US3814561A

US3814561A - Spinnerets for producing multi-segment filaments

Info

Publication number: US3814561A
Application number: US00129799A
Authority: US
Inventors: M Matsui; S Tokura; M Yamabe
Original assignee: Kanegafuchi Spinning Co Ltd
Current assignee: Kanegafuchi Spinning Co Ltd
Priority date: 1970-04-07
Filing date: 1971-03-31
Publication date: 1974-06-04
Anticipated expiration: 1991-06-04
Also published as: DE2117076C3; DE2117076A1; JPS4929129B1; DE2117076B2; GB1304976A

Abstract

Multi-segment filaments can be obtained by feeding a flow of liquid spinning material composed of at least two thin layers, which extend radially from the center portion of the crosssection of a conduit towards the peripheral wall of the conduit so as to reach the peripheral wall, into the conduit from the upper end thereof, and at the same time feeding forcedly a flow of another spinning material into each of small sections between the above radial thin layers and the periphery wall of the conduit to put the above described thin layers between the flows of the latter spinning material, and then extruding the joined flow through the orifice, by the use of spinneret having a simple structure. There are two types of arrangements of the conduit, feed nozzle and duct, in one of which the thin layer forming spinning material is fed from the feed nozzle to the conduit, and in another of which the thin layer forming spinning material is fed from the duct into the conduit.

Description

1 United States Patent 11 1 1111 3,814,561 Matsui et a1. 1 June 4, 1974 [5 1 SPINNERETS FOR PRODUCING 3,568,249 3/1971 Matsui ..1s/x sc Mun-SEGMENT LAMENTS 32131 15 1351331 "1311131 I (1151.11 et Z1 1 Inventors: Masai) Matsui, k k Susumu 3,718,534 2/1973 Okamoto et 111. 264/171 :52? bmh FOREIGN PATENTS OR APPLICATIONS 1,167,390 10/1969 Great Britain 264/171 1 Assigneer Kaflagafuchi Boseki Kabushiki 1 42-4298 2/1967 Japan 264/171 K h y p n 43-30025 12/1968 Japan 264/171 2,014,817 11/1970 Germany 264/171 [221 1971 43-4540 2/1968 264/171 2 App]. 129 799 44-22523 9/1969 Japan 264/171 Primary Examiner-Jay H. Woo [301 Forelgn Apphcatmn Pnomy Data Attorney, Agent, or FirmWoodhams, Blanchard and Apr. 7, 1970 Japan 45-29924 Flynn [52] [1.8. CI 425/131, 264/171, 425/463 57 ABSTRACT Multi-segment filaments can be obtained by feeding a 18/8 SC; l64/l7l l74, 168, 177, 344, 41; flow 0t 11qu1d spinning material composed of at least 425/131 133 463 two thin layers, which extend rad1ally from the center portion of the cross-section of a conduit towards the [56] References Cited peripheral wall of the conduit so as to reach the peripheral wall, into the conduit from the upper end UNITED STATES PATENTS thereof, and at the same time feeding forcedly a flow 2,815,532 12/1957 Bljflul'lHCh 18/8 SC of-another Spin ing material into each of small ec- 3,075,241 1/1963 D etzsch et al. 425/131 tions between i -E hj 2,197,813 8/196; DdtZtZSCl'i et 211...... 435/131 tR the conduit to put the above 3x32 1 scribed thin layers between the flows of the latter spin- 5 10/1967 Kimjm'la et 18/8 SC ning material, and then extruding the joined flow 3:350:4111; 10/1967 Breen............:::. 1. 264/171 through the Orifice by the use of Spinneret having 11 3,403,422 10/1968 Nakagawa el al. 264/171 Simple structure- There are two yp of arrangements 3,418,200 12/1968 Tanner 18/8 sc f th n it. f n z l n duct, in n f whi h 3,453,689 7/1969 Hume 425/133 the thin layer forming spinning material is fed from 6 12/1969 Matsui 18/8 SC the feed nozzle to the conduit, and in another of gs cl l which the thin layer forming spinning material is fed umoto e a 3,540,080 1 1/1970 Goossens 264/171 from the duct the 3,558,755 1/1971 Laban ct a1 264 95 13 Claims, 32 Drawing Figures minnow" 4:914 3814.561

sum 1 OF 7 Fig. 28 Fig. 29

INVENTOR5 M454 0 M4 7290/ 6415a TOM/EA M454 0 WWI/A55 BY Maw i/jg w ATTORNEYS SPINNERETS FOR PRODUCING MULTI-SEGMENT FILAMENTS The present invention relates to a method for producing multi-segment filaments, wherein a first component spinning material A is separated into a plurality of segments by a second component spinning material B in the unitary filament, and a novel spinneret adapted for producing the filaments.

Multi-segment filaments obtained by the method of the present invention have a cross-section as shown, for example, in FIGS. 1 to 6, l3 and 23, and it has been known that when the second component B of multisegment filaments having a cross-sectional structure similar to that of the above described multi-segment filament obtained by the method of the present invention is removed by chemical decomposition or dissolution, the multi-segment filaments can be divided into a large number of segments having a peculiar shape (Japanese Patent Application Publication No. 29,636/64). Further, when the first component A and the second component B constituting the multi-segment filament are poor in the mutual adhesivity, the two components can be peeled off or divided to form fibrillated filaments by subjecting the filament to a mechanically strong strain, for example, by false twisting the filament, or by crumpling the knitted goods or woven fabrics made of the filaments. Such fibrillated filaments have pleasant touch, appearance, gloss, bulkiness and flexibility. However, it is fairly difficult to produce the above described multi-segment filament by means of a commonly used spinneret adapted for spinning conventional composite filament, and it has been desired to develop a spinneret having a simple structure and capable of producing uniform multi-segment filament easily and efficiently.

