JP6206215B2 - Composite base and composite fiber manufactured using composite base - Google Patents

Description

  The present invention relates to a composite base and a composite fiber manufactured using the composite base.

  Since fibers using thermoplastic polymers such as polyester and polyamide are excellent in mechanical properties and dimensional stability, they are widely used not only for clothing but also for interiors, vehicle interiors, and industrial applications. However, with the diversification of fiber applications, the required characteristics are also diversified, and a technique for imparting sensibility effects such as texture and bulkiness depending on the cross-sectional shape of the fiber has been proposed. Among them, “fiber miniaturization” has a great effect on the properties of the fiber itself and the properties after being formed into a fabric, and is a mainstream technique from the viewpoint of controlling the cross-sectional shape of the fiber.

  For ultrafine fiber, when a single polymer is spun, even if the spinning conditions are highly controlled, the diameter of the obtained fiber is limited to about several μm. The “sea-island type composite spinning method” for obtaining fibers is often used. In this composite spinning method, in the fiber cross section, a plurality of island component polymers consisting of difficultly soluble components are arranged in a sea component polymer consisting of easily soluble components, and after forming a fiber or fiber product, the sea component polymer is removed. In this method, ultrafine fibers made of island component polymers are generated. Furthermore, this composite spinning method can form a highly accurate yarn cross-sectional form uniformly and homogeneously in the running direction of the yarn, and is a technology that is widely used in ultra-fine fibers, particularly microfibers, that are currently industrially produced. is there. Recently, with the advancement of this technology, it has become possible to collect nanofibers with extremely thin dimensions.

  By making the fiber with an extremely thin size, it can be applied to artificial leather, new touch textiles, etc., and can be applied to artificial leather and new touch textiles. Since the spacing is fine, it can be developed as a high-density fabric for sports clothing applications that require 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.

  The above-mentioned sea-island type composite spinning method adopts a method in which two or more kinds of polymers are made into a composite polymer flow in the die and discharged from the same discharge hole. Mainly, a pipe-type die and a distribution-type die are used. The two methods used have become mainstream. In order to stably determine the cross-sectional shape of the yarn, this composite die technique is extremely important, and various proposals have been made conventionally.

  For example, Patent Document 1 discloses a distribution type base as shown in FIG. FIG. 17B is a plan view of the composite base, and FIG. 17A is a partially enlarged plan view of FIG. In the figure, black circle 1 indicates an island component discharge hole for discharging an island component polymer, white circle 4 indicates a sea component discharge hole for discharging a sea component polymer, 5 indicates a lowermost layer distribution plate, and 8 indicates a distribution groove. In Patent Document 1, a plurality of distribution plates are stacked, and distribution grooves 8, island component discharge holes 1, and sea component discharge holes 4 are disposed in the lowermost layer of the distribution plate. The polymer discharged from the discharge holes of the distribution plate on the uppermost layer of the lowermost layer distribution plate 5 is bifurcated by the distribution grooves 8 of the lowermost layer distribution plate 5, and the island component polymer and the sea are divided by the plurality of distribution plates. After the component polymer is distributed in a large number in advance, both component polymers are discharged from the island component discharge hole 1 and the sea component discharge hole 4 of the lowermost layer distribution plate 5, respectively, and are composited immediately after discharge to form a sea-island type composite fiber. Can be obtained.

  Patent Document 2 discloses a pipe-type base as shown in FIG. FIG. 18 is a schematic cross-sectional view of a composite base, in which 21 is a pipe, 22 is a sea polymer introduction flow path, 23 is an island polymer introduction flow path, 24 is an upper base plate, 25 is a middle base plate, and 26 is a bottom. A base plate, 29 is a sea component polymer distribution chamber, 30 is a pipe insertion hole, and 31 is a base discharge hole. In Patent Document 2, the sea component polymer is guided from the sea component polymer introduction flow path 22 to the sea component polymer distribution chamber 29 and fills the outer periphery of the pipe 21, whereas the island component polymer is filled with the island component polymer introduction flow. By being guided from the passage 23 to the pipe 21 and discharged from the pipe 21, the polymers of both components merge to form a sea-island composite cross section, and then the composite polymer is discharged from the base discharge hole 31 through the pipe insertion hole 30. Thus, a sea-island type composite fiber can be obtained.

  In the two types of composite die as described above, since the sea component polymer is eluted after melt spinning, from the viewpoint of productivity, the discharge ratio of the polymer is less sea component polymer to be eluted, and the island component polymer “Island ratio increase” is required, and furthermore, “islandization” is required to increase the hole packing density by disposing more island component polymer discharge holes (island component discharge holes 1 or pipes 21). It has been demanded.

  However, as “multi-islandization”, when a large number of island component discharge holes 1 (or pipes 30) of the composite base are arranged, the fiber diameter of the island component that can be arranged in one composite fiber is minimized. If the discharge amount of the island component polymer is set high as “increase in island ratio”, the distance between the island components in one composite fiber becomes extremely small. Therefore, according to the knowledge of the present inventors, in the ultrafine fiber composed of island components obtained after elution of the sea component polymer of this composite fiber, van der Waals force works between the fibers, and a plurality of fibers are Since it aggregates and becomes a bundle shape, the problem that the post-processability after elution processing will deteriorate will arise. In addition, according to the knowledge of the present inventors, if ultrafine fibers such as nanofibers are bundled, there may be cases where performance that should originally be obtained such as soft touch and gas adsorbability may not be exhibited.

  Moreover, in patent document 3, the composite fiber which consists of the island component which consists of a polyester resin, and the sea component which mixed the fluororesin (hardly soluble polymer) is formed, and it is set as the combination of an electrically repulsive polymer. Thus, it has been disclosed that after eluting sea components, bundling and opening of ultrafine fibers can be improved. However, since a polymer alloy is used to disperse and mix the fluororesin in the sea component, the resulting fiber is a mixed fiber in which long fibers (polyester resin) and short fibers (fluororesin) are mixed. It is limited to. In addition, since a polymer alloy is used, there is a case where a mixed fiber having a large fiber diameter variation and a uniform cross-sectional shape cannot be obtained.

  Moreover, patent document 4 is disclosed as a method of forming the mixed fiber which consists of a long fiber. Patent Document 4 is a method of forming a composite fiber in which an island component polymer is a multi-component using a pipe-type base, and FIG. 19A is a schematic cross-sectional view of the composite base of Patent Document 4, FIG. These are sectional drawings of the composite fiber obtained using the composite nozzle | cap | die of Fig.19 (a). Polymers A and B are island component polymers having different components, and polymer C is a sea component polymer. The polymer A is discharged from the supply hole 27 toward the upper end portion 28 of the pipe 21. On the other hand, the polymer B passes through the space 32 partitioned by the hard plate, moves up the annular portion 33, and merges with the flow of the supplied polymer A to form one component flow D. This component flow D and the polymer C supplied to the annular portion 33 through the space 32 partitioned by the hard plate merge to form a composite flow, which is finally discharged as a composite fiber from the die discharge hole 31. The

  However, according to the knowledge of the present inventors, since Patent Document 4 is a technique using a pipe-type base, the pipe thickness is added to produce one island, so the area per one pipe Expands. In particular, the pipe 21 is elongated in order to join the two island component polymers and the sea polymer, and it is necessary to increase the diameter of the pipe 21 in order to improve the strength of the pipe 21. In addition, since the pipe 21 is press-fitted between the hard plates and fixed by welding in the manufacture of the base, a welding allowance is required, and an annular portion 33 for inserting the pipe 21 is further provided. Due to this problem, the gap between the pipes cannot be reduced. For this reason, the pipes 21 cannot be arranged densely per unit area, and it may be difficult to manufacture mixed fibers having a fiber diameter of nano-order. This is because the embodiment described in Patent Document 4 has 28 islands and cannot cope with the number of islands such as hundreds or thousands, and as a result, nanofibers made of multi-component island component polymers. May not be formed. Moreover, since the island polymer A and the island polymer B merge and form one island component as a form of the obtained composite fiber, the island polymer A and the island polymer B become independent after the sea component of the composite fiber is eluted. In some cases, mixed fibers that are present cannot be formed.

