Splitting parent yarn having excellent cross-sectional formability and method for manufacturing the same

Abstract

The present invention relates to a split filament yarn having excellent cross-sectional formability and a manufacturing method thereof. The split filament yarn according to the present invention has excellent split workability, and a filament manufactured from the split filament yarn has excellent cross-sectional formability, the cross-sectional form of the filament can be uniform and diverse, and since the cross-sectional formability of the filament is excellent, a profiled cross-section can be formed, thereby enabling a fabric having improved touch and gloss to be provided. In addition, the manufacturing method of the split filament yarn according to the present invention has excellent split workability, and since the split workability is excellent, the rate of defective products can be reduced, thus having an advantage in terms of processes.

Description

Technical Field

[0001] This invention relates to mother yarn with excellent cross-section forming properties and its manufacturing method. More specifically, it relates to mother yarn with excellent splitting workability and cross-section forming properties, wherein the cross-sectional morphology of the filaments after splitting and dissolving can be uniform and diverse, and can have irregular cross-sections, thereby providing fabrics with improved touch and luster. It also relates to a manufacturing method of mother yarn with excellent splitting workability, reduced defect rate and advantages in process. Background Technology

[0002] In the textile industry, fiber splitting master yarn has attracted much attention as a differentiated material with high added value. Research on endowing fiber splitting master yarn with multiple functions is also being actively carried out. Fiber splitting master yarn is mainly used in curtain fabric, Korean clothing fabric, cushion fabric, carpet and industrial textiles.

[0003] Generally, monofilaments made of materials such as polyester with a fineness of approximately 10 to 50 de are relatively coarse, requiring careful attention during the spinning process to ensure uniform cooling and solidification. Monofilament manufacturing methods mainly include: first producing a mother yrn with 6 to 20 filament bundles during the spinning process, then separating it into individual filaments; and secondly, directly manufacturing individual monofilaments during the spinning process. The latter method avoids complex processes like fiber separation, but when processing the monofilaments through twisting or dyeing, the processing efficiency and productivity are lower because each individual filament is processed individually.

[0004] On the other hand, the splitting master filament requires a special process called splitting. If the monofilament is made into an irregular cross-section, the feel and luster can be improved through its cross-sectional shape. However, due to the increased friction area between the monofilaments caused by the cross-sectional characteristics and the twisting that occurs during the splitting process, the fiber breakage frequency increases, resulting in significantly poor splitting workability. Therefore, the cross-sectional shape of the monofilament is limited to a circular or triangular cross-section. Therefore, a solution is needed that limits the cross-section of each filament constituting the splitting master filament to a circular or triangular cross-section during manufacturing, while making the cross-section of the monofilament after splitting and dissolving an irregular cross-section.

[0005] Existing technical documents Patent documents (Patent Document 1) Korean Patent Publication No. 10-0845096 Summary of the Invention Technical issues The present invention is proposed to overcome the above-mentioned problems. The first problem to be solved by the present invention is to provide a fiber splitting master yarn with excellent fiber splitting workability and cross-section forming properties.

[0006] The second problem to be solved by the present invention is to provide a filament with uniform cross-section and diverse cross-sectional shapes, and a fabric comprising the filament thereby having excellent tactile feel and luster.

[0007] The third problem to be solved by the present invention is to provide a method for manufacturing a fiber-separating masterbatch with improved and superior fiber-separating workability, thereby reducing the defect rate and simplifying the process.

[0008] The problems to be solved by the present invention are not limited to those described above, and other problems not mentioned will be clearly understood by those skilled in the art from the following description.

[0009] means for solving problems To address the aforementioned first problem, a mother yarn with excellent cross-sectional forming properties is provided, comprising a plurality of filaments, wherein at least one filament comprises a soluble polymer and an insoluble polymer.

[0010] Furthermore, the number of the plurality of filaments can be from 2 to 20, and their cross-sections can be circular or triangular.

[0011] According to a preferred embodiment of the present invention, the coefficient of variation (CV%) of the denier distribution of the plurality of filaments can be less than 1.6. In addition, the soluble polymer may include at least one component selected from water-soluble or alkali-soluble components.

[0012] Furthermore, the content ratio of the insoluble polymer to the soluble polymer can be from 90:10 to 30:70.

[0013] Furthermore, at least a portion of the soluble polymer may be exposed outside the filament.

[0014] Furthermore, the cross-sectional shape of the filament after the splitting of the mother filament can be different from the cross-sectional shape of the filament after dissolution.

[0015] Furthermore, the fiber mother filament can satisfy the following conditions 1), 2), 3), 4), and 5): 1) The total fineness of the fiber mother yarn is ≤500de, and ≤60de is ≤500de; 2) 3.0 g / de ≤ Strength of the filament after splitting ≤ 5.0 g / de; 3) 20% ≤ Elongation of the filaments after splitting ≤ 40%; 4) 3.0 g / de ≤ strength of the dissolved filament ≤ 5.5 g / de; 5) 15% ≤ Elongation of the filament after dissolution ≤ 35%.