Moreover, when the first component A constituting the above described multi-segment filament is divided into each segment by dissolving or decomposing the second component B constituting the filament, it is more desirable to separate the first component A by a thinner layer ofthe second component B in order to decrease the weight loss of the filament due to dissolution or decomposition of the second component B. However, such a procedure is difficult in the conventional conjugate spinning method.

An object of the present invention is to provide a method for producing multi-segment filaments, in which a first component A is separated by a thinlayered second component B, and the separated segments composed of the first component A have various crosssectional shapes.

Another object of the present invention is to provide spinnerets having a relatively simple structure and capable of producing uniform multi-segment filaments easily.

The method for producing multi-segment filaments according to the present invention comprises a flowing into the upper end of a conduit a first liquid spinning material composed of at least two thin layers having substantially even thickness, which layers extend radially from the center portion of the cross-section of the peripheral wall of the conduit and at the same time forcedly flowing a second spinning material, different from the above described first spinning material, into each of small sections confined by the above radial thin layers and the peripheral wall of the conduit so that the above described thin layers are located between the flows of the second spinning material, and then extruding the joined flow of the two spinning materials through the orifice without substantially causing disturbance of the stream line of the thin layer.

A spinneret to be used for producing multisegment filaments according to the present invention comprises a spinneret plate provided with at least one conduit connected to an orifice, the upper end of which conduit is open. A distributing block is superposed at the rear of the spinneret plate and is provided on its bottom surface with a feed passage communicating with the conduit, said feed passage havng at least two branches which extend radially from substantially the center portion to the peripheral wall of said conduit, ducts being provided in the abutting surface of the spinneret plate against the distributing block and connected to the small sections defined by the above feed passage branches and the peripheral wall of the conduit and said feed passage and ducts being connected to different chambers for supplying two spinning materials, re-

spectively.

A variant of the spinneret to be used for producing multi-segment filaments according to the present invention comprises a spinneret plate provided with at least one conduit connected to an orifice, the upper end of which conduit is open, and a distributing block superposed at the rear of the spinneret plate and provided on its bottom surface with a feed passage and radial ducts for each conduit, said radial duct having at least two branches which extend radially from substantially the center portion towards the periphery wall of the conduit so as to reach said periphery wall, said feed nozzle being composed of a plurality of small holes each of which opens at each small section confined by the radial duct and the periphery wall of the conduit at the opening of the conduit, and said feed nozzle and radial duct being connected to different chambers for supplying two spinning materials, respectively.

For a better understanding of the invention, reference is taken to the accompanying drawings, wherein:

FIGS. 1 to 6 and 13 are cross-sectional views of multi-segment filaments produced by the method of the present invention;

FIG. 7 is a vertical sectional view of one embodiment of a spinneret according to the present invention;

FIG. 8 is a cross-sectional view of the spinneret shown in FIG. 7 taken on line X-X' in the arrow direction;

FIGS. 9 to l2, l4 and 15 show various arrangements of a feed nozzle, a duct and a conduit to be used in a spinneret according to the present invention for illustrating the mutual relation thereof;

FIG. 16 is a vertical sectional view of a part of a spinneret according to the present invention, which illustrates the mutual relation of a feed nozzle, a duct and a conduit;

FIG. 17 is a plan view of the spinneret shown in FIG. 16 taken on line Y-Y' in the arrow direction;

FIG. 18 is a plan view showing one embodiment of relations between a feed nozzle, a duct and an orifice of a spinneret according to the present invention in the case when the orifice has a non-circular cross-section;

FIGS. 19 and 20 are cross-sectional views of multisegment filaments having a non-circular cross-section obtained by the method of the present invention;

FIG. 21 is a vertical sectional view of a modified emshown in FIG. 24 taken on line X-X in the arrow direction;

FIG. 26 is a vertical sectional view of a modified embodiment of another spinneret according to the present invention;

FIG. 27 is a vertical sectional view of the spinneret shown in FIG. 26 taken on line Y-Y in the arrow direction and shows the bottom surface of the feed nozzle; v

FIGS. 28 to 31 show various arrangements of a feed nozzle, a duct, reservoirs and a conduit to be used in another spinneret according to the present invention for illustrating the mutual relation thereof;

FIG. 32 is a plan view showing one embodiment of relations between a feed nozzle, a duct and an orifice of another spinneret according to the present invention in the case when the orifice has a non-circular crosssection; and

FIG. 7 is a vertical sectional view of one embodiment of a spinneret according to the present invention.

Referring to FIG. 7, a part of the first component A flows through a passage 3 and a reservoir 4 and is fed into a duct I l, and a further part of component A flows through a passage 6 and a reservoir 7 and is fed into another duct 11. A second component B in a passage 9' is fed from a feed passage 10 into a conduit 21 in the form of at least two thin layers having substantially even thickness, which layers extend radially from the center portion of the cross-section of the conduit 21 towards the peripheral wall of the conduit 21 so as to reach the peripheral wall. The parts of the first component A flowing out from the ducts 11 are separated by the thin-layered second component B extruded from the feed passage 10 and are fed into the conduit 21 while holding the second component B between .the flows of the component A. The two components A and B are extruded through an orifice 22 while maintaining the bonded state. Concave recessess are formed on the upper surface of the spinneret plate and are used as the

reservoirs

4 and 7. The numeral 24 shows a holder.