JP 7-26420 A Japanese Patent No. 4220640 JP 2012-177212 A Japanese Examined Patent Publication No. 62-25564

  As described above, even when the single yarn diameter of the fiber composed of island components obtained after elution of the sea component of the composite fiber is extremely small in the nano order, the single yarn does not form a bundle, and the composite has excellent openability. Producing fibers is an important elemental technology. As one of the methods for solving this spreadability, Patent Document 3 discloses a method of combining different types of island component polymers to form a mixed fiber of different types of polymers, thereby providing an electric repulsion property and a single yarn. It is known that it can suppress the bundling of fibers and improve the spreadability, but it is limited to mixed fibers combining single fibers of short fibers and long fibers, and this mixed fiber has variations in the distribution of short fibers When there is a large variation in the yarn diameter of the resulting fibers, because there is a part where the electric repulsion force does not occur partially and a sufficient opening effect cannot be obtained, and the long fibers aggregate together There is. For this reason, it becomes impossible to obtain the excellent performance unique to the ultrafine nanofiber as described above. In addition, according to the knowledge of the present inventors, when the composite base of Patent Document 4 is used, a composite fiber combining two island component polymers can be formed, so that the spreadability of the mixed fiber after the elution treatment is improved. Although it is expected, in reality, since the fiber diameter of the mixed fiber is large, an electric repulsive force does not act, and a sufficient opening effect may not be obtained. Therefore, solving the bundling in the ultrafine fiber has an important industrial significance.

  Therefore, the object of the present invention is to increase island packing density of island component discharge holes for discharging island component polymers in a distribution method base for producing sea-island type composite fibers, and to combine island component polymers with each other. Even in the case where the yarn diameter of the fiber comprising the island component obtained after elution is extremely small, the fiber diameter variation is uniform, the fibers do not form a bundle, and the composite fiber has excellent openability And providing a composite base capable of producing the composite fiber.

In order to solve the above-mentioned problems, the composite base of the present invention and the composite base manufactured using the composite base have the following configuration. That is, according to the present invention,
A composite base for discharging a composite polymer stream composed of a sea component polymer and two or more different island component polymers,
One or more distribution plates formed with distribution holes and distribution grooves for distributing each polymer component;
Located on the downstream side of the polymer spinning path direction of the distribution plate, and composed of 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 island component discharge hole is different from the island component discharge hole X that discharges one kind of island component polymer of the two or more different island component polymers, and the island component polymer discharged from the island component discharge hole X. It is composed of island component discharge holes Y that discharge types of island component polymers,
N island component discharge holes Y equally arranged on an imaginary circumferential line C1 having a radius R1 around any island component discharge hole X, and the shortest center distance between the island component discharge holes X M island component discharge holes X that are equally arranged on a virtual circumferential line C2 having a radius R2, and the phase angle between the X and Y island component discharge holes is the following (1). satisfying one of conditions i ~ e, and the sea component discharge hole, characterized in that it is arranged on the virtual circular line C3 which is a radius R3 which satisfies the following equation (2) A composite base is provided.
(1) Condition a: R2 = √n · R1, phase angle 180 ° / 2n, m = 2n (n = 3)
Condition B: “R2 = √n · R1, phase angle 180 ° / 2n, m = 2n” and
“N island component discharge holes Y are arranged at a phase angle of 180 ° / n at an intermediate point between adjacent island component discharge holes X (n = 2)”
Condition C: R2 = √ (n / 2) · R1, phase angle 180 ° / n, m = n (n = 4)
Condition d: “R2 = R1, phase angle 180 ° / n, m = n (n = 3)” or
“R2 = √ (n / 2) · R1, phase angle 180 ° / n, m = n (n = 6)”
Condition E: “R2 = (n / 3) · R1, phase angle 0 °, m = n (n = 6)” or
“R2 = (2n / 3) · R1, phase angles 0 ° and 180 ° / n, m = 2n (n = 3)” or
“R2 = R1, phase angles 120 ° / n and 240 ° / n, m = n (n = 2)”
(2) 0.5 · R1 ≦ R3 <R1.

  According to a preferred embodiment of the present invention, at least a part of the sea component discharge hole is present in a region surrounded by two common circumscribed lines of the island component discharge hole X and the island component discharge hole Y. A composite base is provided.

Moreover, according to the preferable form of this invention, the composite nozzle | cap | die which the total hole filling density of the said island component discharge hole X and the island component discharge hole Y is 0.5 piece / mm < ² > or more is provided.

  Further, according to a preferred embodiment of the present invention, in a composite fiber in which two or more different island components are present in the same fiber cross section, an arbitrary island component serving as a reference is set as the reference center O1, and the reference center O1 is the most. In the imaginary circumference whose radius is the distance R from the center O2 of the adjacent island component, p island centers O3 of a kind different from the island component having the reference center O1 (p is 2, 3). An integer of any of 4, 6) is provided.

  Moreover, according to the preferable form of this invention, the said island component which has the said center O3 is arrange | positioned equally on the said virtual circumference, The composite fiber characterized by the above-mentioned is provided.

  In addition, according to a preferred embodiment of the present invention, any one of the two or more different island components has an outer diameter of 10 to 1000 nm, and the outer diameter variation of the island component is 1 to 20%. A featured composite fiber is provided.

  Further, according to a preferred embodiment of the present invention, there is relatively a potential difference between a charged train of one kind of island component and a charged train of an island component of a type different from the island component. A composite fiber is provided.

  According to a preferred embodiment of the present invention, there is provided a composite fiber characterized in that at least one of the two or more different island components has an irregular shape.

  Further, according to a preferred embodiment of the present invention, in a fiber having a single yarn diameter of 1000 nm or less and two or more types of single yarn having a potential difference in the charge train, 30 single yarns in a cross section of the fiber Among them, there is provided a fiber characterized in that the ratio of two types of single yarns is mixed at a ratio of 20:80 to 80:20.

  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 “imaginary circumferential line C1 of radius R1” is the island component polymer that is closest to the reference island component discharge hole X and is different from the island component polymer discharged from the reference island component discharge hole X. A virtual circumferential line C1 having a radius R1 as a center-to-center distance from the island component discharge hole Y.

  In the present invention, the “imaginary circumferential line C2 having a radius R2” is the closest island component polymer that is closest to the reference island component discharge hole X and is discharged from the reference island component discharge hole X. A virtual circumferential line C2 having a radius R2 that is a distance between the centers of the island component discharge holes X to be discharged.

  In the present invention, the “phase angle” is different from the center point of the reference island component discharge hole X and the island component polymer discharged from the reference island component discharge hole X disposed on the virtual circumference C1. From the line segment connecting the center point of the island component discharge hole Y for discharging the island component polymer, the center point of the island component discharge hole X serving as a reference, and the reference island component discharge hole X disposed on the virtual circumferential line C2 The angle at which the line connecting the center points of the island component discharge holes X that discharge the same island component polymer as the discharged island component polymer intersects, or the center point of the reference island component discharge hole X and the virtual circumference C1 The line connecting the center point of the island component discharge hole Y that discharges the island component polymer different from the island component polymer discharged from the reference island component discharge hole X disposed above, and the reference island component discharge hole The reference is located at the center point of X and the virtual circumference C2. The island component polymer is disposed at the midpoint between the two island component discharge holes X that discharge the same island component polymer as the island component polymer discharged from the island component discharge hole X, and is discharged from the reference island component discharge hole X. Means the angle at which the center point of the island component discharge hole Y that discharges a different island component polymer intersects.

