MODIFIED CROSS-SECTION HOLLOW FIBER, AND FIBER ASSEMBLY USING SAME

Abstract

The present invention provides a modified cross-section hollow fiber, wherein the fiber comprises a hollow part, a shape maintaining part and a volume control part, the volume control part can have a shape protruding in the direction opposite to the center of the fiber, and an end part has a round shape.

Claims

1. A modified cross-section hollow fiber, comprising: a hollow part, a shape maintaining part, and a volume control part, wherein the volume control part has a shape protruding in an opposite direction to the fiber center and an end part has a rounded shape.

2. The modified cross-section hollow fiber of claim 1, wherein when the top of the end part of the volume control is defined as a peak and a space between the volume control parts is defined as a valley, the following condition is satisfied.
−3≦Z≦4  (1) $\begin{array}{cc}0.9\le \underset{Z=1}{\overset{N}{.Math.}}.Math.Z\le 1.8& \left(2\right)\end{array}$ Herein, Z: R−r N: The number of volume control parts

3. The modified cross-section hollow fiber of claim 1, wherein the following condition is satisfied.
(CT.sub.max−R)/(CT.sub.min−R)≧0.80  (3)
(Ct.sub.max−r)/(Ct.sub.min−r)≧0.30  (4) Herein, T1: The largest value of a distance from a central point M to a peak 310 T2: the smallest value of a distance from the central point M to the peak 310 t1: the largest value of a distance from a central point M to a valley 330 t2: the smallest value of a distance from the central point M to the valley 330 CTmax: a circle formed by connecting tangents of the volume control part 300 having the second largest value of the distance between the center point M and the peak 310 based on T1 CTmin: a circle formed by connecting tangents of the volume control part 300 having the second smallest value of the distance between the center point M and the peak 310 based on T2 Ctmax: a circle formed by connecting tangents of the volume control part 300 having the second largest value of the distance between the center point M and the valley 310 based on t1 Ctmin: a circle formed by connecting tangents of the volume control part 300 having the second smallest value of the distance between the center point M and the valley 310 based on t2 CTmax−R: a difference value between the center point CTmaxM of CTmax and the center point M CTmin−R: a difference value between the center point CTminM of CTmin and the center point M Ctmax−r: a difference value between the center point CtmaxM of Ctmax and the center point M Ctmin−r: a difference value between the center point CtminM of Ctmin and the center point M

4. The modified cross-section hollow fiber of claim 1, wherein a shape for forming the volume control part is prepared by a radically deployed spinneret.

5. The modified cross-section hollow fiber of claim 4, wherein a radically deployed angle θ is 10 to 17° based on the center point M.

6. The modified cross-section hollow fiber of claim 1, wherein the number of volume control parts is 4 to 12.

7. The modified cross-section hollow fiber of claim 1, wherein a hollow ratio of the hollow part is 15 to 30%.

8. Fibrous assemblies including the fiber according to any one of claims 1 to 7.

9. The fibrous assemblies of claim 8, wherein when the fibrous assemblies are prepared by a thermal bonding process, the fibrous assemblies include 60 to 90 wt % of a modified cross-section hollow fiber and 40 to 10 wt % of a bonding material, a length of the modified cross-section hollow fiber is 51 to 64 mm, and a thickness of the fiber is 4 to 8 deniers.

10. The fibrous assemblies of claim 8, wherein when the fibrous assemblies are prepared by a melt blowing process, the fibrous assemblies include 20 to 60 wt % of a modified cross-section hollow fiber and 80 to 40 wt % of a fine PP fiber, a length of the modified cross-section hollow fiber is 32 to 51 mm, and a thickness of the fiber is 4 to 8 deniers.

11. The fibrous assemblies of claim 8, wherein the modified cross-section hollow fiber includes a modified cross-section fiber which applies bulkiness and sound absorption of the assemblies and simultaneously reduces a diffraction effect of sound energy to be separated between adjacent fibers in the assemblies.

12. A sanitary nonwoven fabric including the modified cross-section hollow fiber according to any one of claims 1 to 7.

13. The sanitary nonwoven fabric of claim 12, wherein a modified cross-section hollow fiber in the nonwoven fabric is contained with 40 wt % or more.

14. The modified cross-section hollow fiber of claim 1, wherein the fiber is made of two types of polymers having different intrinsic viscosities as a composite fiber, and the complex-spun fiber has an omega (Ω)-type spontaneous crimp.

15. The modified cross-section hollow fiber of claim 14, wherein the fiber has a side-by-side hollow structure.

16. The modified cross-section hollow fiber of claim 14, wherein the fiber is made of polyethylene terephthalate (PET), poly 1, 4-cyclohexylenedimethylene terephthalate (PCT), polypropylene (PP), nylon, and the like of two components having different viscosities.

17. The modified cross-section hollow fiber of claim 16, wherein the fiber is constituted by polyethylene terephthalate (PET) of two components having different viscosities and has 10 to 10,000 ppm of at least one polyfunctional group selected from a group consisting of polycarboxylic acid, polyol and polyoxycarboxylic acid in the fiber.

18. The modified cross-section hollow fiber of claim 14, wherein the crimp satisfies the following condition (5).
2.5 mm≦R′≦4.5 mm  (5) Herein, R′: Curvature radius of circular are of crimp

19. A nonwoven fabric for thermal insulation including the modified cross-section hollow fiber according to any one of claims 1 to 7.

Description

DESCRIPTION OF DRAWINGS

[0055] FIGS. 1 to 6 are schematic diagrams of fiber cross-sections according to a preferred embodiment of the present invention.

[0056] FIG. 7 is a schematic diagram of a spinneret corresponding to a volume control part according to a preferred embodiment of the present invention.

[0057] FIG. 8 is a cross-sectional schematic diagram of fibrous assemblies according to a preferred embodiment of the present invention.

[0058] FIG. 9 is a schematic diagram of crimp expression according to a preferred embodiment of the present invention.

[0059] FIG. 10 is a schematic diagram of a spinneret in the related art.

BEST MODE

[0060] Hereinafter, the present invention will be described in detail with reference to the accompanying drawings. First, it should be noted that the same elements or components in the drawings will be designated by the same reference numerals. In describing the present invention, a detailed description of publicly known functions or configurations incorporated herein will be omitted so as not to make the subject matter of the present invention unclear.