FIG. 8 is a cross-sectional view of the spinneret shown in FIG 7 taken on line X-X' in the arrow direction. The dotted lines show the shape of the feed passage 10 projected in the direction thereof. One feed passage is composed of a Y-shaped slit 10 having three branches, and ducts 11 are arranged so as to be positioned between the branches of the Y-shaped slit 10. The ducts 11 are connected to the

reservoir

4 or 7.

Filaments having a cross-section as shown in FIG. 1 can be obtained by the use of a spinneret as shown in FIG. 7.

A brief explanation will be made with respect to the feed passage 10, conduit 21 and duct 11 of the spinneret according to the present invention.

The feed passage 10 is composed of at least two slits or at least two groups of small holes aligned closely to one another, which extend radially from substantially the center portion towards the peripheral wall of the conduit 21. One slit or one small hole groupis called as a branch of the feed passage 10. The number and cross-sectional shape of segments of the resulting multi-segment filament vary depending upon the number and shape of the branches of the feed passage 10.

It is necessary that the length of the slit or of the small hole group, that is, the length of a branch constituting the feed passage 10 should be sufficiently long in order that the second component B fed from the feed passage 10 separates completely the streams of the first component A fed from the ducts 11. Namely, it is necessary that when the conduit 21 and the feed passage 10 belonging to one group are projected in the direction of the axes thereof, the ends of at least two branches of the feed passage 10 substantially reach the peripheral wall of the conduit 21 or are outside of said peripheral wall. When the end of the branch of the feed passage 10 does not reach the peripheral wall of the conduit 21 so as to form a wide gap between the end of the branch of the feed passage 10 and the peripheral wall of the I conduit 21, there is a risk that the first component A will not be separated into segments by the second component B fed from the feed passage 10. However, when the gap is as small as that caused by error in the assembling the spinneret, for example, 0. l. to 0.2 mm, the object of the present invention can be attained without practical trouble.

FIGS. 9 to 12 show various embodiments of the arrangement of a conduit 21, a feed passage 10 and ducts of the spinneret according to the present invention, the conduit 21 and feed passage 10 being viewed in the direction of the axes thereof. The ducts is shown by duct 11 in FIGS. 9, IO-and 12, and by ducts ll, 12 and 13 in FIG. 11. The duct 13 in FIG. 11 is used as an auxiliary duct and serves to feed the first component A in the

reservoirs

4 and 7 into the duct 12. The second component B fed from the feed passage 10 and the first component A fed from the duct 11 (FIGS. 9, l0 and 12) or the

ducts

11, 12 and 13 (FIG. 11) are bonded in the conduit 21. In FIG. 9, the number of branches of the feed passage 10 is 4; in FIG. 10, the number is 3; and in FIG. 11, the number is 6. Further, in FIG. 13, the number of branches of the feed passage 10 is 4, but one of the branches is short and the end does not reach the peripheral wall of the conduit 21. Filaments having a cross-section as shown in FIG. 2 can be obtained by the use of a spinneret having an arrangement of the conduut, feed nozzle and duct as shown in FIG. 9. In the same manner, filaments having a cross-section as shown in FIGS. 4 or 3 can be obtained by the use of a spinneret having an arrangement of the conduit, feed passage and duct as shown in FIGS. 10 or 11, respectively. Furthermore, an arrangement, wherein the end of a part of the slits or that of a part of the small hole groups does not reach the peripheral wall of conduit, may be used in the present invention. For example, muIti-segment filaments having a peculiar cross-section as shown in FIG. 13 can be obtained by the use of a spinneret having an arrangement of the conduit, feed passage and duct as shown in FIG. 12.

The width of the slit or the diameter of the small holes in the small hole group constituting the feed passage may be selected optionally, but a smaller width of the slit or a smaller diameter of the small hole is preferably used in order to form thin layers of the second component B separating the segments of the first component A. For example, the width of the slit or the diameter of the small hole is preferred to be 0.05 to 2 mm, preferably 0.1 to 1 mm.

Spinnerets as shown in FIGS. 7 and 21 have two

reservoirs

4 and 7 respectively, but spinnerets each having one reservoir as shown in FIGS. 14 and may be used in the present invention. 1

The abutting surface of the distributing block 1 against the spinneret plate serves to separate the

reservoirs

4 and 7 from the conduit 21 except for the communication provided by the ducts l1, l2 and 13 the abutting surface portions may be formed by circles as shown in FIG. 14 or polygons as shown in FIG. 15, so that the conduits 21 are formed in separate abutting surface portions alternatively, the abutting surface portion may be formed by a band as shown in FIGS. 8 and 22. Of course, the band-shaped abutting surface is most advantageously used because of its easy production and maintenance. the polygonal abutting surface and the circular abutting surface may also preferably be used.