  In the present invention, the “virtual circumferential line C3 having a radius R3” refers to a virtual circumferential line C3 having a radius R3 as the distance between the center points of the sea component ejection hole closest to the reference island component ejection hole.

  In the present invention, “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. The larger the pore packing density, the more the composite fiber is composed of a larger number of island component polymer components.

  In the present invention, the “charging column” is a sequence in which materials that are easily charged on the + (plus) side when two kinds of materials are rubbed are arranged on the upper side and those that are easily charged on the − (minus) side are arranged on the lower side. .

  In the present invention, “unusual shape” means the diameter DB of a circle in contact with all the portions that are convex outward when the cross-sectional shape of the island component is viewed as shown in FIG. A shape in which the value divided by the diameter DA of a circle in contact with all the convex portions toward the inside of the island component (the degree of irregularity = diameter DB ÷ diameter DA) is 1.1 or more.

  According to the composite base capable of producing the conjugate fiber of the present invention, the island filling of the island component discharge holes for discharging the island component polymer is expanded, the island merging between the island component polymers is suppressed, and after elution Even when the yarn diameter of the resulting island component fiber is extremely small, two or more different island component polymers exist in the same composite fiber cross section, and different island component polymers are adjacent to the adjacent island component polymer. Therefore, even if the sea component polymer is eluted, the resulting fibers do not aggregate with each other, and an ultrafine fiber excellent in fiber opening and excellent in fiber cross section can be obtained.

It is sectional drawing which showed the cross-sectional form of the typical composite fiber manufactured with the composite nozzle | cap | die used for the 2nd or 3rd embodiment of this invention. It is a partial expanded sectional view of the composite fiber of FIG. It is a partial expanded sectional view of the typical composite fiber manufactured with the composite nozzle | cap | die used for the 1st Embodiment of this invention. It is a partial expanded sectional view of the typical composite fiber manufactured with the composite nozzle | cap | die used for the 4th Embodiment of this invention. It is a partial expanded sectional view of the typical composite fiber manufactured with the composite nozzle | cap | die used for the 5th Embodiment of this invention. It is a partial expanded sectional view of the typical composite fiber manufactured with the composite nozzle | cap | die used for the 5th Embodiment of this invention. It is a partial expanded sectional view of the typical composite fiber manufactured with the composite nozzle | cap | die used for the 5th Embodiment of this invention. It is a partial expanded sectional view of the typical composite fiber manufactured with the composite nozzle | cap | die used for the 6th 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 in the compound nozzle | cap | die of FIG. It is a general | schematic fragmentary sectional view of the distribution plate used for embodiment of this invention, and a lowermost layer distribution plate. It is a partial expanded sectional view of the compound nozzle | cap | die used for the 1st Embodiment of this invention. It is a partial expanded sectional view of another pattern of a compound mouthpiece used for a 1st embodiment of the present invention. It is a partial expanded sectional view of the compound nozzle | cap | die used for the 2nd Embodiment of this invention. It is the elements on larger scale of another pattern of the composite nozzle | cap | die used for the 3rd Embodiment of this invention. It is a partial expanded sectional view of the compound nozzle | cap | die used for the 4th Embodiment of this invention. It is a partial expanded sectional view of the compound nozzle | cap | die used for the 4th Embodiment of this invention. It is a partial expanded sectional view of the compound nozzle | cap | die used for the 5th Embodiment of this invention. (B) is a top view of the lowermost layer distribution board of the composite nozzle | cap | die of a prior art example, (a) is a partial enlarged plan view of (b). It is a schematic sectional drawing of the composite nozzle | cap | die of a prior art example. (A) is a schematic sectional drawing of the composite nozzle | cap | die of a prior art example, (b) is the schematic diagram which showed the cross-sectional form of the composite fiber manufactured with the composite nozzle | cap | die of (a). It is a partial expanded sectional view of the compound nozzle | cap | die used for embodiment of the comparative example 3. FIG. It is a partial expanded sectional view of the typical composite fiber manufactured with the composite nozzle | cap | die used for the 7th Embodiment of this invention. It is an enlarged view of one island component in Fig.21 (a).

  Hereinafter, embodiments of a composite base and a composite fiber manufactured using the composite base of the present invention will be described in detail with reference to the drawings. FIG. 7 is a schematic cross-sectional view of the composite base used in the embodiment of the present invention, and FIG. 8 is a schematic cross-sectional view of the periphery of the composite base used in the embodiment of the present invention, the spin pack, and the cooling device. FIG. 8 is a view taken along the line XX in the composite base of FIG. 7. Since FIG. 7 is a longitudinal sectional view, there are only two discharge hole groups in which the island component discharge holes 1, the island component discharge holes 2, and the sea component discharge holes 4 are gathered. There are four discharge hole groups as shown in FIG. FIG. 10 is a schematic partial sectional view of a distribution plate and a lowermost layer distribution plate used in the embodiment of the present invention. 12 is a partially enlarged cross-sectional view of the lowermost layer distribution plate of FIG. 9, and FIGS. 11, 13, 14 and 15 are partially enlarged cross-sectional views of a composite base used in another embodiment of the present invention. is there. Note that these are schematic diagrams for accurately transmitting the main points of the present invention, simplifying the drawings, and the composite base of the present invention is not particularly limited, and the number of holes and grooves and the size ratio thereof. These can be changed according to the embodiment.

  As shown in FIG. 8, the composite base 18 used in the embodiment of the present invention is mounted on the spinning pack 15, is fixed in the spin block 16, and the cooling device 17 is configured immediately below the composite base 18. Therefore, after the polymer of two or more components led to the composite base 18 passes through the measuring plate 9, the distribution plate 6, and the lowermost layer distribution plate 5 and is discharged from the base discharge hole 42 of the discharge plate 10, After being cooled by an air flow blown out by the cooling device 17 and given an oil agent, it is wound up as a sea-island composite fiber. In addition, in FIG. 8, 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.

  Further, as shown in FIG. 7, the composite base 18 used in the embodiment of the present invention is formed 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.

  Further, the discharge introduction hole 11 is provided with a certain run-up section from the lower surface of the discharge plate 10 in the direction of the polymer spinning path, so that the flow velocity difference immediately after the island component polymer and the sea component polymer are joined is reduced. The flow can be stabilized. Further, the contraction 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 31 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.

  Further, as shown in FIG. 10, 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. Further, a distribution hole 7 may be formed on one surface of one distribution plate 6 and a distribution groove 8 may be formed on the other surface, and the distribution hole 7 and the distribution groove 8 may communicate with each other. Further, as described above, the distribution hole 7 may be formed through the distribution plate 6, and the distribution groove 8 may be formed through the distribution plate 6. Here, the hole diameters of the island component discharge hole 1, the island component discharge hole 2, and the sea component discharge hole 4 of the lowermost layer distribution plate 5 are preferably in the range of 0.01 to 0.5 mm. It is preferable to be in the range of 0.05 to 0.3 mm.

  First, the island component polymer is obtained after elution of the sea component polymer of the composite fiber while increasing the hole filling density of the island component discharge holes 1 (or 2) for discharging the island component polymer, which is an important point of the present invention. An explanation will be given of the principle by which a composite fiber excellent in spreadability can be formed with high accuracy without the ultrafine fibers being bundled.

