JP2016108672A - Composite spinneret and composite fiber manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a composite spinneret capable of reducing a flow channel pressure loss generated at the composite spinneret and dealing with a large flow of polymer in manufacturing a composite fiber.SOLUTION: A composite spinneret discharges a composite polymer consisting of a first component polymer and a second component polymer. A flow channel of the first component polymer and a flow channel of the second component polymer curve at a section between adjacent branch points in each flow channel and are integrated in a lower stream.SELECTED DRAWING: Figure 1

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.

  The composite fiber includes a core-sheath type, a side-by-side type, and a sea-island type obtained by using a composite die, and an alloy type obtained by melt-kneading polymers. 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, the core-sheath type has a core component covered with a sheath component, so that it can provide a sensory effect such as a texture and bulkiness that cannot be achieved with a single fiber, and mechanical properties such as strength, elastic modulus, and wear resistance. It becomes possible. 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.

  In recent years, fibers that are core-sheath type or side-by-side type have been created for each single yarn, although they are sea-island type ultrafine fibers. Furthermore, by making the core component and the sea component the same component, or by making the core component, the sheath component and the sea component different from each other (the core component and the sea component are soluble polymers), The type of ultrafine fibers has also been created.

  In manufacturing sea-island type composite fibers, a composite base has been proposed that can form various fiber cross-sectional shapes with high accuracy and maintain high dimensional stability of the cross-sectional shapes (for example, Patent Document 1).

  The composite base is located on the downstream side of the distribution plate in the direction of the polymer spinning path of one or more distribution plates in which distribution holes and / or distribution grooves for distributing each polymer component are formed. It is comprised by the lowermost layer distribution plate in which the island component discharge part and the several sea component discharge part were formed. Moreover, each island component discharge part is comprised by the 1 or more island component discharge hole for discharging an island component polymer, and each sea component discharge part is 1 or more for discharging a sea component polymer. It consists of sea component discharge holes. At least a part of the sea component discharge portion exists in a region surrounded by two island component discharge portions adjacent at the shortest center distance and two common circumscribing lines of the two island component discharge portions. Is described.

JP 2011-208313 A

  However, the composite die described in Patent Document 1 can be manufactured at a low cost, and while increasing the hole filling density of the discharge holes of the island component polymer, it prevents the island component polymers from joining together, thereby increasing the variety of fiber cross-sectional forms. It has a characteristic that it can be accurately formed and the dimensional stability of this cross-sectional shape can be maintained high, but because it is composed of a laminate of thin plates, the flow path pressure loss that occurs in the composite die is large, and a high flow rate polymer It may not be possible to respond. Accordingly, an object of the present invention is to provide a composite die that can reduce flow path pressure loss generated in the composite die of each component polymer and can cope with a polymer having a large flow rate.

The composite base of the first embodiment of the present invention that solves the above problems is
A composite base for discharging a composite polymer stream constituted by a first component polymer and a second component polymer,
A first component polymer flow path for flowing the first component polymer and a second component polymer flow path for flowing the second component polymer are formed;
The first component polymer flow path and / or the second component polymer flow path are branched toward the downstream side in the polymer spinning path direction;
The first component polymer flow path and / or the second component polymer flow path is curved between adjacent branch points in each flow path;
One or a plurality of first component polymer channels and one or a plurality of second component polymer channels are integrated at the most downstream side in the polymer spinning path direction.

  The composite die according to the first aspect of the present invention is a branch point where the shape of the flow path when the first component polymer flow path and / or the second component polymer flow path is observed from the direction of the polymer spinning path is adjacent to each flow path. It is preferable that it is curved between the branch point.

Moreover, the composite base of the second embodiment of the present invention that solves the above problems is
A composite base for discharging a composite polymer stream constituted by a first component polymer and a second component polymer,
A first component polymer flow path for flowing the first component polymer and a second component polymer flow path for flowing the second component polymer are formed;
The first component polymer flow path and / or the second component polymer flow path are branched toward the downstream side in the polymer spinning path direction;
The first component polymer flow path and / or the second component polymer flow path is bent at an angle greater than 90 degrees at each of two or more points between the branch points adjacent to each other in the flow paths;
The one or more first component polymer channels and the one or more second component polymer channels are united at the most downstream side of the polymer spinning path.