[0016] To address the second problem mentioned above, a filament in which a soluble polymer is dissolved from a filament split from a master filament is provided, and a fabric comprising the split filament or the dissolved filament is provided.

[0017] To address the aforementioned third problem, a method for manufacturing a fiber-reinforcing filament with excellent cross-sectional forming properties is provided, comprising: a first step of preparing an insoluble polymer and a soluble polymer; a second step of spinning an unstretched fiber-reinforcing filament using a composite spinning spinneret with an insoluble polymer to soluble polymer content ratio of 90:10 to 30:70; and a third step of stretching the spun unstretched fiber-reinforcing filament, wherein the fiber-reinforcing filament has multiple filaments, and at least one of the filaments includes both an insoluble polymer and a soluble polymer.

[0018] The effects of the invention The fiber-splitting master yarn according to the present invention has excellent fiber-splitting workability, and the filaments made from the fiber-splitting master yarn have excellent cross-section forming properties. The cross-section morphology of the filaments can be uniform and diverse, and due to the excellent cross-section forming properties of the filaments, irregular cross-sections can be formed, thereby providing fabrics with improved touch and luster.

[0019] Furthermore, the method for manufacturing the fiber-separating master yarn according to the present invention has excellent fiber-separating workability. Due to the excellent fiber-separating workability, the defect rate can be reduced, thus providing an advantage in the process.

[0020] The effects of the present invention are not limited to those described above, but should be understood to include all effects that can be deduced from the technical solutions described in this specification or claims. Attached Figure Description

[0021] Figure 1 The image shows a photograph of the cross-section of a fiber-splitting mother filament spun using a four-segment composite spinning spinneret, according to a preferred embodiment of the present invention.

[0022] Figure 2 A photographic image of the cross-section of a fiber-splitting mother filament spun using a four-bladed composite spinning spinneret, according to a preferred embodiment of the present invention.

[0023] Figure 3 A photographic image of the cross-section of a fiber-splitting mother filament spun using a windmill-type composite spinning spinneret, according to a preferred embodiment of the present invention.

[0024] Figure 4 The image shows a photograph of the cross-section of a fiber-splitting mother filament spun using an eight-segment composite spinning spinneret, according to a preferred embodiment of the present invention.

[0025] Explanation of reference numerals in the attached figures 100: Fiber mother filament 101: Insoluble polymer 102: Soluble polymer Detailed Implementation Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings, so that those skilled in the art can readily implement the invention. The present invention may be embodied in different forms and is not limited to the embodiments set forth herein. In the drawings, parts unrelated to the description have been omitted for clarity, and throughout the specification, the same or similar structural elements are given the same reference numerals.

[0026] The terminology used in this specification is for illustrative purposes only and is not intended to limit the invention. Unless otherwise expressly understood herein, singular expressions include plural expressions. In this application, terms such as "comprising" or "having" are used to specify the presence of features, numbers, steps, actions, constituent elements, or combinations thereof described in the specification, and should be understood as not precluding the possibility of the presence or addition of one or more other features, numbers, steps, actions, constituent elements, or combinations thereof.

[0027] Unless otherwise defined, all terms used in this specification, including technical or scientific terms, shall have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. Terms that are commonly used and are identical to those defined in dictionaries shall be interpreted according to their meaning in the context of the relevant technical field, and shall not be interpreted as having an idealized or overly formal meaning unless explicitly defined in this specification.

[0028] In this specification, "filament after splitting" refers to filament that has been split by applying a splitting process to the splitting master filament.

[0029] In this specification, "dissolved filament" refers to the filament after the soluble polymer component has been dissolved (reduced) in the filament separated by the above-mentioned fiber separation process.

[0030] In this specification, “reduction” means that the soluble polymer is dissolved by the reduction solution.

[0031] In this specification, “reducing solution” refers to a solution that can dissolve (reduce) the soluble polymers contained in the fiber mother filament.

[0032] As mentioned above, if the filaments included in the splitting masterbatch are made into irregular cross-sections, the feel and luster can be improved through their cross-sectional shape. However, due to the increased friction area between the filaments caused by the cross-sectional characteristics and the twisting that occurs during the splitting process, there is a significant decrease in the workability of the splitting process. Therefore, there is a reality that the cross-sectional shape of the filaments is limited to circular and triangular shapes, which do not cause the above-mentioned problems. Therefore, there is a need for a solution that, while manufacturing the filaments constituting the splitting masterbatch with cross-sectional shapes such as circular and triangular shapes that do not cause the above-mentioned problems, also makes the cross-section of the filaments after the splitting and dissolving of the splitting masterbatch different from the cross-section of the filaments after splitting.

