividing board 45 Array board

Claims (5)

A composite base for discharging a composite polymer flow composed of an island component polymer and a sea component polymer, and one or more distribution plates formed with distribution holes and distribution grooves for distributing each polymer component; The distribution plate is located on the downstream side of the polymer spinning path direction, and includes a lowermost layer distribution plate in which a plurality of island component discharge holes and a plurality of sea component discharge holes are formed. The sea component discharge hole disposed on the virtual circumference line C1 having the radius R1 as the center, the sea component discharge hole disposed on the virtual circumference line C2 having the radius R2, and the virtual circumference line having the radius R4 A plurality of hole groups consisting of the island component discharge holes arranged on C4, satisfying the following formula (1), and having any one of the following conditions (2) to (d): .
(1) R2 ≧ R4 ≧ √3 × R1 Formula (1)
(2) Condition a. C1: Three sea component discharge holes are equally distributed at a central angle of 120 degrees
C2: Three sea component discharge holes are equally distributed at a central angle of 120 degrees
C4: Six island component discharge holes are equally divided at a central angle of 60 degrees
θ3: The phase angle between the discharge holes arranged at C1 and C2 is 60 degrees.
θ5: The phase angle between the discharge holes arranged at C1 and C4 is 30 degrees. C1: Three sea component discharge holes are equally distributed at a central angle of 120 degrees
C2: Three sea component discharge holes are equally distributed at a central angle of 120 degrees
C4: Three island component discharge holes are equally distributed at a central angle of 120 degrees
θ3: The phase angle between the discharge holes arranged at C1 and C2 is 60 degrees.
θ5: The phase angle between the discharge holes arranged at C1 and C4 is 0 degree. C1: Six sea component discharge holes are equally distributed at a central angle of 60 degrees
C2: Six sea component discharge holes are equally distributed at a central angle of 60 degrees
C4: Six island component discharge holes are equally divided at a central angle of 60 degrees
θ3: The phase angle between the discharge holes arranged at C1 and C2 is 0 degree
θ5: The phase angle between the discharge holes arranged at C1 and C4 is 30 degrees. Condition d. C1: Four sea component discharge holes are equally divided at a central angle of 90 degrees
C2: Eight sea component discharge holes are arranged
C4: Four island component discharge holes are equally divided at a central angle of 90 degrees
θ3: The phase angle between the discharge holes arranged at C1 and C2 is 26.6 degrees.
θ5: Phase angle between discharge holes arranged at C1 and C4 is 0 degree Satisfy one of the conditions (b) and (d) in (2), and the island component discharge holes are divided into n pieces (n is a natural number of 3 and 4; the same shall apply hereinafter) on the virtual circumferential line C7 having a radius R7. The composite die according to claim 1, which satisfies the following expression (3) and has the following condition (4).
(3) R7 ≦ R1 · cos (180 / n [degree])
(4) C7: n island component discharge holes are equally arranged at a central angle of 360 / n degrees θ6: phase angle between discharge holes arranged at C7 and C1 is 180 / n degrees The composite die according to claim 3, wherein the number of discharge holes n = 4 satisfies the formula (5).
(5) R7 ≦ R1 / 2 The composite die according to any one of claims 1 to 3, wherein a hole filling density of the island component discharge holes is 0.5 hole / mm ² or more. A method for producing a composite fiber, in which melt spinning is performed with a composite spinning machine using the composite die according to any one of claims 1 to 4 at an island component polymer ratio of 50% or more.