  The composite die according to the second aspect of the present invention is a branch point in which the shape of the flow path when the first component polymer flow path and / or the second component polymer flow path is observed from the direction of the polymer spinning path is adjacent to each flow path. It is preferable to bend at an angle greater than 90 degrees at each of two or more locations between the branch points.

  The method for producing a conjugate fiber of the present invention is a method of producing a conjugate fiber by a conjugate spinning machine using the conjugate die of the present invention.

In the present invention, the “polymer spinning path direction” refers to the main direction in which each component polymer flows from the measuring plate to the die discharge hole of the discharge plate.
In the present invention, “a branch point and a branch point adjacent to each flow path” means that the first component polymer flow path and the second component polymer flow path communicate with each other in the polymer spinning path direction and branch from upstream to downstream. In this flow path, the closest upstream branch point and the downstream branch point are referred to.
In the present invention, the “branch point” refers to a branch point of a flow path in which the upstream flow path is divided into a plurality of downstream streams in the first component polymer flow path and the second component polymer flow path. .

  According to the composite die of the present invention, the flow path pressure loss generated in the composite die can be reduced while expanding the hole filling density of the discharge holes of each component polymer, and it is possible to deal with a polymer having a large flow rate. Moreover, various fiber cross-sectional forms can be formed by using the composite die of the present invention.

It is a general | schematic fragmentary sectional view of the distribution plate used for embodiment of this invention. It is the elements on larger scale seen from the polymer spinning path | route direction of the distribution plate used for 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 a XX arrow line view of FIG. It is a general | schematic fragmentary sectional view of the distribution plate of a prior art example.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. 3 is a schematic cross-sectional view of a composite base used in an embodiment of the present invention, FIG. 5 is a view taken along the line XX of FIG. 3, and FIG. 1 is a schematic of a distribution plate which is a part of FIG. 2 is a partial cross-sectional view, FIG. 2 is a partially enlarged plan view of a distribution plate that is a part of FIG. 3, and FIG. 4 is a schematic view of the periphery of a composite base, a spin pack, and a cooling device used in an embodiment of the present invention. It is sectional drawing. 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. In addition, the composite die of the present invention actually has two polymer channels (first component polymer channel 3 and second component polymer channel 4) of the first component polymer and the second component polymer. However, in order to simplify the explanation, only one component polymer flow path will be explained.

  First, the present invention is also the most important point, the hole filling density of the composite die 18 (hole filling density is a value obtained by dividing the number of discharge holes 5 by the cross-sectional area of the composite die 18; The principle that the flow path pressure loss generated in the composite nozzle can be reduced even with a large flow rate polymer while increasing the value of the cross-section of the composite fiber to allow for multi-island or diversification is possible.

  Here, in order to increase the hole filling density of the composite base 18, fine flow paths are formed in the distribution plate 6 arranged in the composite base 18 with a narrow pitch, and the discharge holes 5 communicating with the flow path are formed with a narrow inter-hole pitch. It is necessary to arrange at.

  Etching is known as a manufacturing method for this fine flow path, and it is usually used for processing electrical and electronic parts. The pattern is transferred to a thin plate and chemically processed. Is to be applied.

  As a feature of this processing, since it is not necessary to consider the distortion of the workpiece, there is no restriction on the lower limit of the thickness of the workpiece, and the joining groove 8 and the distribution hole 7 can be formed in an extremely thin metal plate. It becomes possible. Further, the groove width of the distribution groove 8 that can be manufactured, the hole diameter of the distribution hole 7, and the groove / inter-hole pitch are determined by the thickness of the metal material, and the groove width, hole diameter, groove It becomes possible to drill to the distance between the grooves (holes / holes) (for example, when the metal plate thickness is 0.1 mm, the hole diameter is 0.1 mm, the groove width is 0.1 mm, and the groove-groove distance is 0.1 mm) Can be processed).