[0033] To address this issue, the present invention provides a mother yarn 100 with excellent cross-sectional forming properties, comprising a plurality of filaments, wherein at least one filament comprises a soluble polymer 102 and an insoluble polymer 101, in order to solve the aforementioned problems. The mother yarn 100, comprising filaments of both soluble and insoluble polymer 102, can be spun with circular or triangular cross-sections, thereby dissolving the soluble polymer 102 in the filaments after splitting the mother yarn 100 without causing poor splitting performance, thus providing filaments with various cross-sectional shapes. Therefore, fabrics comprising this filament can have excellent touch and luster.

[0034] Specifically, refer to Figures 1 to 4 As can be described, the fiber mother filament 100 of the present invention includes a plurality of filaments, wherein at least one filament includes a soluble polymer 102 and an insoluble polymer 101.

[0035] The plurality of filaments in the fiber-splitting master yarn 100 may include 2 to 20, preferably 6 to 20. The number of filaments refers to the number of filaments produced after the fiber-splitting master yarn 100 undergoes the fiber-splitting process. If the number of filaments exceeds 20, the insoluble polymer 101, which is the fiber-forming component, will become finer. As the contact surface area with the weight-reducing liquid increases, chemical resistance may decrease, and the possibility of twisting between filaments may increase, thereby significantly reducing the throughput of the fiber-splitting process and increasing the loss when a single filament breakage occurs, thus leading to increased manufacturing costs. Conversely, if the number of filaments is less than 6, the output in the fiber-splitting process will be greatly reduced, resulting in increased manufacturing costs and deteriorated economic efficiency.

[0036] The cross-sections of the plurality of filaments can be circular or triangular. If the cross-sections are limited to circular or triangular, sufficient fiber separation process can be ensured. If the cross-sections are not circular or triangular, the friction area between the filaments in the fiber separation master filament 100 will increase, and twisting may occur during the fiber separation process, resulting in significantly poor fiber separation workability.

[0037] The interior of at least one filament simultaneously includes a soluble polymer 102 and an insoluble polymer 101.

[0038] If a soluble polymer 102 is added inside the filament, the soluble polymer can be dissolved (reduced) by the reducing liquid described later, thereby producing a filament with an irregular cross-section, and thus a fabric comprising the filament with the irregular cross-section can be manufactured. Because the fabric has an irregular cross-section that is different from a circular or triangular cross-section, it can have an excellent tactile feel and a luster superior to that of the prior art.

[0039] The soluble polymer 102 may include at least one component selected from water-soluble or alkali-soluble components. The water-soluble or alkali-soluble components that can be used in this invention are not limited in any way, as long as they are commonly used in the fiber industry.

[0040] Specific examples of water-soluble components include: water-soluble polyalkyl oxides such as polyethylene oxide, polypropylene oxide, and ethylene oxide-propylene oxide copolymers; neutralized (meth)acrylamide-(meth)acrylic acid copolymers; and monopolymers of (meth)acrylamide. The copolymers may be block copolymers or random copolymers. Furthermore, the propylene oxide constituting the polypropylene oxide may typically be 1,2-propylene oxide or 1,3-propylene oxide, or both may be used in combination. In addition, specific examples of alkali-soluble components include polylactic acid, ultra-high molecular weight polyalkyl oxide condensation polymers, esterification products obtained by reacting acid components with glycol components (the acid components include aromatic polycarboxylic acids with 6 to 14 carbon atoms and sodium 3,5-dimethoxybenzenesulfonate), and condensation copolyesters including polyethylene glycol.

[0041] At least a portion of the soluble polymer 102 may be exposed outside the filament. (See reference...) Figures 1 to 4 It can be confirmed that a portion of the soluble polymer 102 is exposed outside the filament. If at least a portion is not exposed, the soluble polymer 102 cannot fully contact the solution in the reducing liquid, which may result in a significant reduction in the dissolution rate and dissolution uniformity.

[0042] The soluble polymer 102 can be dissolved (reduced) by a reduction solution. This reduction solution can be used without restriction as long as it is a solution capable of reducing the volume of the soluble polymer 102. Preferably, if the soluble polymer 102 is a water-soluble polymer, the reduction solution is water. The water used is typically purified water such as ion-exchanged water or pure water, but tap water or industrial water can also be used depending on the intended use of the water-soluble polymer composition. Preferably, if the soluble polymer 102 is an alkali-soluble polymer, the reduction solution can be an alkaline solution. The type of alkaline solution can vary depending on the specific conditions of the reduction process, such as the temperature of the alkaline solution and whether additives are added to increase the reduction speed. This is not particularly limited in this invention. More preferably, an aqueous sodium hydroxide solution can be used. The concentration of the aqueous sodium hydroxide solution is not particularly limited, but is preferably 0.1% to 20% by mass.