  Here, the fiber diameter composed of island components obtained after elution of the sea component polymer of the composite fiber becomes extremely small as “polyislandization” is performed to increase the hole packing density. From the viewpoint of productivity, the polymer discharge rate ratio is preferably “increase in island ratio” in which less sea component polymer is eluted and more island component polymer is used. The distance between island components is extremely small. Therefore, when both “islandization” and “increase in island ratio” are made compatible, van der Waals force works between adjacent ultrafine fibers, and a plurality of fibers aggregate to form a bundle, Deterioration of post-processability after elution treatment and further performance that should be originally obtained such as soft touch and gas adsorbability are not expressed.

  Therefore, even when the hole packing density is increased and the island ratio is high, the ultrafine fiber made of the island component obtained after the elution of the sea component of the composite fiber is not bundled to produce a composite fiber excellent in openability. This is an extremely important technology. Accordingly, 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, the lowermost layer distribution plate 5 according to the embodiment of the present invention is equally distributed on an arbitrary island component discharge hole 1 and an imaginary circumferential line C1 having a radius R1 with the island component discharge hole 1 as the center. The n island component discharge holes 2 for discharging an island component polymer different from the polymer discharged from the component discharge hole 1 and the m island component discharge holes 1 on the virtual circumferential line C2 having the radius R2 are as follows. The sea component discharge hole 4 is disposed on a virtual circumferential line C3 having a radius R3 that satisfies any of the conditions (1) to (e) of (1) and satisfies the following expression (2). Here, equation (2) is calculated by rounding off the third decimal place. In addition, as shown in FIG. 3, the composite fiber obtained by using the arrangement pattern of condition (a) has a triangular arrangement in which different island components are surrounded from three directions around one island component. In addition, as shown in FIG. 2, the composite fiber obtained under conditions b and c has a staggered arrangement in which different island components surround the four islands around one island component. As shown in FIG. 4, the hexagonal arrangement in which different island components are enclosed from six directions around one island component is obtained, and the composite fiber obtained in Condition E is mixed with a triangular arrangement and a hexagonal arrangement as shown in FIG. It will be in the form. 11 and 12, the condition b arrangement pattern is shown in FIG. 13, the condition c arrangement pattern is shown in FIG. 14, the condition d arrangement pattern is shown in FIG. The pattern is shown in FIG.

(1) Condition a: R2 = √n · R1, phase angle 180 ° / 2n, m = 2n (n = 3)
Condition B: “R2 = √n · R1, phase angle 180 ° / 2n, m = 2n” and
“N island component discharge holes Y are arranged at a phase angle of 180 ° / n at an intermediate point between adjacent island component discharge holes 1” (n = 2).
Condition C: R2 = √ (n / 2) · R1, phase angle 180 ° / n, m = n (n = 4)
Condition d: “R2 = R1, phase angle 180 ° / n, m = n (n = 3)” or
“R2 = √ (n / 2) · R1, phase angle 180 ° / n, m = n (n = 6)”
Condition E: “R2 = (n / 3) · R1, phase angle 0 °, m = n (n = 6)” or
“R2 = (2n / 3) · R1, phase angles 0 ° and 180 ° / n, m = 2n (n = 3)” or
“R2 = R1, phase angles 120 ° / n and 240 ° / n, m = n (n = 2)”
(2) 0.5 · R1 ≦ R3 <R1.

  The first arrangement pattern will be described with reference to FIG. When a certain island component discharge hole 1 is used as a reference, three (n = 3) island component discharge holes 2 on the virtual circumference C1 with radius R1 and six on the virtual circumference C2 with radius R2 ( The island component discharge hole 1 of m = 6) is arranged so as to have a phase angle of 30 °, and the sea component discharge hole 4 is satisfied on the virtual circumferential line C3 of radius R3 so as to satisfy the expression (2). Deploy. Here, as shown in FIG. 11, the sea component discharge holes 4 arranged on the virtual circumferential line C3 are arranged in six equality surrounding the island component discharge holes 1 from six directions, as shown in FIG. It is preferable to select appropriately within a range in which island merging does not occur, such as a three-way arrangement surrounding the component discharge holes 1 from three directions.

  By arranging each discharge hole like this, the hole filling density can be increased and the island component polymer ratio can be increased. Even at a high island ratio of 70% or more, the merging of different island component polymers is suppressed. it can. As a result, as shown in FIG. 3, two different types of island components are present close to each other in the same composite fiber cross section, and the center of any island component is defined as the reference center O1, and the island closest to the reference center O1. A composite fiber in which the center O3 of an island component of a type different from the island component having the reference center O1 is equally divided at a central angle of 120 ° within a virtual circumferential line having a radius R from the component center O2. Can be obtained. In this way, because adjacent island components are always different types of island components, in an ultrafine fiber made of island components obtained after elution of sea components, an electrical repulsive force is generated between adjacent fibers. In addition, it is possible to obtain an ultrafine fiber excellent in spreadability without causing the fibers to aggregate with each other. In addition, since different types of island components are uniformly dispersed in the cross section at the stage of the composite fiber, this dispersed state can be maintained even in the mixed fiber after the sea component is eluted. In other words, in an ultrafine fiber that becomes a nanofiber, two types of single yarns having different potential differences are uniformly dispersed in the fiber, so that an electric repulsive force is utilized while maintaining the dispersion state. , Aggregation of fibers can be suppressed. Here, the “center angle” is an island of a kind different from the reference center O1 and the island component having two reference centers O1 adjacent to each other in the circumferential direction, which are respectively arranged on the virtual circumferential line having the radius R. This is the angle at which the line connecting the component center O3 intersects.

  The above principle of the present invention will be explained along the flow form of the polymer. Three polymers, that is, two different island component polymers and sea component polymers, are simultaneously directed toward the discharge introduction holes 11 on the downstream side of the lowermost layer distribution plate 5. Each polymer is widened in a direction perpendicular to the direction of the polymer spinning path while flowing along the direction of the polymer spinning path, and both 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 2 of another component from joining together, the sea component polymer that physically divides the island component polymer. Is effective, and the sea component polymer discharged from the sea component discharge hole 4 on the virtual circumference C3 plays this role.

  Here, in order to increase the hole packing density without different island component polymers joining each other, the radius R3 of the virtual circumferential line C3 is reduced in the conditions (i) to (e) of the above-described formula (1), and the reference The distance between the island component discharge holes 1 and the island component discharge holes 2 may be as close as possible, but in that case, the island component polymer discharged from each hole is widened, and the distance that becomes the limit at which the island component polymers merge with each other The inventor has found that This is because the space between the virtual circumference line C2 and the virtual circumference line C3 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, the sea component discharge holes 4 are arranged so that the island component discharge holes 1 and the island component discharge holes 2 satisfy the condition (1), and the sea adjacent to the reference island component discharge holes 1 is arranged. What is necessary is just to determine radius R3 used as the distance between centers with the component discharge hole 4 so that Formula (2) may be satisfied.

  Here, in the case of R3 <0.5 · R1 in the expression (2), the sea component discharge hole 4 is arranged between the island component discharge holes 2 arranged adjacent to each other on the virtual circumferential line C1. As a result, the island component polymers discharged from the island component discharge holes 2 may join together. Further, in the case of R3 ≧ R1, the sea component discharge hole 4 is not disposed between the reference island component discharge hole 1 and the island component discharge hole 2 disposed on the virtual circumference C1. The island component polymer discharged from the island component discharge hole 1 and the island component discharge hole 2 may be joined together.