  In order to form a fine flow path using this etching process, after making fine grooves and holes in a very thin metal plate with a pitch between narrow grooves / grooves (holes / holes), It is preferable to laminate a plurality of them.

  The flow path structure formed in this case will be described. As shown in FIG. 6, in the plurality of stacked distribution plates 6 (the above metal plates), the distribution holes 7 (the above holes) formed in the distribution plate 6 are located downstream in the polymer spinning path direction. The distribution plate 6 is formed so as to increase in the opposite direction, and the distribution holes 7 for guiding the polymer in the direction of the polymer spinning path are formed, and the distribution groove 8 for guiding the polymer in the direction perpendicular to the direction of the polymer spinning path Distribution plates 6 formed with grooves) are alternately stacked, and distribution holes 7 located on the upstream side in the polymer spinning path direction, and distribution holes 7 located on the downstream side in the polymer spinning path direction, The distribution grooves 8 are formed so as to communicate with each other. Therefore, a single distribution groove 8 that communicates with a single distribution hole 7 at a position downstream in the direction of the polymer spinning path is formed, and a plurality of distribution grooves 8 that communicate with the end of the distribution groove 8 (in FIG. 6). A two-channel distribution hole 7 is formed for a tournament-type polymer flow path. In this case, the junction between the distribution hole 7 arranged on the upstream side and the distribution groove 8 arranged on the downstream side becomes a branching point 14, and the polymer is finely divided toward the downstream in the polymer spinning path direction. And the hole filling density of the discharge holes 5 of the distribution plate 6 arranged on the most downstream side can be increased to the limit.

  However, if this method is adopted, the flow path is formed only in the direction of the polymer spinning path (stacking direction of the distribution plate 6) or in the direction perpendicular to the direction of the polymer spinning path (surface direction of the distribution plate 6). I can't. Therefore, in order to form a flow path that finely divides the polymer from upstream to downstream, only a step-like flow path bent at 90 degrees can be formed, and the flow path length is inevitably long, That is, the flow path pressure loss increases.

  In addition, since the distribution plate 6 having a very thin plate thickness is employed to produce a fine flow path, the groove height of the distribution groove 8 cannot be made larger than the plate thickness of the distribution plate 6. The flow path pressure loss during passage inevitably increases. In addition, there is a method of expanding the groove width when the groove height cannot be increased, but in this case, the number of distribution grooves 8 that can be manufactured is reduced, and as a result, the discharge hole disposed at the most downstream side. The number of 5 decreases, and the hole packing density cannot be increased. Further, since the influence of the groove height with the narrow gap is larger than the groove width, the expansion of the groove width is limited in the flow path pressure loss. In particular, when the flow rate of the polymer supplied to the composite base 18 is large, the flow path pressure loss becomes extremely large, the composite base 18 bends, and it becomes difficult to divide into fine polymers.

  Therefore, it is an extremely important technique to produce fibers having various fiber cross-sectional shapes by expanding the hole packing density, reducing the flow path pressure loss generated in the composite die, and corresponding to a high flow rate polymer. . 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, as shown in FIG. 1, the composite base 18 according to the embodiment of the present invention is formed with a first component polymer flow channel and a second component polymer flow channel as observed from a direction perpendicular to the polymer spinning path direction. (Hereinafter referred to as a polymer flow path for simplification of explanation), and the number of the polymer flow paths becomes plural (two in FIG. 1) at the branch point 14 toward the downstream side in the polymer spinning path direction. It is branched and a tournament type flow path is formed. And this polymer flow path is curved between the branch point adjacent to each flow path, in other words, between the branch point 14 located on the upstream side and the branch point 14 located on the downstream side. Yes. Therefore, this polymer flow path finally communicates with the discharge hole 5 which is the most downstream of the distribution plate, and is integrated with the discharge introduction hole 11 which is the most downstream in the polymer spinning path direction.