[0043] The insoluble polymer 101 may be any polymer commonly used in the art for fiber splitting filaments 100, preferably including at least one of polyester or polyamide components. More preferably, if it is a polyester component, it may include the group consisting of polyethylene terephthalate (PET), polybutylene terephthalate (PBT), hexane terephthalate, polyethylene naphthalate, polybutylene naphthalate, polyethylene-1,2-bis(phenoxy)ethane-4,4'-dicarboxylate, polyethylene isophthalate / naphthalate copolymer, polybutylene terephthalate / isophthalate copolymer, and polybutylene terephthalate / sebate copolymer; or if it is a polyamide component, it may include one or more components selected from the group consisting of nylon 6, nylon 66, nylon 6.10, and aramid.

[0044] In a preferred embodiment of the present invention, the content ratio of insoluble polymer 101 to soluble polymer 102 included in the fiber mother filament 100 can be from 90:10 to 30:70, preferably from 80:20 to 50:50. If the ratio exceeds the above range, the molten polymer may produce filament twisting when passing through the spinning spinneret, thus potentially leading to poor spinning. Specifically, if the content ratio of insoluble polymer 101 exceeds 90, the content of soluble polymer 102 may decrease, potentially resulting in poor flowability of soluble polymer 102, thus potentially causing problems with cross-sectional variation, and the distribution of soluble polymer 102 on the cross-section may not be appropriate, thus potentially leading to poor cross-sectional formation after dissolution. If the content of insoluble polymer 101 is less than 30, the strength and elongation of the splitting master filament 100, as well as the split filament and dissolved filament, will decrease due to the reduced content of insoluble polymer 101 as a component of cross-section formation. This may lead to fabric defects. Furthermore, the reduced content of insoluble polymer 101 will result in insufficient flowability, which may cause problems in terms of cross-section variation.

[0045] The coefficient of variation (CV%) of the denier distribution of the multiple filaments can be below 1.6, preferably between 0.5 and 1.6. In this case, the CV% value represents the extent to which the denier distribution expands (denier deviation) relative to the average value (arithmetic mean denier). The CV% value is calculated using the following formula: CV% = (standard deviation / average value) × 100. If the CV% value exceeds 1.6, the denier distribution range of the filaments becomes wider, and the properties of each filament may differ. This makes it difficult to control the properties of the fabric made from the filament, and it is impossible to achieve a uniform cross-section after dissolution. The cross-sectional shape is difficult to control, and due to the uneven thickness between the filaments, a significant decrease in fiber separation may occur. If the CV% value is below 0.5, additional equipment and processes are required to reduce the coefficient of variation, leading to increased manufacturing costs, but the quality difference may be minimal. On the other hand, by adjusting the content ratio of insoluble polymer 101 to soluble polymer 102, the fluidity of the polymer with a lower content can be improved, thereby reducing cross-sectional variation and thus helping to reduce the CV value.

[0046] The cross-section and physical properties of the fiber mother filament 100 are described below.

[0047] The cross-sectional shape of the filament after splitting the master filament 100 can differ from that of the filament after dissolution. Specifically, the cross-section of the split filament can be circular or triangular, while the cross-section of the dissolved filament can be non-circular or non-triangular, preferably a four-segment, four-blade, windmill, or eight-segment type. In the split filament, a soluble polymer 102 can be used to fill the portion other than the cross-section forming component (insoluble polymer) using a composite spinning method, thereby achieving a circular or triangular cross-section. Because the cross-section of the split filament is circular or triangular, the splitting process can be improved. Subsequently, the soluble polymer 102 is partially dissolved (reduced) using a reducing agent, which allows the cross-section of the dissolved filament to be formed as non-circular or non-triangular, thus obtaining a fabric with excellent touch and luster.

[0048] The total fineness of the splitting master filament 100 can be 60–500 de, preferably 80–400 de. If the total fineness of the splitting master filament 100 is less than 60 de, the low fineness of the individual filaments may result in extremely poor passability of the splitting process. Furthermore, if the fineness exceeds 500 de, the increased fineness of the individual filaments will result in coarse fineness, making it impossible to achieve sufficient curing in the quenching chamber of ordinary spinning equipment. This may lead to extremely poor yarn production and significant dyeing abnormalities due to incomplete stretching.

[0049] On the other hand, the fineness of the filaments after splitting can be 5 to 50 de, preferably 8 to 30 de. If the fineness of the filaments after splitting is less than 5 de, the weavability may be extremely poor, and the woven fabric will be weak and prone to tearing. If the fineness of the filaments after splitting exceeds 50 de, the fabric may have poor dyeing due to insufficient curing, and the weaving throughput may be insufficient due to uneven filament fineness.

[0050] The strength of the filaments after the splitting of the mother filament 100 can be 3.0–5.0 g / de. If the strength is below 3.0 g / de, not only will the filamentation properties be poor, but the chemical resistance will also decrease, which may lead to the erosion of insoluble polymer 101 during the dissolution process, and there is also a risk of insufficient tear strength on the fabric, making it prone to tearing and pilling. If the strength exceeds 5.0 g / de, the reduction rate of soluble polymer 102 will decrease, resulting in a longer dissolution process time, which will increase the process cost and may cause the insoluble polymer 101 to become embrittled.