[0061] The terms representing the degree used in this specification of approximately, substantially, and the like are used as the value or a meaning close to the value when unique manufacturing and material tolerances are proposed in the aforementioned meaning, and used for preventing the disclosed content in which accurate or absolute figures are mentioned in order to help in the understanding of the present invention from being wrongly used by unscrupulous infringers.

[0062] In this specification, a fiber aggregation includes all of long fibers and staple fibers and means that one or more fibers such as cloths, knitted fabrics, fabrics, nonwoven fabrics, webs, slivers, and tows as a non-limiting example.

[0063] A modified cross-section hollow fiber according to a preferred embodiment of the present invention may be made of all materials which may be formed in a fiber shape. Preferably, polyethylene terephthalate (PET) may be used, but is not limited to it and polypropylene (PP), nylon, and the like may be used. A melt viscosity of the melt-spun PET polymer is preferably 0.60 to 0.64, and an in-out type spinning chimney capable of maximizing a cooling effect is suitable. A thickness of the fiber may be variously applied as 4 to 15 De and a fiber length may be 22 to 64 mm.

[0064] FIG. 1 is a schematic diagram of a modified cross-section hollow fiber according to a preferred embodiment of the present invention, and the fiber 10 may be formed by a hollow part 100, a shape maintaining part 200, and a volume control part 300. A hollow ratio of the hollow part 100 may be about 15 to 30% relative to the total fiber area. In the case of more than the range, there is a problem in fiber formability, and in the case of less than the range, there is a limit in expressing hollow maintenance and various functionalities of the present invention. The shape maintaining part 200 means a fiber shape between the hollow part 100 and the volume control part 300.

[0065] The volume control part 300 may have a shape protruding in an opposite direction to the fiber center and an end part may have a rounded shape. In this case, the top of the end part of the volume control part 300 may be defined as a peak 310 and a space between the volume control parts 300 may be defined as a valley 330. In this case, a curvature radius of the peak may be defined as R and a curvature radius of the valley may be defined as r, and R and r values may be determined to be the same as or different from each other for each volume control part (see FIG. 2).

[0066] Further, the largest value of a distance between a center point M of the hollow part 100 and the peak 310 may be defined as T1, the smallest value of the between the center point M and the peak 310 may be defined as T2, the largest value of a distance between the center point M and the valley 330 may be defined as t1, and the smallest value of the between the center point M and the valley 330 may be defined as t2. Meanwhile, a circle formed by connecting tangents of the volume control part 300 having the second largest value of the distance between the center point M and the peak 310 based on T1 may be defined as CTmax, a circle formed by connecting tangents of the volume control part 300 having the second smallest value of the distance between the center point M and the peak 310 based on T2 may be defined as CTmin, a circle formed by connecting tangents of the volume control part 300 having the second largest value of the distance between the center point M and the valley 310 based on t1 may be defined as Ctmax, and a circle formed by connecting tangents of the volume control part 300 having the second smallest value of the distance between the center point M and the valley 310 based on t2 may be defined as Ctmin.

[0067] Meanwhile, when a difference value between a center point CTmaxM of CTmax and the center point M is defined as CTmax−R, a difference value between a center point CTminM of CTmin and the center point M is defined as CTmin−R, a difference value between a center point CtmaxM of Ctmax and the center point M is defined as Ctmax−r, and a difference value between a center point CtminM of Ctmin and the center point M is defined as Ctmin−r, the fiber according to the present invention may satisfy the following conditions (FIGS. 3 to 6).

[0068] When a deviation of the curvature radius R of the peak and the curvature radius r of the valley is defined as Z, the Z may be made by conditions (1) and (2) below.

−3≦Z≦4  (1)

[00002]$\begin{array}{cc}0.9\le \underset{Z=1}{\overset{N}{.Math.}}.Math.Z\le 1.8& \left(2\right)\end{array}$

[0069] Herein,

[0070] Z: R−r

[0071] N: The number of volume control parts

[0072] As a plurality of test results of the inventors through the fiber cross-sectional shape analysis, beyond the range, a volume control part of one fiber is inserted to a valley between adjacent volume control parts of another fiber to have a structural characteristic as if gears are engaged, and it is analyzed that after insertion, the volume control part is not separated by flow and the like to have a bad effect on uniformity of the fibrous assemblies. Within the range, the volume control parts between the fibers are interfered from each other to maintain bulkiness, and even though the volume control part is inserted to the valley between the adjacent fibers, the volume control part is easily separated by flow and the like to improve the uniformity in the fibrous assemblies.

[0073] Further, in a fiber according to a preferred embodiment of the present invention, CT.sub.max−R, CT.sub.min−R, Ct.sub.max−r, and Ct.sub.min−r may satisfy the following condition.

(CT.sub.max−R)/(CT.sub.min−R)≧0.80  (3)

(Ct.sub.max−r)/(Ct.sub.min−r)≧0.30  (4)

[0074] Herein,

[0075] T1: The largest value of a distance from a central point M to a peak 310

[0076] T2: the smallest value of a distance from the central point M to the peak 310

[0077] t1: the largest value of a distance from a central point M to a valley 330

[0078] t2: the smallest value of a distance from the central point M to the valley 330

[0079] CTmax: a circle formed by connecting tangents of the volume control part 300 having the second largest value of the distance between the center point M and the peak 310 based on T1

[0080] CTmin: a circle formed by connecting tangents of the volume control part 300 having the second smallest value of the distance between the center point M and the peak 310 based on T2

[0081] Ctmax: a circle formed by connecting tangents of the volume control part 300 having the second largest value of the distance between the center point M and the valley 330 based on t1

[0082] Ctmin: a circle formed by connecting tangents of the volume control part 300 having the second smallest value of the distance between the center point M and the valley 330 based on t2

[0083] CTmax−R: a difference value between a center point CTmaxM of CTmax and the center point M

[0084] CTmin−R: a difference value between a center point CTminM of CTmin and the center point M

[0085] Ctmax−r: a difference value between a center point CtmaxM of Ctmax and the center point M

[0086] Ctmin−r: a difference value between a center point CtminM of Ctmin and the center point M

[0087] The conditions (3) and (4) may relate to formability of the fiber according to the embodiment of the present invention. Ideally, the value needs to be 1, but may not 1 by a rheological property of a polymer. The condition (3) may relate to formation of the volume control part, and beyond the above range, a deviation between the volume control parts is increased and a deviation of the r values may be increased to have an effect on carding in the process or bulkiness in the fibrous assemblies. The condition (4) may be interpreted as fiber morphology and have an effect on the formality of the hollow part 100 and the shape maintaining part 200. Beyond the range, the hollow formality and the shape maintenance of the fiber may be unstable.