In the spinneret accoding to the present invention, the ducts I1, 12, etc. may be arranged on the upper surface of the spinneret plate 20 or on the bottom surface of the distributing block 1, or on both of them. In the spinneret shown in FIG. 7, the duct 11 is arranged on the upper surface of the spinneret plate 20, but the duct 11 may be arranged on the bottom surface of the distributing block 1 as shown in the spinneret of FIG. 16. FIG. 17 is a cross-sectional view of the spinneret shown in FIG. 16 taken on line Y-Y' in the arrow direction. The numeral 21' shows an auxiliary conduit connecting the conduit 21 with the feed passage 10 and the ducts 11. This auxiliary conduit 21' can be considered as a part of the conduit 21. The end of the branch of the feed passage 10 reaches the peripheral wall of the auxiliary conduit 21, and the ducts 11 open to the I auxiliary conduit 21'. The spinneret shown in FIG. 16 can be easily produced and advantageously used. In the spinneret shown inFIG. 16, the ducts 11 may be arranged on both of the bottom surface of the distributing block I and of the upper surface of the spinneret plate 20.

In the spinneret of the present invention, the crosssectional shape of the ducts ll, 12, etc. may be optional. For example, semi-circular, rectangular, square or triangular cross-sections may be used. Furthermore, when in the ducts ll, 12, etc., which open to one conduit 21, the cross-sectional dimensions and lengths are different, two or more different shapes of segments composed of the first component A in the unitary filament can be obtained.

In the spinneret according to the present invention, it isnecessary that the distributing block 1 is contacted tightly with the spinneret plate 20 at the abutting surface so that the first componet A flows into the conduit 21 only via the ducts 11.

The cross-sectional shape of the orifice 22 may be circular or non-circular. For example, when a trilobal filament, wherein segments of the first component A are positioned in each lobe as shown in FIG.'19, is intended to be produced by the use of a Y-shaped slit as the orifice 22, such filament can be obtained by arranging a duct 11 so as to be put in'opposition to the end of a slit of the orifice 22 as shown in FIG. 18. While, when a trilobal filament, wherein the second component B is positioned in the center portion of each lobe in the form of a thin layer as shown in FIG. 20, is intended to be produced by the use of a Y-shaped slit as the orifice 22, such filament can be obtained by arranging the Y-shaped slit of the feed passage 10 so as to be coincided with the Y-shaped slit of the orifice 22.

FIG. 21 is a vertical sectional view of a modified embodiment of the spinneret according to the present invention. Referring to FIG. 21, a part of the first component A is passed through the annular passage 5 and reservoir 7 and fed into ducts 11, and a further part of component A is passed through a central cylindrical passage 2 and reservoir 4 and fed into ducts 11. While, a second component B in an annular passage 9 is extruded from a feed passage 10 into a conduit 21 in the form of a thin layer having an even thickness and having at least two radial branches, at least two of which reach the peripheral wall of the conduit 21. As the result, the flow of the first component A is separated in its cross-section into at least two segments-by the second component B and is fed into the conduit 21 while holding the second component B between the segments of the first component A. The two components A and B are extruded through an orifice 22 while maintaining the bonded state. In the above process, the component A or B can be fed from the supplying portion into the

reseroirs

4 and 7 or into the feed passage 10 by any conventional means.

FIG. 22 is a cross-sectional view of the spinneret shown in FIG. 21 taken on line Z-Z in the arrow direction and shows the upper surface of the spinneret plate 20. As seen from FIG. 22, in this spinneret, one feed nozzle is composed of a cross-shaped passage 10, and corresponds to one conduit 21 and one orifice 22. The dotted lines show a feed passage 10 which opens at the bottom surface of the distributing block 1 and communicates with the conduit 21. The ducts 11 are positioned between the branches of a cross-shaped passage 10. Pin 30 serves to adjust the positions of the conduit 21 and the feed nozzle 10. The numeral 24 shows a holder. v

FIG. 8 shows an embodiment of spinnerets, wherein a plurality of orifies 22 and feed passages l0.corresponding to the orifices 22 are arranged on a straight line, respectively. FIG. 22 shows an embodiment of spinnerets, wherein these orifices 22 and feed passages 10 are arranged on a circumference of a circle respectively. Particularly, the spinneret as shown in FIG. 21 has relatively simple structure and is easy in the production and maintenance.

FIG. 24 is a vertical sectional view of another spinneret according to the present invention for producing a filament of the structure illustrated in FIG. 23. Referring to FIG. 24, a first component A in a passage 9 is extruded from-a feed passage 10 into a doncuit 21. While a part of a second component B is passed through a passage 3 and a reservoir 4 and fed into one end of a duct 11, and another part is passed through a passage 6 and a reservoir 7 and fed into the other end of the duct 11. The second component B coming out from'the duct 11 is fed into the conduit 21 while separating the first component A coming out from the feed nozzle 10, and then the two components A and B in the conduit 21 are extruded through an orifice 22. Recesses are formed on the bottom surface of the distributing block 1 and are used as the

reservoirs

4 and 7. In the spinneret shown in FIG. 24, a gasket 23 is used in the abutting surface (tightly adhered surface) between the distributing block 1 and the spinneret plate 20, but of course this gasket 23 may be omitted. The numeral 24 shows a holder.

FIG. 25 is a cross-sectional view of the spinneret shown in FIG. 24 taken on line X-Xf in the arrow direction, and shows the bottom surface of the distributing block 1. One feed passage is composed of two small holes 10. One duct 11 is arranged so as to separate these two small holes, and communicates with

reservoirs

4 and 7.