[0051] The elongation of the filaments after splitting the master fiber 100 can be 20-40%. If the elongation is less than 20%, the reduction rate of the soluble polymer 102 will decrease, leading to a longer dissolution process time, which may increase process costs and cause the insoluble polymer 101 to become embrittled. If the elongation exceeds 40%, uneven dyeing may occur due to uneven stretching, and because the insoluble polymer 101, as a fiber-forming component, is not stretched sufficiently, the non-crystalline portion will increase significantly, resulting in decreased chemical resistance and the possibility of corrosion by the insoluble polymer 101 during the dissolution process.

[0052] The strength of the filament after dissolving the mother filament 100 can be 3.0–5.5 g / de. If the strength of the dissolved filament is less than 3.0 g / de, the tear strength on the fabric will be poor, and there is a risk of tearing and pilling. If the strength of the dissolved filament exceeds 5.5 g / de, the fabric may be relatively stiff, and there is a risk of insufficient tactile feel.

[0053] On the other hand, the splitting mother filament 100 includes a soluble polymer 102 that is weaker than the insoluble polymer 101. If the soluble part is dissolved and partially disappears during the process, the content of the insoluble polymer 101 becomes higher, which may increase the strength of the filament after dissolution compared to the filament after splitting.

[0054] The elongation of the filament after dissolving the splitting masterbatch 100 can be between 15% and 35%. Due to prolonged exposure to high temperatures during the dissolution process, the elongation may be lower than that of the filament before splitting. If the elongation of the filament after dissolution is less than 15%, it may negatively impact the process flow during weaving and dyeing, and may lead to defects such as fabric breakage. If the elongation of the filament after dissolution exceeds 35%, it may cause dyeing abnormalities due to incomplete stretching of the insoluble polymer 101, which is a fiber-forming component, and may result in weft stripes due to uneven cross-section.

[0055] On the other hand, the splitting filament 100 can be a twisted splitting filament 100 that has undergone a twisting process (DTY) and then a splitting process. If the splitting filament 100 undergoes a twisting process, it can exhibit a soft touch and volume like natural fibers, thus making it easy to manufacture high-sensory, high-value-added products.

[0056] To address the aforementioned issues, a filament (dissolved filament) is provided in which the soluble polymer 102 is dissolved from the filament (filament after splitting) formed from the splitting master filament 100.

[0057] The fiber separation can be carried out through a fiber separation process, which may include the conventional fiber separation process, preferably the twisting fiber separation process, and more preferably the DTY (Draw Textured Yarn) process in the twisting process.

[0058] Furthermore, the dissolving process can be carried out using the aforementioned reduction solution. The dissolving process can be performed before the dyeing and finishing processes described later, but is not limited to this order. Through the dissolving process, the cross-section of the split filaments, which originally had a circular or triangular cross-section, is transformed into an irregular cross-section, thereby improving the feel and enhancing the luster.

[0059] To address the aforementioned issues, a fabric comprising the split filament (splitting filament) or the dissolved filament (dissolved filament) is provided.

[0060] The fabric is not particularly limited in its type and can be woven or knitted. If the fabric is woven, it can be a woven fabric woven using the filaments as warp or weft yarns. Preferably, the weaving can be any of the following methods: plain weave, twill weave, satin weave, and double weave. The density of the warp and weft yarns is not particularly limited. Furthermore, if the fabric is knitted, it can be a knitted fabric including the filaments. Preferably, the knitting can be conventional weft knitting or warp knitting.

[0061] The fabric can be manufactured by weaving or knitting the split filaments, followed by fabric fabrication and pretreatment, dyeing and finishing, and washing processes. A dissolving process can be added before dyeing and finishing to form the desired cross-section. The fabric is then dyed and finally finished through dissolving and washing processes, thus providing a fabric with an irregular cross-section. However, the above processing steps are not mandatory, and the order of the dissolving process is not limited to before dyeing and finishing.

[0062] To address the aforementioned issues, a method for manufacturing a fiber-retaining filament 100 with excellent cross-sectional forming properties is provided, comprising: a first step of preparing an insoluble polymer 101 and a soluble polymer 102; a second step of spinning an unstretched fiber-retaining filament 100 with the content ratio of the insoluble polymer 101 to the soluble polymer 102 being 90:10 to 30:70; and a third step of stretching the spun unstretched fiber-retaining filament 100, wherein the fiber-retaining filament 100 has a plurality of filaments, and at least one of the filaments includes both the insoluble polymer 101 and the soluble polymer 102.

[0063] The insoluble polymer 101 and soluble polymer 102 and their content ratio are the same as described above, so they will not be repeated here.

[0064] The unstretched fiber mother filament 100 can be stretched using any stretching method commonly used in the art, therefore the present invention does not particularly limit it. The plurality of filaments and the insoluble polymer 101 and soluble polymer 102 constituting the filaments are the same as described above, so the specific details will not be repeated here.