[0088] Meanwhile, in order to form the fiber cross-section, a spinneret of the volume control part 300 may be formed in a radial shape as illustrated in FIG. 7. In this case, an angle θ may be 10 to 17° based on the center point M. As many test results of the inventors, while a hollow property is maintained within the above range, as a volume control element of a modified cross-section, a fiber cross-sectional shape capable of satisfying the above conditions for expressing the function of the member 300 is implemented.

[0089] In the cross-sectional shape of the modified cross-section hollow fiber used in the present invention, 4 to 12 volume control parts may be formed on the fiber surface.

[0090] Further, the fiber according to the embodiment of the present invention may be made of polyester as a thermoplastic resin as an non-limited example and contribute to improve bulkiness and elasticity in a staple fiber state or a nonwoven fabric shape through spontaneous crimp expression due to a difference in crystallization rate in cooling and solidifying processes.

[0091] The fiber according to the present invention may be prepared by molding fibrous assemblies including a binding material for forming only the fiber or a binding structure between fibers according to the present invention in a nonwoven fabric form through a needle punching process, a thermal bonding process, or a melt blowing process.

[0092] In the fibrous assemblies applying the modified cross-section hollow fiber according to the present invention, as a staple fiber shape of a binding material generally used for binding between the fibers, in the thermal bonding process, a sheath-core modified low-melting point PET staple fiber may be used and in the melt blowing process, a fine PP fiber may be used.

[0093] The material prepared in the thermal bonding process is constituted by a composition including 60 to 90 wt % of the modified cross-section hollow fiber and 40 to 10 wt % of the bonding material, and herein, a length of the modified cross-section hollow fiber may have 51 to 64 mm and the thickness (fineness) of the fiber may be 4 to 8 deniers. When the length of the modified cross-section hollow fiber is less than 51 mm in the thermal bonding process, a gap between the fibers is increased, it is difficult to form a matrix structure, and it is difficult to form and produce the fibrous assemblies. Further, a result of deteriorating sound absorption and sound performance due to excessive porosity may be caused.

[0094] A composition weight ratio of the modified cross-section hollow fiber and the bonding material is preferably 6:4 to 9:1. Herein, when the content of the modified cross-section hollow fiber is less than 60 wt %, the surface area of the fiber is reduced and thus physical properties cannot be implemented, and particularly, since the content of low-melting point PET used in the thermal bonding process is relatively increased, bulkiness having large porosity is not maintained and the fibrous assemblies are hardened. On the contrary, when the content of the modified cross-section hollow fiber is more than 90 wt %, relatively, the content of a binder fiber, that is, the bonding material is less than 10% and thus sufficient bonding force between the fibers is not maintained, and as a result, it is difficult to form the assemblies in any shape.

[0095] The material prepared in the melt blowing process is constituted by a composition including 20 to 60 wt % of the modified cross-section hollow fiber and 80 to 40 wt % of a fine PP fiber, and herein, a length of the modified cross-section hollow fiber may have 32 to 51 mm and the thickness (fineness) of the fiber may be 4 to 8 deniers. When the length is more than 51 mm, in a blowing process by air after opening, an ununiform web is formed due to fiber entanglement. As a result, according to a subsequent process applied to a sound absorbing material and a filler, it is required to select a suitable fiber length in a range of 32 to 64 mm.

[0096] A nonwoven fabric prepared by the thermal bonding process or the melt blowing process may ensure a dead air layer 400 in the space between fibers made by contacting the fiber adjacent to the volume control part 300 of the modified cross-section fiber. The dead air layer 400 may ensure a wider dead air layer 400 so that a space between the fibers may be formed by contacting the peak 310 of the fiber and the peak 310 of the adjacent fiber.

[0097] Thermal insulation by the dead air layer is used to store a large amount of air in pores between the fibers. Dead air ensured by the dead air layer is supported by the fiber as immobile air to have small mobility and may have thermal insulation due to a function of blocking heat without transmitting the heat.

[0098] The volume control parts 300 are limited to a predetermined range and thus the volume control part 300 between the fibers is not easily inserted to the valley 330 of the adjacent fibers and even though the volume control part 300 is inserted, the volume control part 300 may be easily separated and thus it is advantageous in ensuring the dead air layer 400.

[0099] The thermal insulation of a heat retaining nonwoven fabric including a modified cross-section hollow fiber according to an embodiment of the present invention is improved by ensuring dead air layers 400 more than the heat retaining nonwoven fabric including a circular cross-section fiber or a circular cross-section hollow fiber in Comparative Example.

[0100] The circular structure has excellent density compared with a modified structure and an arrangement between adjacent fibers is closer, and thus it is difficult to widely ensure the dead air layer 400.

[0101] Further, the structure of the hollow fiber has a hollow layer 100 for each fiber to more ensure the dead air layer 400. Air is present in the hollow layer 100 to maintain thermal insulation by using low thermal conductivity of the air.

[0102] In a nonwoven fabric including the modified cross-section hollow fiber according to an embodiment of the present invention, density is relatively deteriorated by the modified cross-section structure and the volume control element to ensure more dead air layers 400 and simultaneously more improve thermal insulation by holding the dead air layer 400 through the hollow layer.

[0103] A method of measuring the thermal insulation may use KS K 0560 (2011 constant temperature method).

[0104] In the constant temperature method which is one of the KS K 0560 methods, preliminary tension is applied to a specimen by using a thermal insulation retaining tester having appropriate performance and then attached to a constant temperature heater. A heat loss emitted by transmitting the specimen after 2 hours from the time when an amount of the heat released to outer air at a low temperature becomes constant and then a surface temperature of the heater has a constant value is calculated. The value and a heat loss emitted at the same temperature difference while there is no specimen and at the same time are calculated to measure thermal insulation due to a difference between the two values.