  The first component polymer and the second component polymer supplied to the distribution plate 6 pass through the respective polymer flow paths formed in the tournament system, and are divided into a plurality of polymer streams each time they pass through the branch points 14. . Then, after the divided polymers are discharged from the discharge holes 5, they merge at the discharge introduction holes 11 to form a composite polymer flow.

  In this case, since the polymer flow path is curved between the adjacent branch points 14, the length of the flow path can be shortened compared to a conventional step-shaped flow path. It is possible to reduce the flow path pressure loss. When hundreds to hundreds of thousands of channels are formed as fine channels on the distribution plate 6, the first component polymer channel 3 and the second component polymer channel 4 are completely separated. In addition, since the discharge holes 5 communicating with the first component polymer flow path 3 and the second polymer flow path 4 are adjacent to each other and arranged in a mixed state, a staircase is formed between the branch point 14 and the branch point 14. It is impossible to form a continuous flow path only with the flow paths connected in a shape.

Therefore, by using the curved polymer flow path of the present invention, interference between the polymer flow paths can be avoided freely, and a composite polymer flow path can be formed. By utilizing this, it becomes possible to concentrate the discharge holes 5 in an extremely narrow region, and as a result, composite fibers having various cross sections can be obtained. In addition, although it demonstrated in 2 components of a 1st component polymer and a 2nd component polymer, the composite nozzle | cap | die 18 of this invention is applicable not only to 2 components but to a polymer more than 3 components. . (The above polymer flow path may be a third component polymer flow path)
As another embodiment of the present invention, as shown in FIG. 2, the polymer flow path is observed between the branch points 14 adjacent to each other in the flow paths when observed from the direction of the polymer spinning path. It may be curved, and the interference between the polymer flow paths can be avoided as described above.

  Further, as another embodiment of the present invention, the flow path may be bent at an angle larger than 90 degrees at each of two or more points between the branch points 14. The flow path between the bent portions may be straight or slightly curved. In this way, the flow path between the branch point 14 and the branch point 14 is bent a plurality of times at an angle larger than 90 degrees so that the flow path between the branch point 14 and the branch point 14 is curved as a whole. It can be. Also in this embodiment, the polymer channel is observed from the direction of the polymer spinning path, and is at an angle greater than 90 degrees at each of two or more points between the branch points 14 adjacent to each other in each channel. It may be bent.

  As a manufacturing method of the curved fine flow path used in the present invention, it is preferable to use an additive manufacturing method. The additive manufacturing methods that can be applied to metals can be broadly divided into the Fused Deposition Molding method and the Direct Metal Deposition method. The former (Thermolytic lamination method) uses metal powder. It is possible to form three-dimensionally by laying in layers and sintering directly with a laser. The latter (directed energy deposition method) can be formed by spraying molten metal with a high-power laser. These can be used for different purposes. As a feature of this processing method, a metal plate material (distribution plate 6) having a polymer flow path is manufactured from scratch using the above-described method, so that not only a straight flow path but also a three-dimensional shape. It is possible to freely manufacture a polymer flow path bent in a straight line.

  Next, each member and the shape of each member common to the composite base 18 of the embodiment of the present invention shown in FIGS. 1, 2, 3, 4, and 5 will be described in detail.

  The composite base 18 in the present invention is not limited to a circular shape, and may be a quadrangle or a polygon. Further, the arrangement of the base discharge holes 7 in the composite base 18 may be appropriately determined according to the number of composite fibers, the number of yarns, and the cooling device 17. The cross section of the nozzle discharge hole 7 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, when the cross-sectional shape other than the round shape is used, it is preferable to increase the length of the die discharge hole 7 in order to ensure the meterability of the polymer.

  In addition, the first polymer flow channel, the second polymer flow channel, and the discharge hole 5 in the present invention are not limited to a round shape in cross section, and may have an irregular cross sectional shape other than a round shape. The said composite form may be sufficient. In addition, the cross-sectional areas of the first polymer flow path and the second polymer flow path are preferably constant in the polymer flow direction between the branch points 14 and 14, but the cross-sectional areas gradually decrease or increase, Alternatively, it may be gradually decreased and gradually increased. In this invention, since it processes mainly using the layered manufacturing method, it becomes possible to change a cross-sectional shape and a cross-sectional area easily.