[0065] The manufacturing method of the splitting master yarn 100 may include a twisting process, preferably including a DTY (Draw Textured Yarn) process. The twisting process of the splitting master yarn 100 can be performed before the splitting process. If the splitting master yarn 100 undergoes a twisting process, it can exhibit a soft touch and fluffiness similar to natural fibers, thus making it easy to manufacture high-sensory, high-value-added products.

[0066] The present invention will be described in more detail below through embodiments, but the following embodiments do not limit the scope of the present invention and should be understood as being used to help understand the present invention.

[0067] <Example> Example 1: Manufacturing of four-segmented split filament 100, split filaments and dissolved filaments Insoluble polymer 101 was TORAY's SD (SemiDull), and soluble polymer 102 was TORAY's alkali-soluble ESP (Easy Soluble Polyester). A four-segment composite spinning spinneret was used, with insoluble polymer 101 and soluble polymer 102 mixed in a 7:3 ratio. The spinning speed was fixed at 4000 MPM (meters per minute). Stretching was performed under conditions ensuring good yarn uniformity and preventing dyeing defects to produce a splitting master yarn 100 with a fineness of 200 de, containing 10 filaments, and with a circular cross-section of the filaments before splitting. Figure 1 ). Subsequently, the splitting master filaments 100 are wound into 10kg bundles and then split into 1kg bundles at a speed of 600MPM using an automatic splitting machine of model DY-101 from DAEYOUNG INDUSTRY Co., Ltd., with a tension of less than 20cN and a speed of 600MPM, thereby producing split filaments with a four-section cross-section.

[0068] After the filaments are split, they are fed into a sock knitting machine to form knitted fabric. Then, they are dissolved in a 1% sodium hydroxide aqueous solution at 100°C under normal pressure to completely remove the soluble polymer 102 contained in the filaments, thereby producing dissolved filaments.

[0069] Example 2: Manufacturing of four-leaf wing-shaped splitting master filament 100, splitting filament, and dissolving filament Except for the spinneret being a four-bladed composite spinning spinneret, the process was carried out in the same manner as in Example 1, and a fiber splitting masterbatch 100 was manufactured. Figure 2 ), filaments after splitting and filaments after dissolution.

[0070] Example 3: Manufacturing of windmill-type fiber splitting master filament 100, split filaments, and dissolved filaments Except for the spinneret being a windmill-shaped composite spinning spinneret, the remaining steps were the same as in Example 1, producing a fiber-splitting master filament 100 ( Figure 3 ), filaments after splitting and filaments after dissolution.

[0071] Example 4: Manufacturing of eight-segmented split filament 100, split filaments, and dissolved filaments Except that the spinneret is an eight-segment composite spinning spinneret, the process was carried out in the same manner as in Example 1, and 100 microfibers were produced. Figure 4 ), filaments after splitting and filaments after dissolution.

[0072] Example 5: Manufacturing of eight-segmented splitting master filament 100, splitting filaments, and dissolving filaments Except that the spinneret is an eight-segment composite spinning spinneret and the ratio of insoluble polymer 101 to soluble polymer 102 is 9:1, the process was carried out in the same manner as in Example 1, and the splitting master filament 100 was manufactured. Figure 4 ), filaments after splitting and filaments after dissolution.

[0073] <Comparative Example> Comparative Example 1: Manufacturing of four-segmented split filament 100, split filaments, and dissolved filaments Except that the ratio of insoluble polymer 101 to soluble polymer 102 is 9.5:0.5, the process was carried out in the same manner as in Example 1 to produce split master filament (100), split filament, and dissolved filament.

[0074] Comparative Example 2: Manufacturing of four-leaf wing-shaped splitting master filament 100, splitting filament, and melting filament Except that the ratio of insoluble polymer 101 to soluble polymer 102 is 9.5:0.5 and the spinneret is a four-blade composite spinning spinneret, the process was carried out in the same manner as in Example 1, and the splitting master filament 100, the split filament, and the dissolved filament were manufactured.

[0075] Comparative Example 3: Manufacturing of windmill-type splitting master filament 100, splitting filaments, and dissolving filaments Except that the ratio of insoluble polymer 101 to soluble polymer 102 is 9.5:0.5 and the spinneret is a windmill-shaped composite spinning spinneret, the process was carried out in the same manner as in Example 1, and the splitting master filament 100, the split filament, and the dissolved filament were manufactured.

[0076] Comparative Example 4: Manufacturing of 100-segmented split filament, split filament, and dissolved filament Except that the ratio of insoluble polymer 101 to soluble polymer 102 is 9.5:0.5 and the spinneret is an eight-segment composite spinning spinneret, the process was carried out in the same manner as in Example 1, and the splitting master filament 100, the split filament, and the dissolved filament were manufactured.

[0077] Comparative Example 5: Manufacturing of four-segmented split filament 100, split filaments, and dissolved filaments Except that the ratio of insoluble polymer 101 to soluble polymer 102 is 2:8, the process was carried out in the same manner as in Example 1 to produce splitting master filament 100, split filament, and dissolved filament.