[0105] A thermal insulation ratio may be calculated by the following Equation based on the KS K 0560.

[0106] The thermal insulation ratio (%) is (1−α2/α1)×100, and herein, α1 is a heat dissipation amount (cal/cm.sup.2/sec or w/hr) when there is no specimen in the heater and α2 is a heat dissipation amount when the specimen is attached to the heater.

[0107] Meanwhile, in the present invention, even as the sound absorbing material, the function is expressed, and the sound absorption means that an object absorbs the sound. As the sound absorbing material, a plurality of fiber materials is used, and in energy of a sound input to a fiber material, a part is reflected from the surface, a part is transmitted, and the remaining part is absorbed in the material. The sound absorption in the material occurs due to friction, viscous resistance, or vibration of a fibril in the case of a porous material, membrane vibration in the case of a thin plate or cloth, and a loss of sound energy by resonance in the case of a narrow jar.

[0108] The sound absorption means that when the sound is projected to one side of the material and observed only at the side, a non-reflected sound is absorbed and transmitted to the material, and apparently, the sound is absorbed in the material, and an energy ratio of the non-reflected sound to energy of the input sound is referred to as a sound absorption ratio. The sound absorption ratio varies according to a frequency of the sound, an incident angle, a thickness of the material, an installation method, a situation on the back side, and the like. A sound absorbing material having various sound absorption ratios is used for improving a sound effect in the interior or lowering a noise level.

[0109] Further, the sound has a characteristic of transmitting the sound by a diffraction effect as the energy. Due to the characteristic, even in a space installed with the sound absorbing material, the sound may be propagated to the outside. Accordingly, in the fiber according to the present invention, a function capable of suppressing a sound transmission phenomenon by the diffraction effect as well as the sound absorption will be further proposed.

[0110] In the fiber according to the present invention, the volume control part ensures the bulkiness by a physical interference in the fibrous assemblies as described above to further ensure the space therebetween, thereby improving the sound absorption through vibration of the fiber, securing of the relative thickness, and the like.

[0111] Further, the volume control part may have a characteristic that sound energy propagated through the diffraction effect by enlarging a specific surface area compared with a circular cross-section is consumed while moving along the volume control part according to the present invention to be reduced. As a result, the fiber and the fibrous assemblies according to the present invention may achieve sound insulation and sound blocking effects.

[0112] Meanwhile, in the fibrous assemblies according to the embodiment of the present invention, fine pores in the assemblies are generated by the volume control element to express a water transition characteristic by a capillary phenomenon. In the concept of water discharge, it is important to remove an absolute amount of water retained in the assemblies from the assemblies, but the water rapidly moves to another constitute element in the assemblies to express a water discharge function. For example, when the fibrous assemblies according to the present invention is used for a surface sheet of a diaper or a sanitary pad, a water element generated in the human body is rapidly absorbed through a capillary phenomenon and may rapidly move to an absorbing layer formed on a back surface thereof. In this case, the generated water element rapidly moves to improve an absorption rate and simultaneously, water rapidly moves to the absorbing layer from the surface contacting the skin surface again to express comfortability.

[0113] Meanwhile, the modified cross-section hollow fiber according to the present invention may be prepared by complex spinning. In this case, the modified cross-section hollow composite fiber may be made of all materials which may be formed in a fibrous shape. Preferably, polyethylene terephthalate (PET) having a different viscosity may be used, but is not limited and polypropylene (PP), nylon, poly 1, 4-cyclohexylenedimethylene terephthalate (PCT), and the like may be used by complex spinning.

[0114] In two types of polymers having different intrinsic viscosities, a polymer having a relative high intrinsic viscosity may be defined as a first polymer 400 and a polymer having a relative low intrinsic viscosity may be defined as a second polymer 410.

[0115] The modified cross-section hollow composite fiber according to the embodiment of the present invention includes all intrinsic viscosities which may be formed in a fibrous shape. Preferably, the first polymer 400 may have an intrinsic viscosity of 0.60 to 0.80 and the second polymer 410 may use a polymer having an intrinsic viscosity of 0.50 to 0.64.

[0116] Further, the fiber according to the embodiment of the present invention may be made of two types of polyesters having different intrinsic viscosities as an non-limited example and contribute to improve bulkiness and elasticity in a staple fiber state or a nonwoven fabric shape through spontaneous crimp expression due to a difference in intrinsic viscosity. In this case, the spontaneous crimp shape may be an omega shape (that is, similar to a Greek letter (Ω)) and the top may be formed in a rounded shape.

[0117] The omega-shaped crimp has a spontaneous crimp shape expressed in a side-by-side type composite fiber and a omega-shaped fiber crimp exhibits excellent bulkiness and restoration force after compression as compared with a zigzag-shaped fiber crimp which is given artificially.

[0118] More preferably, PET polymers having an intrinsic viscosity of 0.64 and an intrinsic viscosity of 0.55 may be complex-spun. When the first and second polymers have intrinsic viscosities of 0.50 or less, the cross-section is closer to a circle, and thus it is not desirable to implement a modified cross-section and the hollow formation is also difficult.

[0119] Meanwhile, the modified cross-section hollow composite fiber may be a modified cross-section hollow composite fiber made of polyethylene terephthalate (PET), poly 1, 4-cyclohexylenedimethylene terephthalate (PCT), polypropylene (PP), nylon, and the like of two components having different viscosities. Further, the modified cross-section hollow composite fiber may be a modified cross-section hollow composite fiber which is constituted by two polyethylene terephthalates (PET) having different viscosities and has 10 to 10,000 ppm of at least one polyfunctional group selected from a group consisting of polycarboxylic acids, polyols, and polyoxycarboxylic acids in the fiber.

[0120] In the composite fiber according to the embodiment of the present invention, a spontaneous crimp may be expressed in addition to the hollow fiber as one of the embodiments, and the crimp may have an omega shape and the top may be formed in a rounded shape. A curvature radius of the crimp may be defined as R′ and may vary according to fineness of the spun fiber, but may basically satisfy the following condition (5) (see FIG. 9).