FIG. 26 is a vertical sectional view of a modified embodiment of another spinneret according to the present invention. Referring to FIG. 26, a first component A is supplied into an annular supplying portion 8, and a part of the second component B is supplied into an annular supplying portion 5 and a further part of component B is supplied into a central cylindrical supplying portion 2. The first component A in the supplying portion 8 is passed through a passage 9 and extruded from a feed passage 10 into a conduit 21. The second component B in the supplying portion 2 is passed through a reservoir 4 and

ducts

11 and 12 and then is'fed into the conduit 21. The second component B in the supplying portion 5 is passed through a reservoir 7 and ducts l1 and is 12 and fed into the conduit 21. In the above process, the component A or B can be fed from the supplying portion into the feed passage 10 or into the

reservoirs

4 and 7 by means of any conventional means.

FIG. 27 is a cross-sectional view of the spinneret shown in FIG. 26 taken on line Y-Y' in the arrow direction, and shows the bottom surface of the distributing block 1. One feed passage is composed of four small holes 10, and corresponds to one conduit 21 and one orifice 22. The

ducts

11 and 12 separate the above described four small holes from each other. A duct 13, in FIG. 27 serves to feed the second component B in the

reservoirs

4 and 7 into the duct 12. One of the duct 11 and the duct 12 may be omitted. In this case, the spinneret shown in FIG. 26 is substantially the same with that shown in FIG. 24, and filaments having a crosssection as shown in FIG. 23 are obtained. When, a spinneret having both of the ducts I1 and 12 is used, filaments having a cross-section as shown in FIG. 2 are obtained.

As seen from FIGS. 24 and 25, the spinneret shown in FIG. 24 shows one embodiment of spinnerets. wherein a plurality of orifices 22 and feed passages 10 corresponding to the orifices 22 are arranged on a straight line, respectively. While, as seen from FIG. 26 and FIG. 27, the spinneret shown in FIG. 26 shows one embodiment of spinnerets, wherein a plurality of orifices 22 and feed passages 10 corresponding to the orifices 22 are arranged on a circumference of a circle, respectively. Both of these spinnerets have a relatively simple structure, and are easy in the production and maintenance.

When one feed passage is formed by 3 small holes and a Y-shaped duct is arranged so as to separate these holes, filaments having a cross-section as shown in FIG. 1 can be obtained, but the production of a Y-shaped duct is somewhat difficult. A large number of segments of the first component A in the unitary filament is generally more desirable. Therefore, unitary filaments having a cross-section as shown in FIG. 1 or 2 are more desirable than unitary filaments having a cross-section as shown in FIG. 23. However, it is somewhat difficult to produce unitary filaments having a cross-section as shown in FIG. 1 as described above. Similarly, it is fairly difficult to produce unitary filaments having five or more of segments of the first component A. However, among these filaments, ones having 6 segments can be relatively easily produced. Therefore, a spinneret as shown in FIG. 26 is most preferably used.

FIGS. 28 to 31 are plan views showing various embodiments of the shape and arrangement of a feed passage 10, a duct 11,

reservoirs

4 and 7 for feeding the second component B and a conduit 21 corresponding to the duct 11 at the bottom surface of a distributing block 1. In FIGS. 28 to 31, the dotted lines show the position of the conduit 21 of the spinneret plate 20 corresponding to the feed passage 10. Spinnerets shown in FIGS. 24 to 27 have two

reservoirs

4 and 7, but spinnerets each having one reservoir 4 (or 7) as shown in FIGS. 28 and 29 may be used in the present invention. FIG. 28 shows an embodiment of cross-shaped ducts 11, FIG. 29 shows that of T-shaped ducts 11, FIG. 30 shows that of .X-shaped ducts l1 and FIG. 31 shows that of ducts l1 composed of three

diagonals

11 and 12 connecting opposite apexes of a hexangle.

Spinnerets having an arrangement of the feed passage 10, duct 11,

reservoirs

4 and 7, and conduit 21 as shown in FIGS. 28 and 30 can produce filaments wherein the first component A is separated into 4 segments by the second component B similarly to the spinneret shown in FIG. 26. A spinneret having the arrangement as shown in FIG. 29 can produce filaments wherein the first component A is separated into 3 segments by the second component B. A spinneret having the arrangement as shown in FIG. 31 can produce filaments wherein the first component A is separated into six segments by the second component B.

y In another spinneret according to the present invention, the abutting surface of the distributing block 1 against the spinneret plate 20, which surface serves to separate the

reservoirs

4 and 7 from the conduit 21, except for the communication provided by the ducts ll, 12 and 13, may be formed by circles as shown in FIG. 28 or polygons as shown in FIG. 29, which are isolated independently from each other at every conduit 21, or may be formed by a band as shown in FIGS. 24 to 27,

30 and 31. Of course, the band-shaped abutting surface is most advantageously used because of its easy production and maintenance. Abutting surfaces having a quadrilateral shape, a quadrilateral-like shape, such as a fan-shape, or a circular shape may also preferably be used.

In another spinneret according to the present invention, the cross-sectional shape of the

ducts

11 and 12 may be optional. For example, semi-circular, rectangular, square and triangular cross-sectional shapes may be used. However, in order to obtain a thin-layered second component B as shown in FIGS. 1 to 6 and 23, a duct having a certain extent of depth and a certain extent of narrow width is preferably used. For example, the depth and width of the duct are preferred to be 0.2 to 3 mm, preferably 0.5 to 2 mm. In the spinneret shown in FIG. 27, the width and depth of the duct 11 may be same with or different from those of the duct 12. The

duct 13 is used as an auxiliary duct, and may be formed in an optional cross-sectional sahpe. However, the width and depth of the duct 13 can be varied properly to control the ratio of the amount fed into the duct 11 to that fed into the duct 12 of the component B.