  In addition, the discharge introduction hole 11 and the contraction hole 12 of the present invention are not limited to a round shape in cross section perpendicular to the polymer spinning path direction, and may have an irregular cross section shape other than a round shape. However, in consideration of the flow stability of the composite polymer flow, it is preferable that the discharge introduction hole 11, the contracted flow hole 12, and the base discharge hole 7 are similar.

  In addition, the distribution plate 6 of the present invention may be integrated, or a plurality of the distribution plates 6 may be stacked. In addition, the first component polymer flow path 3 and / or the second component polymer flow path is located above, below, or in the middle (in the middle of the plurality of distribution plates 6) of the distribution plate 6 of the present invention. 4 has another polymer flow channel (for example, a polymer flow channel formed by etching), but the distribution plate 6 may be formed.

  Next, the manufacturing method of the composite fiber common to the composite nozzle | cap | die 18 of embodiment of this invention shown in FIG.1, FIG.2, FIG.3, FIG.4 and FIG. 5 is demonstrated in detail. The composite fiber manufacturing method of the present invention may be a known composite spinning machine using the composite base 18 of the present invention. In melt spinning, in order to produce a core-sheath type composite fiber, one of the first component polymer and the second component polymer may be a core component polymer and the other may be a sheath component polymer. In order to produce a sea-island type composite fiber, one is an island component polymer and the other is a sea component polymer. Moreover, what is necessary is just to select a polymer suitably, when manufacturing composite fibers other than a core-sheath type or a sea-island type.

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

DESCRIPTION OF SYMBOLS 1 1st component polymer 2 Composite polymer 3 1st component polymer flow path 4 2nd component polymer flow path 5 Discharge hole 6 Distribution plate 7 Base discharge hole 8 Distribution groove 9 Measuring plate 10 Discharge plate 11 Discharge introduction hole 12 Reduction hole 13 1st Two-component polymer 14 Branch point 15 Spin pack 16 Spin block 17 Cooling device 18 Composite base

Claims (5)

A composite base for discharging a composite polymer stream constituted by a first component polymer and a second component polymer,
A first component polymer flow path for flowing the first component polymer and a second component polymer flow path for flowing the second component polymer are formed;
The first component polymer flow path and / or the second component polymer flow path is branched toward the downstream side in the polymer spinning path direction;
The first component polymer flow path and / or the second component polymer flow path is curved between adjacent branch points in each flow path;
One or a plurality of the first component polymer flow paths and one or a plurality of the second component polymer flow paths are integrated at the most downstream side in the polymer spinning path direction.   The shape of the flow path when the first component polymer flow path and / or the second component polymer flow path is observed from the direction of the polymer spinning path is curved between adjacent branch points in each flow path. The composite base of claim 1. A composite base for discharging a composite polymer stream constituted by a first component polymer and a second component polymer,
A first component polymer flow path for flowing the first component polymer and a second component polymer flow path for flowing the second component polymer are formed;
The first component polymer flow path and / or the second component polymer flow path is branched toward the downstream side in the polymer spinning path direction;
The first component polymer flow path and / or the second component polymer flow path are bent at an angle greater than 90 degrees at each of two or more points between the branch points adjacent to each other in the flow paths;
One or a plurality of the first component polymer flow paths and one or a plurality of the second component polymer flow paths are integrated at the most downstream side of the polymer spinning path.   The shape of the flow path when the first component polymer flow path and / or the second component polymer flow path is observed from the direction of the polymer spinning path is two or more between the branch points adjacent to each other in each flow path. The composite base according to claim 3, wherein each is bent at an angle greater than 90 degrees.   The manufacturing method of a composite fiber which manufactures a composite fiber with the composite spinning machine using the composite nozzle | cap | die in any one of Claims 1-4.

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