2.5 mm≦R′≦4.5 mm  (5)

[0121] Herein, R′: Curvature radius of circular arc of crimp

[0122] Hereinafter, the present invention will be described by the following Examples.

Examples 1 to 3

[0123] Fibers having 4, 6, and 12 volume control parts were prepared by using polyester having a limiting viscosity of 0.64. At a spinning temperature of 285° C., a fiber having staple-fiber fineness of 6 De and a fiber length of 64 mm was prepared by applying a crimp by a crimper after performing spinning at a spinning velocity of 1,000 m/min and then stretching at a stretching rate of 3.8.

Comparative Examples 1 to 3

[0124] Comparative Examples 1 to 3 are the same as Example 1, but a circular cross-section fiber, a circular hollow cross-section fiber, and a complex-spun circular hollow cross-section fiber with polyester limiting viscosities of 0.64 and 0.50 were prepared.

Examples 4 to 6

[0125] Fibers having 4, 6, and 12 volume control parts were prepared by using polyester having a limiting viscosity of 0.64. A fiber having staple-fiber fineness of 5.2 De and 125/24De/fil. was prepared by applying a crimp by a crimper after performing spinning at a spinning temperature of 285° C. and a spinning velocity of 1,000 m/min and then stretching at a stretching rate of 3.8 and then warp knitted matters were prepared by using the fibers, respectively.

Example 7

[0126] A fiber having 6 volume control parts was prepared by using polyester having a limiting viscosity of 0.64. A fiber having staple-fiber fineness of 6 De and a fiber length of 64 mm was prepared by applying a crimp by a crimper after performing spinning at a spinning temperature of 285° C. and a spinning velocity of 1,000 m/min and then stretching at a stretching rate of 3.8. The fiber was opened and then prepared in a web form.

Example 8

[0127] A fiber having 6 volume control parts was prepared by using polyester having a limiting viscosity of 0.64. A fiber having staple-fiber fineness of 6 De and a fiber length of 64 mm was prepared by applying a crimp by a crimper after performing spinning at a spinning temperature of 285° C. and a spinning velocity of 1,000 m/min and then stretching at a stretching rate of 3.8. The fiber was used and combined with a polyester-based low-melting point yarn to be 25 wt % to prepare a nonwoven fabric by needle punching. The nonwoven fabric had a size of 840*840 (mm*mm) and a weight of about 330 g.

Example 9

[0128] A fiber having 6 volume control parts was prepared by using polyester having a limiting viscosity of 0.64. A fiber having staple-fiber fineness of 6 De and a fiber length of 64 mm was prepared by applying a crimp by a crimper after performing spinning at a spinning temperature of 285° C. and a spinning velocity of 1,000 m/min and then stretching at a stretching rate of 3.8. The fiber was used and combined with a polyester-based low-melting point yarn to be 25 wt % to prepare a nonwoven fabric by needle punching. The nonwoven fabric had a size of 840*840 (mm*mm) and a weight of about 380 g.

Example 10

[0129] A fiber having 6 volume control parts was prepared by using polyester having a limiting viscosity of 0.64. A fiber having staple-fiber fineness of 6 De and a fiber length of 64 mm was prepared by applying a crimp by a crimper after performing spinning at a spinning temperature of 285° C. and a spinning velocity of 1,000 m/min and then stretching at a stretching rate of 3.8. The fiber was used and combined with a polyester-based low-melting point yarn to be 25 wt % to prepare a nonwoven fabric by needle punching. The nonwoven fabric had a size of 840*840 (mm*mm) and a weight of about 440 g.

Example 11

[0130] A fiber having 6 volume control parts was prepared by using polyester having a limiting viscosity of 0.64. A fiber having staple-fiber fineness of 6 De and a fiber length of 64 mm was prepared by applying a crimp by a crimper after performing spinning at a spinning temperature of 285° C. and a spinning velocity of 1,000 m/min and then stretching at a stretching rate of 3.8. The fiber was used and combined with a polypropylene meltblown yarn to be 55 wt % to prepare a nonwoven fabric. The nonwoven fabric had a size of 840*840 (mm*mm), a weight of about 240 g, and a thickness of about 20 mm.

Examples 12 and 13

[0131] A fiber having 6 volume control parts was prepared by using polyester having a limiting viscosity of 0.64. A fiber having staple-fiber fineness of 4 De and 6 De and a fiber length of 51 mm was prepared by applying a crimp by a crimper after performing spinning at a spinning temperature of 285° C. and a spinning velocity of 1,000 nm/min and then stretching at a stretching rate of 3.8.

Examples 14 and 15

[0132] The fiber of Example 12 was used and combined with a polyester-based low-melting point yarn to be 25 wt % to prepare a nonwoven fabric by needle punching. The nonwoven fabric had a size of 840*840 (mm*nm) and a weight of about 400 g and 700 g.

Examples 16 and 17

[0133] The fiber of Example 13 was used and combined with a polyester-based low-melting point yarn to be 25 wt % to prepare a nonwoven fabric by needle punching. The nonwoven fabric had a size of 840*840 (mm*mm) and a weight of about 400 g and 700 g.

Comparative Examples 4 to 6

[0134] Comparative Examples 4 to 6 are the same as Example 4, but a circular cross-section fiber (Comparative Example 4), a circular hollow fiber (Comparative Example 5), and a -modified cross-section fiber (Comparative Example 7) were prepared. In this case, a fiber having staple-fiber fineness of 2.5 De and 125/24De/fil. was prepared and then a warp knitted matter was prepared by using the fibers, respectively.

Comparative Examples 7 to 9

[0135] Comparative Examples 7 to 9 are the same as Example 7, but a circular cross-section fiber, a circular hollow fiber, and a complex-spun circular hollow cross-section fiber with polyester intrinsic viscosities of 0.64 and 0.50 were prepared. In this case, a fiber having staple-fiber fineness of 6 De and a fiber length of about 64 mm was prepared and then a web form was prepared after opening by using the fibers.

Comparative Examples 10 and 11

[0136] Comparative Examples 10 and 11 were the same as Example 8, but a circular cross-section fiber and a -modified 8-leaf cross-section fiber were prepared. In this case, a fiber having staple-fiber fineness of 6 De and a fiber length of about 64 mm was prepared. The fiber was used and combined with a polyester-based low-melting point yarn to be 25 wt % to prepare a nonwoven fabric by needle punching. The nonwoven fabric had a size of 840*840 (mm*mmm) and a weight of about 330 g.