In another spinneret according to the present invention, it is necessary that the distributing block 1 is tightly contacted with the spinneret plate 20 at the abutting surface in order that the second component B flows into the conduit 21 only via the ducts l1, l2 and 13.

The cross-sectional shapes of the feed passage and orifice 22 may be circular or non-circular. For example, when a Y-shaped slit or a cross-shaped slit is used as an orifice 22, a trilobal filament or a tetralobal filament can be obtained. Multi-lobal filaments having various cross-sectional shapes can be obtained by changing the arrangement of the feed passage 10, duct 11 and orifice 22. H6. 32 is a plan view showing one embodiment of the arrangements of the feed passage 10, duct ll and orifice 22, wherein the orifice 22 is composed of a Y-shaped slit, the feed passage 10 is composed of three small holes, the duct 11 is a Y-shaped duct arranged so as to separate these three small holes of the feed passage 10, and each small hole is arranged so as to be substantially coincided with the slit portion of the orifice 22. In such arrangement, filaments having a cross-section as shown in FIG. 19 wherein the first component A is positioned in the lobe can be obtained. While, when the direction of each duct of the Y-shaped duct is coincided with that of the slit portion of the orifice 22 in the above arrangement, filaments having a cross-section as shown in FIG. can be obtained.

In another spinneret according to the present invention, the cross-sectional shape of the small hole in a small hole group constituting one feed nozzle may be circular or non-circular, but small holes having a circular cross-section are generally used. When one feed nozzle is composed of a combination of two or more small holes having different diameters, a filament composed of two or more segments having different dimensions can be obtained. In the same manner, when a plurality of the small holes constituting one feed nozzle is separated non-uniformly-by the duct, that is, when the separation is carried out so that the number of small holes corresponding to each segment is two or more different numbers (for example, the separation is carried out so as to form segments corresponding to one small hole and segments corresponding to two small holes at the same time), a filament composed of two or more segments having different dimensions can be obtained. Filaments composed of such non-uniform segments have a particular gloss and touch, and are often preferably used.

The spinning material to be used in the present invention includes any commonly known fiber-forming polymers, for example, polyamides, such as nylon-4, nylon- 6, nylon-l l, nylon-l2, nylon-66, nylon-610, polyme taxylylene adipamide and poly-bis- (paramethylcyclohexylmethane)azelaic acid amide;

polyesters, such as polyethylene terephthalate, polytetramethylene terephthalate. polyethylene oxybenzoate, polypivalolacetone, polydimethylcyclohexane terephthalate; polyethers, such as polyethylene oxide, polypropylene oxide; polyvinyl compounds, such as polyvinyl alcohol, polyacrylonitrile, polyacrylic acid ester, polyacrylamide, polyvinyl chloride; and polyolefins,

blends thereof.

In the present invention, polymers having an excellent fiber-forming ability and capable of producing filaments having an excellent strength and elasticity are preferably used as the segment-forming component (the first component A), and polymers which can be easily dissolved or decomposed under such a condition that the first component A is not dissolved or decomposed are preferably used as the radially extending thin-layered component (the second component B). Polymers to be preferably used as the second component B are water-soluble polymers (in hot water or cold water), and include, for example, polyvinyl alcohol; polyacrylic acid, particularly alkali metal salts thereof; polyethers, such as polyethylene oxide; polyalkyleneimine; and polyamides having a large amount of ether linkages and/or primary, secondary and tertially amino groups. Particularly, melt-spinnable and water soluble polymers, for example, polyethylene oxide is most advantageously used as the second component B, because the polymer can be used as a water-soluble polymer in combination with non-water soluble polymers of the first component A, such as polyamide, polyester and polyolefin.

Other preferable polymers to be used as the second component B are ones which are easily soluble in organic solvents, for example, chlorides, such as ethylene chloride, carbon chloride, alcohols, ketones and hydrocarbons. In general, copolymers have higher solubility than homopolymers.

When polyamide is used as the second component B, the polyamide can be removed by dissolving it in phenol or acid. When polyester is used as the second component B, the polyester can be removed by decompoosing it with aqueous alkali solution. Accordingly, in a combination of polyamide and polyester, any one of them can be removed as the second component B and the other can be remained as the first component A.

According to the present invention, the conjugate ratio of the first component A to the second component B can be selected optionally. However, when the second component B is intended to be removed later,

a smaller amount of the second component B is more preferable. For example, an amount of the second component B in a composite filament is preferred to be less than 50 percent by weight, preferably 10 to 40 percent by weight and most preferably 10 to 30 percent by weight, an amount of less than 10 percent by weight of the second component B is fairly difficult in spinning technics.

The number of branches of the second component B, i.e., the number of segments of the first component A in a unitary filament is at least two as described above, but is most preferred to be three to six. In view of spinning technics, two to six are preferable, and four is most preferable. However, five is exceptional and requires a spinneret having a complicated structure. in view of the use of the composite filament, the number of segments in a unitary filament is preferred to bethree to six, andfour is most preferable from the view point of the easiness of spinning.

The following examples are given in illustration of this invention and are not intended as limitations thereof.