  Next, as a different arrangement pattern, the arrangement of the condition (b) in Expression (1) will be described with reference to FIG. Similarly to the condition i, when a certain island component discharge hole 1 is used as a reference, two (n = 2) island component discharge holes 2 and a virtual circumference line of radius R2 on the virtual circumference line C1 of radius R1. Four (n = 4) island component discharge holes 1 are arranged on C2 so as to have a phase angle of 45 °, and adjacent to four (m = 4) island component discharge holes 1 adjacent to each other. The two island component discharge holes 2 are arranged on the midpoint connecting the center points of the two island component discharge holes 1 so that the phase angle is 90 °. The sea component discharge holes 4 are arranged so as to satisfy the expression (2) as in the condition (a).

  As shown in FIG. 2, the composite fiber obtained by arranging each of the discharge holes as described above has the center of any island component as the reference center O1, and the center O2 of the island component closest to the reference center O1. To obtain a composite fiber in which the center O3 of an island component of a different type from the island component having the reference center O1 is equally arranged at a central angle of 90 ° within a virtual circumferential line having a radius R of it can. The feature of the arrangement pattern of condition b is that it can be increased in pore packing density compared to condition i, and is therefore excellent in multi-island formation and, in turn, ultra-thinning. In addition, in the ultrafine fiber obtained after the elution treatment of the composite fiber, the number of single yarns of the two types of island components is the same number, so the charge charged on the entire fiber is not greatly biased, and the spreadability is excellent. .

  Further, as another arrangement pattern for obtaining the conjugate fiber shown in FIG. 2, there is an arrangement of condition (1) as shown in FIG. This is because four island components (n = 4) on the virtual circumferential line C1 having the radius R1 when a certain island component discharge hole 1 is used as a reference, as in the conditions (i) to (b) of the above-described equation (1). Disposing the discharge holes 2 and four (m = 4) island component discharge holes 1 on a virtual circumferential line C2 having a radius R2 so that the phase angle is 45 °, (2) It arrange | positions so that Formula may be satisfied. By adopting such an arrangement of the discharge holes, the interval between the island component discharge holes 1 and the island component discharge holes 2 is shortened as compared with the arrangement pattern of the condition (b) in Equation (1). Since it can be enlarged, it is a more preferable arrangement from the viewpoint of “islanding”.

  Further, as different arrangement patterns, the arrangement of the condition (2) will be described with reference to FIGS. 15 (a) and 15 (b). When a certain island component discharge hole 1 is used as a reference, three (n = 3) island component discharge holes 2 on a virtual circumferential line C1 with a radius R1 and three on a virtual circumference line C2 with a radius R2 ( The island component discharge holes 1 of m = 3) are arranged so that the phase angle is 60 °. Alternatively, when the island component discharge hole 2 is used as a reference, six (n = 6) island component discharge holes 1 on the virtual circumferential line C1 and six (m = 6) islands on the virtual circumferential line C2. The component discharge holes 2 are arranged so that the phase angle is 30 °. In addition, about the sea component discharge hole 4, it arrange | positions so that (2) Formula may be satisfied. Here, FIG. 15A shows a case where an island component discharge hole for discharging one island component polymer is used as a reference, and FIG. 15 shows a case where an island component discharge hole for discharging another different island component polymer is used as a reference. Although shown as b), the arrangement of the holes is the same pattern in all cases. In the case of this arrangement pattern, as shown in FIGS. 15A and 15B, when the reference island component discharge hole is replaced with another island component discharge hole, the number of island component discharge holes and the radii R1 and R2 Although the relational expression and the expression of the phase angle change, the same conditions are shown for the arrangement of the discharge holes.

  With such an arrangement of the discharge holes, the obtained composite fiber has a center O2 of the island component 14 closest to the reference center O1 as a reference center O1 as shown in FIG. To obtain a composite fiber in which the center O3 of an island component of a different type from the island component having the reference center O1 is equally arranged at a central angle of 120 ° in a virtual circumferential line having a radius R of it can. Further, when the reference center O1 is changed to the center of the island component 13, a composite fiber in which the six centers O3 are equally divided at a central angle of 60 ° can be obtained. As a characteristic of the composite fiber obtained by the condition D, since the hole packing density can be maximized among all the arrangements of the conditions i to e, it is excellent in multi-island formation. In addition, since the same island components are adjacent to each other, in the ultrafine fibers obtained after the elution treatment, fibers having different potentials attract each other, and fibers having the same potential rub against each other, thereby generating static electricity. In addition, since the electrical repulsion is increased, the fiber has a feature of excellent fiber openability.

  Further, as a different arrangement pattern, the arrangement of the condition E in the expression (1) will be described with reference to FIG. When a certain island component discharge hole 1 is used as a reference, six (n = 6) island component discharge holes 2 on the virtual circumferential line C1 with the radius R1 and six pieces on the virtual circumference line C2 with the radius R2 ( The island component discharge holes 1 of m = 6) are arranged so that the phase angle is 0 °, and the sea component discharge holes 4 are arranged so as to satisfy the expression (2). In this arrangement pattern, if the reference island component discharge hole is replaced with another island component discharge hole as in the condition (1), the relational expression of the number of island component discharge holes and the radii R1 and R2, The expression of the phase angle changes, and becomes the conditional expression described in (1) or after.

  As shown in FIG. 5 (a), the composite fiber obtained by arranging the discharge holes as described above has the center of any island component 13 as the reference center O1, and the island component closest to the reference center O1. A composite fiber in which a center O3 of an island component of a type different from the island component having the reference center O1 is equally divided at a central angle of 60 ° within a virtual circumferential line having a radius R from the center O2 Can be obtained. In this case, if the island component used as the reference center O1 is changed as in the conjugate fiber shown in FIG. 4, or if the same island component is selected at a different position, the condition of the center O3 changes, and FIG. 5 (b) As shown in FIG. 5, when the island component 14 is the reference center O1, the two centers O3 are composite fibers that are equally arranged at a central angle of 180 °, or the island that is the reference center as shown in FIG. When the component 13 having a position different from that shown in FIG. 5A is selected, a composite fiber in which the three centers O3 are equally arranged at a central angle of 120 ° is obtained, but only the condition of the center O3 is changed. The same composite fibers are shown. A characteristic of the composite fiber obtained by Condition E is that, in the ultrafine fiber obtained after the elution treatment, the ratio of the single yarn of one island component is relatively large among the 30 single yarns in the cross section of the fiber. However, since the two types of single yarns having different potential differences are uniformly dispersed in the fiber, the single yarns do not aggregate with each other, and the characteristics of excellent spreadability can be maintained.

  In the above embodiment, in the obtained composite fiber cross-section, for one island component, the adjacent island components are necessarily arranged so as to be different types of island components, but this is not a limitation. One island component may form an island group composed of a plurality of island components. For example, as shown in FIG. 6, four island components 13 form an island group 19, and similarly four island components 14 form an island group 20, and island groups of different components are formed around one island group. It may be a staggered arrangement that surrounds from four directions. By arrange | positioning in this way, the ultrafine fiber excellent in the openability like the embodiment mentioned above can be obtained. In this case, as the form of the obtained composite fiber, the center of the circumscribed circle of the island group surrounding the island component may be regarded as the center of the island component described above. For example, in FIG. The center O4 of the circle is regarded as the reference center, and is different from the island group having the reference center O4 in a virtual circumferential line having a radius R from the center O5 of the circumscribed circle of the island group closest to the reference center O4. The center O6 of the circumscribed circle of the type of island group is a composite fiber that is equally divided at a central angle of 90 °. In addition, as the number of island components forming the island group, if the island components of the same component increase too much, they are preferably aggregated, so that the number of island components is 6 or less in order to obtain excellent spreadability. More preferably, it is 4 or less. Further, regarding the arrangement of the component discharge holes of the final layer distribution plate 5 for forming this island group, the island component discharge holes for discharging a plurality of adjacent island component polymers are defined as the island component discharge hole group. The component discharge holes may be replaced with island component discharge hole groups and arranged so as to satisfy the conditions of the expression (1). The sea component discharge holes are preferably arranged not only on the virtual circumferential line C3 but also in a range where the island component polymers in the island component discharge hole group do not merge.