Comparative Examples 12 and 13

[0137] Comparative Examples 12 and 13 were the same as Example 9, but a circular cross-section fiber and a -modified 8-leaf cross-section fiber were prepared. In this case, a fiber having staple-fiber fineness of 6 De and a fiber length of about 64 mm was prepared. The fiber was used and combined with a polyester-based low-melting point yarn to be 25 wt % to prepare a nonwoven fabric by needle punching. The nonwoven fabric had a size of 840*840 (mm*mm) and a weight of about 380 g.

Comparative Examples 14 and 15

[0138] Comparative Examples 14 and 15 were the same as Example 10, but a circular cross-section fiber and a -modified 8-leaf cross-section fiber were prepared. In this case, a fiber having staple-fiber fineness of 6 De and a fiber length of about 64 mm was prepared. The fiber was used and combined with a polyester-based low-melting point yarn to be 25 wt % to prepare a nonwoven fabric by needle punching. The nonwoven fabric had a size of 840*840 (mm*mm) and a weight of about 440 g.

Comparative Example 16

[0139] A fiber having staple-fiber fineness of 6 De and a fiber length of 64 mm was prepared by applying a crimp by a crimper after spinning a hollow cross-section fiber at a spinning temperature of 285° C. and a spinning velocity of 1,000 m/min by using polyester having a limiting viscosity of 0.64 and then stretching the spun hollow cross-section fiber at a stretching rate of 3.8. The fiber was used and combined with a polypropylene meltblown yarn to be 55 wt % to prepare a nonwoven fabric. The nonwoven fabric had a size of 840*840 (mm*mm), a weight of about 240 g, and a thickness of about 20 mm.

Comparative Examples 17 and 18

[0140] Under the same condition as Examples 12 and 13, a circular cross-section fiber of 4 De and a hollow composite staple fiber of 6 De were prepared.

Comparative Examples 19 and 20

[0141] The fiber of Examples 18 and 19 was used and combined with a polyester-based low-melting point yarn to be 25 wt % to prepare a nonwoven fabric by needle punching. The nonwoven fabric had a size of 840*840 (mm*mm) and a weight of about 400 g and 700 g.

[0142] In Examples and Comparative Examples below, measurement of physical properties was performed as follows.

[0143] Bulkiness of Composite Fiber

[0144] A. Test Method [0145] A prepared sample was quantified with 20□2 g. [0146] The sample was opened for 1 minute by using an opening device. [0147] The opened sample was put in a measuring beaker and downed two times (4 cm) to the end part to be uniformly filled. [0148] A pressure plate was positioned on the top of a container and then an electronic balance was set to “0”. [0149] A weight of the balance was recorded while decreased by a unit of 1 cm from an initial point of 10 cm to a point of 4 cm. [0150] The weight was recorded while increased up to a point of 10 cm again.

[0151] (Scale moving speed of 2 sec/cm)

[0152] B. Bulkiness [0153] Initial bulky: A bulky characteristic of fiber, a value during 10 cm compression [0154] Compressive bulky: Repulsion characteristic of fiber, (compression value of 10 to 5 cm+value of 4 cm)/2 [0155] Restorative bulky: Elastic restorative characteristic of fiber, (restoration value of 10 to 5 cm+value of 4 cm)/2

[0156] Hollow Ratio

[0157] A hollow ratio of the fiber was calculated by a ratio of an area occupied by a hollow part to the entire area and measured by an area ratio occupied by a hollow part to an area of an inner circle contacting a pinion in the case of a hollow fiber having volume control parts.

[0158] Sound Characteristics

[0159] A. Measurement of Sound Absorption Rate by Reverberation Method

[0160] A sound absorption rate was measured by using equipment equivalent to ISO 354 (KS F 2805: method of measuring sound absorption rate in reverberation room). A size of the specimen was set to 1.0 m×1.2 m, a reverberation time was the time when the sound pressure was reduced to 20 dB compared with initial sound pressure, and a ⅓ Octave band sound source was used as a sound source. At a frequency range of 0.4 to 10 kHz, a sound absorption rate was measured.

[0161] Evaluation Test of Water Absorption Rate of Fiber

[0162] A. Application Range

[0163] A feather touch fiber applied to advanced padding was washed and then in order to find a dehydration effect, a water absorption rate test was evaluated.

[0164] B. Outline of Method

[0165] An absorption rate was evaluated by comparing weights before immersing in distilled water and after dehydration after opening the fiber.

[0166] C. Appliances and Devices [0167] Opening appliance [0168] Two sample bags (100% nylon knitted fabric: warp (92 patterns/inch), weft (60 patterns/inch), 12 cm×12 cm) [0169] Stapler, fine pin, steel bar [0170] Water bath

[0171] D. Test Method [0172] 30 g of a prepared fiber was opened with air for 1 min by an opening appliance. [0173] The opened fiber was quantified by 10 g twice. [0174] The opened fiber was put in each of two sample bags, the bags were sealed by a stapler, and then a weight Ms was measured. [0175] The two sample bags were hung on a steel bar by using a fine pin. [0176] The two sample bags were immersed in a water bath with distilled water at 20 □ 2° C. for 1 hr. [0177] The two sample bags were dehydrated for 30 minutes. [0178] A weight Mf of the dehydrated sample bags after immersing was measured.

[0179] E. Measurement [0180] Samples before and after absorption

[0181] A weight Ms before immersing the sealed sample bag was measured.

[0182] A weight Mf after immersing for 1 hr and dehydrating for 30 minutes was measured. [0183] Calculation method

Water absorption rate (%)=(Mf−Ms)/Ms×100

TABLE-US-00001 TABLE 1 Example Comparative Example 1 2 3 1 2 3 Cross-sectional shape 4 volume control 6 volume control 12 volume control Circle Circular Circular parts, hollow parts, hollow parts, hollow hollow hollow Hollow ratio 19 21 18 — 22 6 Bulky Initial 310 390 380 20 47 280 Compression 11050 11900 11000 6500 8800 9000 Restoration 4600 4900 4800 2500 3400 3900

[0184] Like Table 1 above, it was tested that the fiber according to the present invention had an excellent bulkiness due to an interference effect of the volume control parts, and as illustrated in FIG. 8, it was illustrated that in the fibers according to the present invention in the fibrous assemblies, the volume control part was interfered with the volume control part of the adjacent fiber to ensure a space and improve the bulkiness.