EXAMPLE I A spinneret as shown in FIG. 26, which had 22

orifices

22, 22 feed nozzles 10, each corresponding to the orifice 22, and ducts 11, was used. Polyethylene terephthalate (hereinafter abridged as PET) having an intrinsic viscosity of 0.70 in o-chlorophenol at 30C was used as a first component A. polycapronamide having an intrinsic viscosity of 1.10 in m-cresol at 30C was used as a second component B. The two polymers were melted separately, and the PET was supplied into a supplying portion 8 and the polycapronamide was supplied into supplying portions 5 and 2 while metering by means of metering pumps so that the conjugate ratio of PET/polycapronamide was 1/1 (by weight). After the two polymers were bonded in the spinneret, the bonded polymers were extruded through the orifices 22 arranged on a spinneret plate 20 kept at 290C, cooled in air and taken up on a bobbin at a rate of 700 m/min after oiling to obtain an undrawn filament 'Y, of 330 d/22 f. An undrawn filament Y of 330 d/22fwas prepared in the same manner as described above, except that the conjugate ratio of PET/polycapronamide was 4/l (by weight).

These undrawn filaments Y and Y were drawn to 3.5 times their original length on a draw pin kept at IC to obtain drawn filaments Y and Y respectively. The drawn filaments Y and Y were dyed with an acid dye.

Particularly, it has never hitherto been anticipated that multi-segment filaments, wherein a plurality of segments are separated by a thin-layered polymer can be obtained by the use of'a spinneret having a simple structure as shown in FIG. 26.

EXAMPLE 2 Aspinneret as shown in FIG. 21, which had 28 orifices 22 and 28 feed nozzles 10, each corresponding to the orifice 22, and ducts ll, was used. The PET used in Example I was used as a first component A, and polyethylene oxide having an averagemolecular weight of 300,000 was used as a second component B. After the two polymers were melted separately by means of screw extruders, the PET was supplied into passages 5 and 2, and the polyethylene oxide was supplied into a passage 9 while metering so that the conjugate ratio of PET/polyethylene oxide was 3/ l (by weight). After the two polymers were bonded in the spinneret, the bonded two polymers were extruded through the orifices 22 kept at 285C, cooled in air and taken up on a bobbin at a rate of 800 m/min after oiling to obtain an undrawn filament Y of 220 d/28 f having substantially the same cross-section as shown in FIG. 2. The resulting undrawn filament Y was drawn to 3.9 times its original length on a draw pin kept at l l0C to obtain a drawn filament Y During the above drawing, yarn breakage did not substantially occur, and the resulting drawn filament Y had a strength of 3.52 g/d.

The drawn filaments Y were woven into a twill fabric, and the twill fabric was dyed with a disperse dye and then subjected to a finishing set. The resulting twill fabric was composed of fine denier PET filaments and had a silk-like gloss and an excellent flexible touch. When a part of the twill fabric was unravelled and the strength of an unravelled filament was measured, the strength was found to be 4.21 g/d.

breakage occurs very often at the spinning, taking up.

and drawing, and consequently commercial production of such very fine denier filaments is almost impossible.

EXAMPLE 3 A spinneret as shown in FIG. 26, wherein the bottom surface of the distributing block 1 had a shape as shown in FIG. 29, was used. The PET used in Example I was used as a first component A. A copolyamide of polycapronamide/polyhexamethylene isophthalamide in a copolymerization ratio of /15 (by weight) was used as a second component B. The two polymers were metered so that the conjugate ratio of PET/the copolyamide was 4/1 (by weight), spun and drawn in substantially the same manner as described in Example 1 to obtain a drawn filament Y.,- of 70 d/l8 f having a crosssection as shown in FIG. 4.

The drawn filaments Y were knitted into a tricot knit fabric. The resulting tricot knit fabric had a rigid touch.

Then, the tricot knit fabric was dipped in percent aqueous solution of formic acid at room temperature for 10 minutes, washed with water and dried. The resulting' knit fabric had a pleasant gloss and a moderate resilience and flexibility. The reasonwhy such an excellent knit fabric is obtained is probably due to the facts that the copolyamide has been removed by the formic acid, one unitary filament has been divided into three fine segments and the divided segments have different dimensions and shapes.

What is claimed is:

1. A spinneret for producing multi-segment filaments, comprising:

a spinneret plate having at least one spinning orifice extending through the front surface of the spinneret plate and communicating with the front end of a conduit in the spinneret plate, the rear end of the conduit being open to the rear surface of the spinneret plate;

a distributing block superposed on the rear surface of the spinneret plate, the distributing block having a front surface sealingly contacting the rear surface of the spinneret plate, the front'surface of the distributing block having a branched duct formed therein and a plurality of reservoirs communicating with the outer ends of the branched duct, said branched duct comprising at least three duct branches of smaller width than the width of the rear end of the conduit and which are open along one side thereof to the rear end of the conduit, said duct branches intersecting in the central portion of the cross-section of the conduit and extending radially therefrom along the front surface of the distributing block and to and beyond the peripheral wall of the conduit, thereby to define at least three separate zones at the rear surface of said spinneret plate, each zone being defined by two of said duct branches and the peripheral wall of the conduit;

said distributing block also having formed therein feed passage means comprising at least three small holes arranged so that each of said zones has at least one hole communicating therewith, said holes extending axially of said conduit and extending through the front surface of the distributing block at locations inside the peripheral wall of the rear end of the conduit and between said radial duct branches;

the rear surface of the spinneret plate and the front surface of the distributor block being in sealed contact with each other in the regions between the duct branches and in the region surrounding the conduit so that spinning materials can enter the rear end of the conduit only through said small holes and said duct branches;

and means for supplying a first spinning material to said holes and means for applying a second spinning material to said reservoirs.