[0078] Comparative Example 6: Manufacturing of four-leaf wing-shaped splitting master filament 100, splitting filament, and melting filament Except that the ratio of insoluble polymer 101 to soluble polymer 102 is 2:8 and the spinneret is a four-blade composite spinning spinneret, the process was carried out in the same manner as in Example 1 to produce splitting master filament 100, split filament and dissolved filament.

[0079] Comparative Example 7: Manufacturing of windmill-type splitting master filament 100, splitting filaments, and dissolving filaments Except that the ratio of insoluble polymer 101 to soluble polymer 102 is 2:8 and the spinneret is a windmill-shaped composite spinning spinneret, the process was carried out in the same manner as in Example 1, and the splitting master filament 100, the split filament, and the dissolved filament were manufactured.

[0080] Comparative Example 8: Manufacturing of Eight-Sectioned Splitting Mother Yarn 100, Splitting Filaments, and Dissolving Filaments Except that the ratio of insoluble polymer 101 to soluble polymer 102 is 2:8 and the spinneret is an eight-segment composite spinning spinneret, the process was carried out in the same manner as in Example 1, and the splitting master filament 100, the split filament, and the dissolved filament were manufactured.

[0081] <Experimental Example> Experimental Example 1: Evaluation of CV% value of fineness distribution The fineness of each filament after splitting was measured, and the coefficient of variation (CV%) of the measured fineness distribution was calculated. The coefficient of variation (CV%) represents the extent to which the fineness distribution expands (fineness deviation) relative to the average value (arithmetic mean fineness), and is calculated by CV% = (standard deviation / average value) × 100. The fineness of the filaments after splitting in Examples 1-5 and Comparative Examples 1-8 was measured, and the results are shown in Tables 1 and 2.

[0082] Table 1

[0083] Table 2

[0084] Analysis of Table 1 confirms that as the ratio of insoluble polymer 101 to soluble polymer 102 becomes closer, the fiber splitting workability improves and the CV value decreases. Specifically, the spinneret types of Examples 1, Comparative Examples 1 and 5 are all four-segment types. Example 1, with the closest ratio of insoluble polymer 101 to soluble polymer 102, has a CV% value of 7.5, while Comparative Example 5, with a larger ratio difference, has a CV% value of 16.4, and Comparative Example 1, with an even larger ratio difference, has a CV% value of 18.4. The same applies to Examples 2, Comparative Examples 2 and 6 (four-blade type), Examples 3, 3 and 7 (windmill type), and Examples 4, 4 and 8 (eight-segment type). Therefore, if the ratio of insoluble polymer 101 to soluble polymer 102 is within the range of 90:10 to 30:70, the section forming properties are excellent.

[0085] On the other hand, referring to Table 2, it can be confirmed that the content ratios of Examples 4 and 5 are both in the range of 90:10 to 30:70. However, the proportion of insoluble polymer 101 in Example 5 is higher than that in Example 4, resulting in a content ratio biased towards insoluble polymer 101, and therefore its CV% value is higher. Consequently, the cross-section of Example 5 is less uniform than that of Example 4, and its fiber separation is poor.

[0086] Experimental Example 2: Evaluation of Dissolution Time To evaluate the dissolution rate of soluble polymer 102 in the split filaments manufactured in Examples 1-4 and Comparative Examples 1-8, the split filaments were fed into a sock knitting machine to form knitted fabric, and then dissolved in a 1% by weight sodium hydroxide aqueous solution at 100°C under normal pressure. The time required for complete removal of soluble polymer 102 contained in the filaments was measured. The results are shown in Table 3 below.

[0087] Table 3

[0088] The results, as explained in Table 3, show that the dissolution time varies depending on the spinneret type and the content of soluble polymer 102. As the content of soluble polymer 102 increases, the content of soluble polymer 102 in the filament increases, thus prolonging the time required to dissolve the soluble polymer 102 using the reducing agent. For example, when comparing Examples 1, Comparative Example 1, and Comparative Example 5, which were manufactured using a four-segment spinneret, Comparative Example 1, with the lowest soluble polymer 102 content, had the shortest dissolution time of 17 minutes, while Comparative Example 5, with the highest soluble polymer 102 content, had the longest dissolution time of 41 minutes.

[0089] Furthermore, it can be confirmed that if the number of externally exposed soluble polymers 102 within the cross-section increases, the contact area between the soluble polymers 102 and the reducing liquid increases, thereby accelerating the dissolution rate of the soluble polymers 102. For example, in Example 1 using a four-segment spinneret, since there are four externally exposed soluble polymers 102 within the cross-section, the dissolution time is 26 minutes. In Example 4 using an eight-segment spinneret, since there are eight externally exposed soluble polymers 102 within the cross-section, the dissolution time is shorter than in Example 1, at 22 minutes. Therefore, it can be confirmed that if the number of externally exposed soluble polymers 102 increases, the dissolution process is easier to perform; if there are no externally exposed soluble polymers 102, the dissolution rate and dissolution uniformity may decrease significantly.