TABLE-US-00002 TABLE 2 Comparative Comparative Comparative Example Example Example Example Example Example Classification 4(Hz) 5(Hz) 6(Hz) 4(Hz) 5(Hz) 6(Hz) 0.4k 0.1390 0.1120 0.1230 0.0721 0.1170 0.0734 0.5k 0.0685 0.0633 0.0656 0.0656 0.0889 0.0622 0.63k  0.0598 0.0594 0.0596 0.0347 0.0683 0.0231 0.8k 0.1070 0.1050 0.1055 0.0617 0.1080 0.0634 .sup. 1k 0.1320 0.1300 0.1313 0.0800 0.1370 0.0747 1.25k  0.1970 0.1960 0.1961 0.1050 0.1940 0.1030 1.6k 0.1960 0.2010 0.1980 0.1340 0.2080 0.1260 .sup. 2k 0.1750 0.1690 0.1720 0.1100 0.1870 0.1050 2.5k 0.1560 0.1450 0.1510 0.0987 0.1520 0.0954 3.15k  0.1860 0.1710 0.1810 0.1000 0.1950 0.0958 .sup. 4k 0.1630 0.1490 0.1610 0.0782 0.2000 0.0935 .sup. 5k 0.1160 0.0931 0.1060 0.0832 0.1450 0.0855 6.3k 0.0529 0.0547 0.0528 0.0454 0.0934 0.0128 .sup. 8k 0.1560 0.0853 0.1460 0.1370 0.2220 0.0488  10k 0.0872 0.1440 0.1170 0.0637 0.2010 0.0034

TABLE-US-00003 TABLE 3 Comparative Comparative Comparative Example 7 Example 7 Example 8 Example 9 Classification (Hz) (Hz) (Hz) (Hz) 0.4k 0.22 0.20 0.20 0.20 0.5k 0.41 0.37 0.36 0.35 0.63k 0.47 0.43 0.40 0.39 0.8k 0.51 0.47 0.45 0.42 1k 0.59 0.55 0.54 0.50 1.25k 0.64 0.60 0.59 0.54 1.6k 0.64 0.61 0.62 0.55 2k 0.64 0.61 0.60 0.56 2.5k 0.65 0.61 0.58 0.55 3.15k 0.61 0.57 0.54 0.52 4k 0.57 0.53 0.52 0.50 5k 0.59 0.52 0.52 0.51

TABLE-US-00004 TABLE 4 Comparative Comparative Classification Example 8 (Hz) Example 10 (Hz) Example 11 (Hz) 0.4k 0.18 0.18 0.15 0.5k 0.23 0.23 0.20  0.63k 0.22 0.22 0.20 0.8k 0.24 0.23 0.21 1k   0.23 0.22 0.20  1.25k 0.22 0.21 0.20 1.6k 0.27 0.25 0.25 2k   0.34 0.31 0.30 2.5k 0.40 0.36 0.36  3.15k 0.40 0.37 0.36 4k   0.39 0.38 0.36 5k   0.46 0.46 0.43 6.3k 0.53 0.52 0.50 8k   0.57 0.55 0.55 10k   0.62 0.62 0.66

TABLE-US-00005 TABLE 5 Comparative Comparative Example 9 (Hz) Example 12 (Hz) Example 13 (Hz) 0.4k 0.16 0.18 0.15 0.5k 0.21 0.23 0.21  0.63k 0.22 0.22 0.21 0.8k 0.24 0.21 0.21 1k   0.24 0.20 0.20  1.25k 0.23 0.19 0.19 1.6k 0.29 0.24 0.24 2k   0.36 0.31 0.30 2.5k 0.43 0.37 0.37  3.15k 0.42 0.37 0.37 4k   0.41 0.36 0.36 5k   0.47 0.43 0.44 6.3k 0.54 0.50 0.51 8k   0.59 0.56 0.53 10k   0.71 0.61 0.52

TABLE-US-00006 TABLE 6 Comparative Comparative Example 10 (Hz) Example 14 (Hz) Example 15 (Hz) 0.4k 0.11 0.15 0.18 0.5k 0.21 0.20 0.22  0.63k 0.23 0.21 0.21 0.8k 0.25 0.22 0.22 1k   0.25 0.22 0.20  1.25k 0.24 0.21 0.19 1.6k 0.30 0.26 0.24 2k   0.38 0.33 0.32 2.5k 0.45 0.39 0.40  3.15k 0.45 0.39 0.39 4k   0.44 0.37 0.37 5k   0.52 0.43 0.45 6.3k 0.62 0.51 0.53 8k   0.66 0.55 0.58 10k   0.69 0.60 0.65

TABLE-US-00007 TABLE 7 Comparative Example Example 11 (Hz) 16 (Hz) 0.4k 0.25 0.20 0.5k 0.46 0.38  0.63k 0.58 0.46 0.8k 0.72 0.58 1k   0.94 0.77  1.25k 1.12 0.93 1.6k 1.14 0.99 2k   1.03 0.96 2.5k 1.02 0.99  3.15k 0.98 0.96 4k   0.89 0.87 5k   0.92 0.86 6.3k 0.93 0.84 8k   0.94 0.80 10k   0.95 0.74

TABLE-US-00008 TABLE 8 Example Example Comparative Example Example Comparative Classification 14 15 Example 19 16 17 Example 20 400 0.17 0.14 0.17 0.17 0.19 0.19 500 0.18 0.14 0.13 0.19 0.2 0.19 630 0.15 0.11 0.09 0.18 0.19 0.17 800 0.17 0.13 0.11 0.23 0.23 0.21 1k 0.23 0.19 0.17 0.3 0.3 0.27 1.25k   0.32 0.25 0.22 0.4 0.38 0.36 1.6k.sup.  0.42 0.3 0.28 0.52 0.48 0.46 2k 0.47 0.34 0.3 0.6 0.54 0.53 2.5k.sup.  0.51 0.37 0.34 0.64 0.61 0.57 3.15k   0.52 0.38 0.37 0.64 0.59 0.56 4k 0.55 0.41 0.42 0.65 0.59 0.57 5k 0.55 0.49 0.44 0.67 0.62 0.58 6.3k.sup.  0.59 0.5 0.48 0.68 0.65 0.61 8k 0.65 0.56 0.56 0.68 0.65 0.64 10k  0.54 0.5 0.44 0.48 0.47 0.48

[0185] In Tables 2 to 8 above, by comparing sound absorption rates in Examples and Comparative Examples of the fibrous assemblies formed of the fiber according to the present invention, the result that the fiber assemblies according to the present invention had excellent sound absorption was derived.