2. A spinneret according to claim 1, in which said spinneret has a. series of orifices and communicating conduits arranged in the shape of an annulus, said distributing block having a first central reservoir disposed inside said annulus and a second annular reservoir surrounding said annulus, said duct branches including branches extending from both said reservoirs to said conduits.

3. A spinneret according to claim 2, in which one of said duct branches is an annular duct disposed between said reservoirs and extending between and communicating with all of said conduits.

4. A spinneret according to claim 1, in which said orifice is a Y-shaped slit, said feed passage means is composed of three small holes with each small hole being axially aligned with one of the legs of said slit, and said duct branches forming a Y-shaped duct with the legs of said duct being circumferentially offset from the legs of said slit.

5. A spinneret according to claim 1, in which said orifice is a Y-shaped slit, sai'd duct branches form a Y- shaped duct with the legs of the Y-shaped duct being axially aligned with the legs of said slit, and said feed passage means is composed of three small holes circumferentially offset from the legs of said slit and said duct.

6. A spinneret according to claim 1, in which the width and depth of said duct branches are from 0.2 to 3 mm.

7. A spinneret according to claim 1, in which the number of duct branches is 3.

8. A spinneret according to claim I, in which the number of duct branches is 4.

9. A spinneret according to claim 1, in which the number of duct branches is 5.

10. A spinneret according to claim 1, in which the number of duct branches is 6.

11. A spinneret according to claim 1, in which the orifice has a circular cross-section. I

12. A spinneret according to claim 1, in which the orifice has a non-circular cross-section.

13. A spinneret according to claim 1, in which said conduit has a frusto-conical rear end portion which flares in a direction toward the rear surface of said spinneret plate.

UNITED STATES PATENT OFFICE v I CERTIFICATE ()F CORRECTION Patent No. 3 814 561 Dated June 4', 1974 Inventor(s) Mesao Matsui, Susumu Tokura and Masahiro Yamabe It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

, In the heading; under "Inventors; change the residence of the in rr entor "Susumu Tolgura" from "Neyagewa" to -=-Joto--ku- I I V Ih the heading, under "Assignee"; change "Kanegafuchi" to -e-=-Ka negafuch. i. Q I v Col. 13, line 13; change "applying" to -sup plying-*-.

In item "both of" and "all of" should be canceled.-

- Signed and sealed this 31st day of December'1974. I

(SEAL) Attest: H

McCOY M. GIBSON J-R. C. MARSE IALL DANN Attesting Officer Commissioner of Patents FORM PO-IOSO (10459) I USCOMWDC 6037M," fi' U.S, GOVERNNENT PRINTING OFFICE: HQ 0- 356-334.

Claims

1. A spinneret for producing multi-segment filaments, comprising: a spinneret plate having at least one spinning orifice extending through the front surface of the spinneret plate and communicating with the front end of a conduit in the spinneret plate, the rear end of the conduit being open to the rear surface of the spinneret plate; a distributing block superposed on the rear surface of the spinneret plate, the distributing block having a front surface sealingly contacting the rear surface of the spinneret plate, the front surface of the distributing block having a branched duct formed therein and a plurality of reservoirs communicating with the outer ends of the branched duct, said branched duct comprising at least three duct branches of smaller width than the width of the rear end of the conduit and which are open along one side thereof to the rear end of the conduit, said duct branches intersecting in the central portion of the crosssection of the conduit and extending radially therefrom along the front surface of the distributing block and to and beyond the peripheral wall of the conduit, thereby to define at least three separate zones at the rear surface of said spinneret plate, each zone being defined by two of said duct branches and the peripheral wall of the conduit; said distributing block also having formed therein feed passage means comprising at least three small holes arranged so that each of said zones has at least one hole communicating therewith, said holes extending axially of said conduit and extending through the front surface of the distributing block at locations inside the peripheral wall of the rear end of the conduit and between said radial duct branches; the rear surface of the spinneret plate and the front surface of the distributor block being in sealed contact with each oTher in the regions between the duct branches and in the region surrounding the conduit so that spinning materials can enter the rear end of the conduit only through said small holes and said duct branches; and means for supplying a first spinning material to said holes and means for applying a second spinning material to said reservoirs.

2. A spinneret according to claim 1, in which said spinneret has a series of orifices and communicating conduits arranged in the shape of an annulus, said distributing block having a first central reservoir disposed inside said annulus and a second annular reservoir surrounding said annulus, said duct branches including branches extending from both said reservoirs to said conduits.

5. A spinneret according to claim 1, in which said orifice is a Y-shaped slit, said duct branches form a Y-shaped duct with the legs of the Y-shaped duct being axially aligned with the legs of said slit, and said feed passage means is composed of three small holes circumferentially offset from the legs of said slit and said duct.

7. A spinneret according to claim 1, in which the number of duct branches is 3.

8. A spinneret according to claim 1, in which the number of duct branches is 4.

9. A spinneret according to claim 1, in which the number of duct branches is 5.

11. A spinneret according to claim 1, in which the orifice has a circular cross-section.