  Moreover, in the above embodiment, the case where two different types of island component polymers are discharged as island components has been described. However, when trying to obtain a composite fiber having three different types of island components, In the conditions (i) to (e) of the form (1), the island component that discharges the third different island component polymer to the half of the island component discharge holes 1 and the island component discharge holes 2 that are arranged evenly. What is necessary is just to arrange | position so that it may replace with a discharge hole and may be located in a line on the virtual circumference line C1 or C2.

  The lowermost layer distribution plate 5 of the embodiment of the present invention discharges island component discharge holes 1 for discharging one island component polymer and different island component polymers adjacent to the island component discharge holes 1 at the shortest center distance. It is preferable that each discharge hole is disposed so that at least a part of the sea component discharge hole exists in a region surrounded by two common circumscribing lines with the island component discharge hole 2 to be performed. Specifically, as shown in FIG. 14, island component discharge for discharging a different island component polymer adjacent to the reference island component discharge hole 1 at the shortest center-to-center distance, with reference to a certain island component discharge hole 1. When the hole 2 is used, the region is surrounded by the reference island component discharge hole 1, another component island component discharge hole 2, and the two common circumscribing lines 3 of the two island component discharge holes 1 and 2. In addition, the sea component discharge hole 4 is arranged so that at least a part of the sea component discharge hole 4 exists. By adopting such a configuration, it is possible to reliably prevent the merging of the polymers between the island component discharge holes 1 and the island component discharge holes 2 where the merging of the polymers is most likely to occur.

Moreover, in this invention, it is preferable that the hole filling density which combined the island component discharge hole 1 and the island component discharge hole 2 which are formed in the lowest layer distribution plate 5 is 0.5 piece / mm < ² > or more. When the hole filling density is 0.5 / mm ² or more, the difference from the conventional composite die technique becomes clearer. In the range examined by the present inventors, the hole filling density was 0.5 to 20 holes / mm ² , and it could be carried out. From the viewpoint of the hole filling density, 1.0 to 20 pieces / mm ² is a preferable range for obtaining the superiority of the composite die of the present invention.

  By using the composite base 18 described in the above embodiment, two or more different island components exist in the same fiber cross section, and the most adjacent island component is centered on the center O1 of any arbitrary island component. Two, three, or four centers O3 of island components of a type different from the island component as the reference center O1, in a virtual circumferential line having a radius R between the center O2 and the center O2. Alternatively, it is possible to obtain a composite fiber in which any of the six is arranged. In composite fibers in which island components are arranged in this manner, different types of island components are always present in adjacent island components, so that fibers obtained after elution of sea components are opened without agglomeration of single yarns. A composite fiber excellent in fineness can be obtained. Further, since the geometrically arranged arrangement pattern is such that the island components are close-packed, a composite fiber excellent in multi-island formation can be obtained.

  In addition, the composite fiber obtained by the composite base 18 of the present invention is such that the van der Waals force works between the ultrafine fibers obtained after the elution treatment as the island diameter of the composite fiber becomes nano-order, causing the fibers to aggregate. Is more likely to do. For this reason, the composite base 18 of the present invention is particularly effective when producing a composite fiber having an outer diameter of 10 to 1000 nm and an outer diameter variation of 1 to 20% for any kind of island component in the composite fiber. is there.

  Moreover, in the composite fiber obtained by the composite base 18 of the present invention, as two or more different island components, a charge train of one type of island component and a charge train of an island component of a different type from the island component It is preferable that there is a relative potential difference between the two. Here, since charging is a surface phenomenon, it is affected by sample differences, surface roughness, measurement methods, and environmental conditions. (Edited by Textile Society, Maruzen Co., Ltd.). According to this document, it is described that a polymer having a side chain with a strong electron-donating property is charged to the positive electrode and a polymer having a side chain with a strong electron-accepting property is charged to the negative electrode by combining two substances. . Therefore, in the fiber obtained after the sea component polymer is eluted, the chargeability is different as the material is further away in the charge train, so that it can be opened even if the ultrafine fibers are close to each other due to electric repulsion. it can. In addition, as a combination of island components having a potential difference in the charge train, for example, a combination of polyester and nylon is preferably used. However, the combination is not limited to this as long as it is a combination of island components having the same potential difference. Since the electrical repulsion works more greatly in the above-described combination than in the combination with a small potential difference such as polyester and polypropylene, excellent spreadability can be obtained.

  The fiber obtained by the composite base 18 of the present invention is a nanofiber having a single yarn diameter of 1000 nm or less, and a fiber having two or more types of single yarn having a potential difference in the charge train, and a single fiber having a cross section of the fiber. Of the 30 yarns, the ratio of the two types of single yarns is preferably mixed at a ratio of 20:80 to 80:20. By taking such a fiber form, the single yarns of the same component are not biased as a single yarn group in the cross section of the fiber, and the single yarns of different components are uniformly dispersed. A fiber excellent in openability can be obtained without damage. In addition, as a method of measuring the mixing ratio indicating the ratio of single yarn mixed, for example, in the stage before spinning a composite fiber composed of two different island components, one island component polymer is colored in advance, After the ultrafine fibers obtained after the elution treatment are bundled and hardened with a resin, the cross section of the fibers is observed with a scanning electron microscope or the like for evaluation. Therefore, it is only necessary to randomly select 30 single yarns adjacent to each other, count the number of colored single yarns and the number of uncolored single yarns, and derive the ratio of these single yarns.

  Further, the single yarn cross section of the composite fiber obtained by the composite base 18 of the present invention may be not only a round shape but also an irregular cross sectional shape other than a round shape such as a triangle or a flat shape. In that case, the center of gravity of the island component may be regarded as the center of the island component. 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.

  Further, as shown in FIG. 21A, the cross section of the island component obtained by the composite base 18 of the present invention has a polygonal shape such as a triangle, or an irregular cross section other than a round shape such as a Y shape, a cross shape, or a flat shape. (Cross section in FIG. 21). By making the island component into an irregular cross section, a space is formed between the adjacent island components, and when the sea component is dissolved, it is possible to produce an ultrafine fiber having bulkiness. In addition, when the obtained ultrafine fiber is used as a fabric, it is possible to obtain functions of heat retention, water absorption, and quick drying. In this case, as the composite base, the island component discharge hole 1 (island component discharge hole 2) of the lowermost layer distribution plate 5 shown in FIG. 14 is preliminarily modified so as to have a similar cross section. (For cross-section yarns, the discharge hole has a cross-section shape). Alternatively, a plurality of round island component discharge holes 1 (island component discharge holes 2) may be arranged side by side, and the island component polymer may be merged after being discharged (in the case of a cross-section yarn, the circular island component discharge holes may be discharged). Place the holes in a cross in a row). Here, by arranging a plurality of round island component discharge holes side by side, it becomes possible to form the corners of the obtained irregular cross section more sharply (the radius of curvature can be easily reduced). However, when the island component discharge holes 1 and the island component discharge holes 2 have irregular cross-sectional shapes, a round distribution hole 7 is provided in communication with the island component discharge hole 7 so that the polymer is formed in the round distribution hole 7 immediately above. It is preferable to discharge the polymer through the island component discharge holes 1 and 2 having an irregular cross section after securing the measurement property.