[0186] Further, like Table 9 below, it was tested that the fiber according to the present invention had an excellent water discharge characteristic (low water absorption rate) due to an interference effect of the volume control parts, and as illustrated in FIG. 8, it was illustrated that in the fibers according to the present invention in the fibrous assemblies, the volume control part was interfered with the volume control part of the adjacent fiber to ensure a space and improve a water discharge property.

TABLE-US-00009 TABLE 9 Average Absorption rate absorption rate Ms (g) Mf (g) (%) (%) Example 12 11.66 16.51 41.60 41.1 11.68 16.42 40.58 Example 13 11.68 19.41 66.18 67.7 11.66 19.74 69.30 Comparative 11.37 100.03 779.77 686.3 Example 18 11.37 78.77 592.79 Comparative 11.60 26.76 130.69 130.0 Example 19 11.52 26.41 129.25

Example 18

[0187] A fiber was prepared by a spinneret having 6 volume control parts by using polyester having intrinsic viscosities of 0.64 and 0.50. A fiber having staple-fiber fineness of 6 De and a fiber length of 64 mm was prepared by applying a crimp by a crimper after performing spinning at a spinning temperature of 285° C. and a spinning velocity of 1,000 nm/min and then stretching at a stretching rate of 3.8.

Example 19

[0188] A fiber was prepared by a spinneret having 6 volume control parts by using polyester having intrinsic viscosities of 0.64 and 0.55 under the same condition as Example 18.

Example 20

[0189] A fiber was prepared by a spinneret having 6 volume control parts by using polyester containing 900 ppm of polyfunctional groups and having intrinsic viscosities of 0.64 and 0.60 under the same condition as Example 18.

Comparative Example 21

[0190] A fiber was prepared by a spinneret having 6 volume control parts by using polyester having an intrinsic viscosity of 0.64. A fiber having staple-fiber fineness of 7 De and a fiber length of 64 mm was prepared by applying a crimp by a crimper after performing spinning at a spinning temperature of 285° C. and a spinning velocity of 1,000 m/min and then stretching at a stretching rate of 3.8.

Comparative Examples 22 to 25

[0191] A fiber was prepared under the same condition as Example 18, and by applying a spinneret to a circular hollow cross-section and using [0192] polyester having intrinsic viscosities of 0.64 and 0.46 [0193] polyester having intrinsic viscosities of 0.64 and 0.50 [0194] polyester having intrinsic viscosities of 0.64 and 0.55 [0195] polyester containing 900 ppm of polyfunctional groups and having intrinsic viscosities of 0.64 and 0.60, a circular hollow cross-section fiber was prepared.

Comparative Example 26

[0196] Comparative Example 26 was the same as Comparative Example 16, and a nonwoven fabric was prepared with the circular cross-section fiber.

TABLE-US-00010 TABLE 10 Example Comparative Example 18 19 20 21 22 23 24 25 Spinneret type 6 volume control parts, hollow 6 volume control Hollow circle parts, hollow High/low PET 0.64/0.50 0.64/0.55 0.64 + polyfunctional 0.64 0.64/0.46 0.64/0.50 0.64/0.55 0.64 + polyfunctional intrisic viscosity group/0.60 group/0.60 Hollow ratio 11 17 25 21 5 12 18 24 Crimp form Omega Omega Omega Zigzag Omega Omega Omega Omega Bulky Initial 512 853 980 390 310 433 724 930 Compression 9125 12530 13100 11900 7850 8640 10200 11500 Restoration 4531 5310 5932 4900 3320 4074 4810 5530

[0197] It can be verified that average initial bulkiness of the modified cross-section hollow composite fiber prepared in Examples 18 to 20 is about 781.6 and average initial bulkiness of the circular cross-section hollow composite fiber prepared in Comparative Examples 22 to 25 is about 366.8.

[0198] Further, as illustrated in FIG. 2, in the fiber according to the present invention, an omega (Ω)-shaped crimp was formed. It can be verified that average initial bulkiness in Examples 18 to 20 having the omega (Ω)-shaped crimp is about 781.6 and average initial bulkiness in Comparative Example 1 having a zigzag-shaped crimp is 310. That is, in order to have high bulkiness, it may be determined that it is preferred to have the omega (Ω)-shaped crimp.

[0199] Meanwhile, when the thermal insulation of the fiber according to the embodiment of the present invention was evaluated, like Table 11 below, it was tested that thermal insulation was excellent by a dead air layer ensured due to an interference effect of the volume control parts of the modified hollow fiber.

TABLE-US-00011 TABLE 11 Comparative Comparative Classification Example 26 Example 16 Example 11 Cross-sectional shape Circular cross- Circular hollow Modified section cross-section hollow cross- section Hollow ratio (%) — 21 22 Thermal 100 gsm 71.3 75.2 81.5 insulation 170 gsm 75.3 82.2 88.1 ratio 250 gsm 82.3 86.7 93.2 (%) * gsm: Mean grams per square meter

[0200] 100 gsm is 100 g per 1 square meter, and as a gsm value is increased, grams are increased, a weight is increased, and a thickness is increased. The thickness of the nonwoven fabric per unit area is increased and a total sum of the dead air layers between the fibers is further increased to maximize thermal insulation.

[0201] The aforementioned present invention is not limited to the aforementioned exemplary embodiments and the accompanying drawings, and it will be obvious to those skilled in the technical field to which the present invention pertains that various substitutions, modifications, and changes may be made within the scope without departing from the technical spirit of the present invention.