[0090] Experiment Example 3: Evaluation of Fiber Splitting Operation In Examples 1-5 and Comparative Examples 1-8, the splitting master yarn 100 was wound into 10 kg bundles and then split into 1 kg bundles of 10 strands at a speed of 600 MPa using a DY-101 splitting machine from DAEYOUNG INDUSTRY Co., Ltd., under a tensile tension of less than 20 cN. Each operation was repeated 10 times, and the splitting workability value was calculated as the average number of yarn breaks during the 10 splitting processes. The results are shown in Tables 4 and 5.

[0091] Table 4

[0092] Table 5

[0093] The results, as explained in Table 4, show that for each spinneret type, the fiber splitting performance of Comparative Examples 1-4 was slightly worse than that of Examples 1-4, while the fiber splitting performance of Comparative Examples 5-8 decreased sharply. Furthermore, it can be confirmed that the fiber splitting performance improved as the ratio of insoluble polymer 101 to soluble polymer 102 became closer. This is because in the composite spinning process, if the polymer ratio is biased towards one side, the amount of polymer with the lower ratio forming within the cross-section is insufficient, resulting in insufficient cross-section formation.

[0094] For example, when comparing Example 1, which uses a four-segment spinneret, with Comparative Examples 1 and 5, it can be seen that in Example 1, the contents of insoluble polymer 101 and soluble polymer 102 are similar, resulting in fewer filament breakages; while in Comparative Examples 1 and 5, the content of one polymer is higher than that of the other polymer, resulting in more filament breakages.

[0095] On the other hand, referring to Table 5, it can be confirmed that even when the content ratio of insoluble polymer 101 to soluble polymer 102 is in the range of 90:10 to 30:70, as the contents of insoluble polymer 101 and soluble polymer 102 become closer, the CV% value of the fineness distribution decreases, thereby improving the fiber separation workability.

[0096] While one embodiment of the present invention has been described above, the concept of the present invention is not limited to the embodiment disclosed in this specification. For those skilled in the art who understand the concept of the present invention, other embodiments can be easily proposed within the same technical concept by adding, changing, deleting or adding constituent elements, and these also fall within the concept and scope of the present invention.

Claims

1. A type of fiber-forming mother filament, characterized in that, Includes multiple filaments, At least one of the filaments comprises a soluble polymer and an insoluble polymer.

2. The fiber mother filament with excellent cross-sectional forming properties according to claim 1, characterized in that, The number of the plurality of filaments is 2 to 20.

3. The fiber mother filament with excellent cross-sectional forming properties according to claim 1, characterized in that, The cross-sections of the multiple filaments are circular or triangular.

4. The fiber mother filament with excellent cross-sectional forming properties according to claim 1, characterized in that, The coefficient of variation (CV%) of the fineness distribution of the plurality of filaments is less than 1.

6.

5. The fiber-splitting mother filament according to claim 1, characterized in that, The soluble polymer includes at least one component selected from water-soluble or alkali-soluble components.

6. The fiber mother filament with excellent cross-sectional forming properties according to claim 1, characterized in that, The content ratio of the insoluble polymer to the soluble polymer is 90:10 to 30:

70.

7. The fiber mother filament with excellent cross-sectional forming properties according to claim 1, characterized in that, At least a portion of the soluble polymer is exposed outside the filament.

8. The fiber mother filament with excellent cross-sectional forming properties according to claim 1, characterized in that, The cross-sectional shape of the filament after the splitting of the master fiber is different from the cross-sectional shape of the filament after dissolution.

9. The fiber mother filament with excellent cross-sectional forming properties according to claim 1, characterized in that, The fiber mother filament satisfies the following conditions 1), 2), 3), 4), and 5): 1) The total fineness of the fiber mother yarn is ≤500de, and ≤60de is ≤500de; 2) 3.0 g / de ≤ Strength of the filament after splitting ≤ 5.0 g / de; 3) 20% ≤ Elongation of the filaments after splitting ≤ 40%; 4) 3.0 g / de ≤ strength of the dissolved filament ≤ 5.5 g / de; 5) 15% ≤ Elongation of the filament after dissolution ≤ 35%.

10. A filament from which the soluble polymer is dissolved in the filament derived from the fiber-splitting masterbatch of claim 1.

11. A fabric, characterized in that, Includes the filament as described in claim 10.

12. A method for manufacturing a fiber mother filament with excellent cross-sectional forming properties, characterized in that, include: The first step is to prepare insoluble and soluble polymers; The second step involves spinning unstretched microfiber masterfilaments using a composite spinning spinneret with a ratio of insoluble polymer to soluble polymer of 90:10 to 30:

70. The third step is to stretch the unstretched filaments of the spun yarn. The fiber mother filament has multiple filaments, and at least one of the filaments includes both an insoluble polymer and a soluble polymer.

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