  In FIG. 21A, all types of island components have irregular cross sections, but at least one type of island component may have an irregular cross section. However, it is preferable that all types of island components have irregular cross sections because the functions of heat retention, water absorption, and quick drying are enhanced.

  The following examples will be given to specifically explain the effects of the composite base 18 of the present embodiment.

(1) Precipitation of the island component of the composite fiber In order to deposit the island component from the composite fiber, the composite fiber is immersed and removed in a solution or the like in which the sea component of the easily eluted component can be dissolved. A multifilament 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) Fiber diameter and fiber variation of multifilament The multifilament made of ultrafine fibers obtained was embedded in epoxy resin, frozen with Reichert's FC-4E cryosectioning system, and Reichert-Nissei equipped with a diamond knife. After cutting with ultracut N (ultramicrotome), the cut surface was photographed at a magnification of 5000 times with a VE-7800 scanning electron microscope (SEM) manufactured by Keyence Corporation. 150 ultrafine fibers randomly selected from the obtained photographs were extracted, and all fiber diameters of the photographs were measured using image processing software (WINROOF) to obtain an average fiber diameter and a fiber diameter standard deviation. Further, when the ultrafine fiber had an irregular cross section, the diameter of a circle in contact with all the portions convex toward the outside of the fiber cross sectional shape was calculated as the fiber diameter (fiber diameter DB). From these results, the fiber diameter CV% (coefficient of variation) was calculated based on the following formula. The above values are all 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) Polymer melt viscosity The chip-like polymer was adjusted to a moisture content of 200 ppm or less with a vacuum dryer, and the strain rate was changed stepwise by "Capillograph 1B" manufactured by Toyo Seiki, and the melt viscosity was measured. 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.

(4) Intrinsic viscosity Measured at 25 ° C using orthochlorophenol as a solvent.

  The following evaluation was performed in order to confirm the effect of the spreadability by the two types of island component polymers.

(5) Opening property The following evaluation was performed in order to confirm the effect of opening property of the ultrafine fiber which consists of two types of island components. Using a composite fiber, a Zokki fabric having a warp density of 100 / 2.54 cm and a weft density of 95 / 2.54 cm was prepared and scoured at a temperature of 95 ° C. Subsequently, the sea component was dissolved and removed by the same method as the precipitation of the island component of the composite fiber described above, and the final set was performed through the dyeing process. The fiber surface of this fabric was observed with SEM, qualitatively evaluated in three stages, and after electron staining of the fiber cross section, the ultrafine fiber portion was observed with an H-7100FA transmission electron microscope (TEM) manufactured by Hitachi, Ltd. Overall evaluation. ○ and △ are acceptable and × are unacceptable.
A: There is no aggregation and the aggregated portion of the fibers is 10 μm or less.
(Triangle | delta): There is no aggregation and the aggregate part of a fiber is larger than 10 micrometers and 40 micrometers or less.
X: There exists aggregation and the aggregate part of a fiber is larger than 40 micrometers.

(6) Deformation degree The cross section of the multifilament was photographed by the same method as the fiber diameter and fiber variation described above. From the image, the fiber diameter DB is the diameter of a circle that touches all the portions that are convex toward the outside of the cut surface shape, and further touches all the portions that are convex toward the inside of the cut surface shape. The diameter of the circle was the fiber diameter DA. The degree of irregularity = fiber diameter DB ÷ fiber diameter DA was obtained up to the third digit of the decimal point, and the value rounded to the third decimal place was obtained as the degree of irregularity. This irregularity was measured for 150 ultrafine fibers randomly extracted in the same image, and the average value was calculated.

[Example 1]
As two types of island components having greatly different potential differences in the charge train, polyethylene terephthalate (PET) having a melt viscosity of 120 Pa · s and nylon 6 (N6) having a melt viscosity of 145 Pa · s are used, and a melt viscosity of 140 Pa · s is used as a sea component. Of 5-sodium sulfoisophthalic acid 5.0 mol% of PET (copolymerized PET) was melted separately at 290 ° C. and weighed to incorporate the composite die of this embodiment shown in FIG. It was made to flow into a spinning pack and the sea-island composite polymer flow was discharged from the nozzle discharge hole. 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 form a composite fiber of 50 dtex-15 filaments, and the sea component is dissolved by the above-described method to obtain 12,000 multifilaments Were collected.

Here, in the composite base used in Example 1, a distribution plate in which distribution holes are perforated and a distribution plate in which distribution grooves are perforated are alternately laminated, and as shown in FIG. A lowermost layer distribution plate having the condition (1) is stacked. The lowermost distribution plate has an island component discharge hole and a sea component discharge hole diameter of 0.15 mm, a radius R1 of the virtual circumferential line C1 is 0.647 mm, a radius R2 of the virtual circumferential line C2 is 1.120 mm, a virtual The circumferential line C3 was perforated with a radius of 0.373 mm, and the hole packing density was 0.9 (pieces / mm ² ). As shown in Table 1, the fiber diameter of the multifilament was 656 nm, the fiber diameter variation was 5.3%, the mixture ratio per 30 single yarns was 42/58, and the openability was “◯”.

[Example 2]
As shown in FIG. 13, the same composite base as that of 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 (b) of the formula (1). Spinning was performed under the same polymer as in No. 1, the same fineness, and spinning conditions, and 13500 multifilaments were collected.

Here, the composite base used in Example 2 has an island component discharge hole and a sea component discharge hole with a hole diameter of 0.15 mm, a radius R1 of the virtual circumferential line C1 of 0.647 mm, and a virtual circumferential line. The C2 radius R2 is 0.988 mm, the virtual circumference C3 has a radius R3 of 0.373 mm, and the hole packing density is 1.0 (pieces / mm ² ). As shown in Table 1, the fiber diameter of the multifilament was 591 nm, the fiber diameter variation was 4.8%, the mixture ratio per 30 single yarns was 48/52, and the openability was “◯”.

[Example 3]
As shown in FIG. 14, Example 1 using the same composite base as Example 1 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 (1). 14,000 multifilaments were collected by spinning under the same polymer, fineness and spinning conditions.

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 0.15 mm, a radius R1 of the virtual circumferential line C1 of 0.676 mm, and a virtual circumferential line. The C2 radius R2 is 0.956 mm, the virtual circumference C3 has a radius R3 of 0.366 mm, and the hole packing density is 1.1 (pieces / mm ² ). As shown in Table 1, the fiber diameter of the multifilament was 537 nm, the fiber diameter variation was 4.6%, the mixture ratio per 30 single yarns was 48/52, and the openability was “◯”.

[Example 4]
As shown in FIG. 15, the same composite base as in Example 1 was used except that the arrangement of the island component discharge holes and sea component discharge holes in the lowermost layer distribution plate was changed to the condition (1). Using the same composite die, spinning was carried out under the same polymer, equivalent fineness and spinning conditions as in Example 1, and 17,500 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 0.15 mm, a radius R1 of the virtual circumferential line C1 of 0.647 mm, and a virtual circumferential line. The C2 radius R2 is 1.120 mm, the virtual circumference C3 has a radius R3 of 0.373 mm, and the hole packing density is 1.3 (pieces / mm ² ). As shown in Table 1, the fiber diameter of the multifilament was 454 nm, the fiber diameter variation was 5.9%, the mixture ratio per 30 single yarns was 30/70, and the openability was “◯”.

[Example 5]
As shown in FIG. 16, 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 (1). Using the same composite die, spinning was performed under the same polymer, equivalent fineness and spinning conditions as in Example 1, and 12,000 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 0.15 mm, a radius R1 of the virtual circumferential line C1 of 0.647 mm, and a virtual circumferential line. The C2 radius R2 is 1.293 mm, the virtual circumference C3 has a radius R3 of 0.373 mm, and the hole packing density is 0.9 (pieces / mm ² ). As shown in Table 1, the fiber diameter of the multifilament was 656 nm, the fiber diameter variation was 5.3%, the mixture ratio per 30 single yarns was 24/76, and the openability was “◯”.

[Example 6]
In Example 6, as two different types of island component polymers, PET having a melt viscosity of 120 Pa · s and polypropylene (PP) having a melt viscosity of 54 Pa · s were used. Otherwise, the same composite die as in Example 3 was used. 14,000 multifilaments were collected by spinning under the same sea-island ratio, equivalent fineness, and spinning conditions. As shown in Table 1, the fiber diameter of the multifilament was 537 nm, the fiber diameter variation was 4.6%, and the mixing ratio per 30 single yarns was 48/52, but there was not much electrical repulsion. In comparison with other examples, the openability was “Δ”.

[Example 7]
In Example 7, except that the hole shape of the island component discharge hole of the lowermost layer distribution plate was changed to a cross-shaped cross section, using the same composite die as in Example 3, the same polymer as in Example 3, the same fineness, Spinning was performed under spinning conditions, and 14,000 multifilaments were collected.

  Here, in the composite base used in Example 7, the island component discharge hole has a diameter of 0.15 mm in contact with all the portions that are convex toward the outside, and is all convex toward the inside. It is perforated with a diameter of 0.08 mm of a circle in contact with the portion. As shown in Table 1, the fiber diameter DB of the multifilament having a modified cross section is 536 nm, the fiber diameter DA is 383 nm (degree of irregularity 1.4), the fiber diameter variation is 5.2%, and the mixing ratio per 30 single yarns is It became 48/52, and the opening property was “◯”.

[Comparative Example 1]
In Comparative Example 1, only one component of polyethylene terephthalate (PET) having a melt viscosity of 120 Pa · s was used as the island component polymer, and other than that, the same composite base as in Example 3 was used, and the equivalent sea-island ratio and equivalent fineness were used. Spinning was performed under spinning conditions, and 14,000 multifilaments were collected. As shown in Table 1, the fiber diameter of the multifilament was 537 nm and the fiber diameter variation was 4.6%. However, the single yarns aggregated, and the openability was “x”.

[Comparative Example 2]
In Comparative Example 2, as shown in FIG. 20, at first glance, the arrangement of the island component discharge holes and the sea component discharge holes of the lowermost layer distribution plate is similar to the condition c in the formula (1), but the difference is that In the condition C, the island component discharge hole Y is not disposed on the virtual circumferential line C2, but the island component discharge hole Y is disposed except for the above. Spinning was performed under fineness and spinning conditions, and 14,000 multifilaments were collected. As shown in Table 1, the fiber diameter of the multifilament was 537 nm and the fiber diameter variation was 4.6%. In this case, the mixing ratio per 30 single yarns was 17/83, and the single yarns of the same component They were agglomerated with each other, and the spreadability was “x”.

  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 X
2: Island component discharge hole Y
3: Common outer tangent 4: Sea component discharge hole 5: Lowermost layer distribution plate 6: Distribution plate 7: Distribution hole 8: Distribution groove 9: Metering plate 10: Discharge plate 11: Discharge introduction hole 12: Reduction hole 13: Island component A
14: Island component B
15: Spin pack 16: Spin block 17: Cooling device 18: Composite base 19: Island group A
20: Island group B
21: Pipe 22: Sea component polymer introduction channel 23: Island component polymer introduction channel 24: Upper mouth plate 25: Middle mouth plate 26: Lower mouth plate 27: Supply hole 28: Upper end 29: Sea component polymer distribution chamber 30 : Pipe insertion hole 31: Base discharge hole 32: Space partitioned by hard plate 33: Annulus C1, C2, C3: Virtual circumferential lines O1, O2, O3: Centers of island component polymers O4, O5, O6: Island Center of circumscribed circle of group R, R1, R2, R3: Radius of imaginary circumferential line DB: Diameter of circle in contact with all portions convex toward outside of island component DA: Inward of island component The diameter of the circle that touches all the convex parts

Claims (9)

A composite base for discharging a composite polymer stream composed of a sea component polymer and two or more different island component polymers,
One or more distribution plates formed with distribution holes and distribution grooves for distributing each polymer component;
Located on the downstream side of the polymer spinning path direction of the distribution plate, and composed of 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 island component discharge hole includes an island component discharge hole X that discharges one type of island component polymer of the two or more different island component polymers, and an island component polymer discharged from the island component discharge hole X. It is composed of island component discharge holes Y that discharge different types of island component polymers,
N island component discharge holes Y equally arranged on an imaginary circumferential line C1 having a radius R1 around any island component discharge hole X, and the shortest center distance between the island component discharge holes X M island component discharge holes X that are equally arranged on a virtual circumferential line C2 having a radius R2, and the phase angle between the X and Y island component discharge holes is the following (1). satisfying one of conditions i ~ e, and the sea component discharge hole, characterized in that it is arranged on the virtual circular line C3 which is a radius R3 which satisfies the following equation (2) Compound base.
(1) Condition a: R2 = √n · R1, phase angle 180 ° / 2n, m = 2n (n = 3)
Condition B: “R2 = √n · R1, phase angle 180 ° / 2n, m = 2n” and
“N island component discharge holes Y are arranged at a phase angle of 180 ° / n at an intermediate point between adjacent island component discharge holes X (n = 2)”
Condition C: R2 = √ (n / 2) · R1, phase angle 180 ° / n, m = n (n = 4)
Condition d: “R2 = R1, phase angle 180 ° / n, m = n (n = 3)” or
“R2 = √ (n / 2) · R1, phase angle 180 ° / n, m = n (n = 6)”
Condition E: “R2 = (n / 3) · R1, phase angle 0 °, m = n (n = 6)” or
“R2 = (2n / 3) · R1, phase angles 0 ° and 180 ° / n, m = 2n (n = 3)” or
“R2 = R1, phase angles 120 ° / n and 240 ° / n, m = n (n = 2)”
(2) 0.5 · R1 ≦ R3 <R1   The at least part of the sea component discharge hole is present in a region surrounded by two common circumscribed lines of the island component discharge hole X and the island component discharge hole Y. Composite base. 3. The composite die according to claim 1, wherein a total hole filling density of the island component discharge holes X and the island component discharge holes Y is 0.5 / mm ² or more.   In a composite fiber in which two or more different island components are present in the same fiber cross section, an arbitrary island component serving as a reference is defined as a reference center O1, and a distance R from the center O2 of the island component closest to the reference center O1. P is the center O3 of the island component of a type different from the island component having the reference center O1 in the virtual circumference line with a radius of p (p is an integer of 2, 3, 4, 6) A composite fiber characterized by being arranged.   The composite fiber according to claim 4, wherein the island component having the center O <b> 3 is equally arranged on the virtual circumference.   The composite fiber according to claim 4 or 5, wherein any one of the two or more different island components has an outer diameter of 10 to 1000 nm and an outer diameter variation of 1 to 20%. .   7. A potential difference between a charge train of one kind of island component and a charge train of an island component of a different type from the island component relatively. Composite fiber.   The composite fiber according to any one of claims 4 to 7, wherein at least one of the two or more different island components has an irregular shape. In a fiber having a single yarn diameter of 1000 nm or less and two or more types of single yarn having a potential difference in the charge train, the ratio of the two types of single yarns in 30 single yarns in the cross section of the fiber is A fiber characterized by being mixed in a ratio of 20:80 to 80:20.

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