Polyphenylene sulfide monofilament and method of producing the same, and fiber package

Abstract

A polyphenylene sulfide monofilament has a phenylene sulfide unit as a main structural unit and satisfies (1) to (5): (1) a fineness of 6 to 35 dtex; (2) a breaking strength of 3.4 cN/dtex or more; (3) a breaking elongation of 24% to 45%; (4) a 5% modulus of 1.0 to 1.6 cN/dtex; and (5) a 10% modulus of 1.4 to 2.3 cN/dtex.

1 . A polyphenylene sulfide monofilament having a phenylene sulfide unit as a main structural unit and satisfying (1) to (5):
 (1) a fineness of 6 to 35 dtex;   (2) a breaking strength of 3.4 cN/dtex or more;   (3) a breaking elongation of 24% to 45%;   (4) a 5% modulus of 1.0 to 1.6 cN/dtex; and   (5) a 10% modulus of 1.4 to 2.3 cN/dtex.   
     
     
         2 . A pirn-shaped fiber package made up of the polyphenylene sulfide monofilament according to  claim 1 . 
     
     
         3 . The fiber package of the polyphenylene sulfide monofilament according to  claim 2 , having a winding width of 100 to 250 mm, a taper angle of 300 to 140°, a lead angle of 0.6° to 2°, and a heat shrinkage stress ratio between innermost and outermost layers of 0.85 to 1.15. 
     
     
         4 . A method of producing the polyphenylene sulfide monofilament having the phenylene sulfide unit as the main structure unit according to  claim 1  by using a direct spinning drawing method in which a polyphenylene sulfide resin is melt-extruded, cooled and solidified, and an obtained undrawn yarn is, without being wound once, continuously drawn and wound up with a winder, the method satisfying (1) to (4):
 (1) the polyphenylene sulfide resin has an MFR of 100 to 250 g/10 min.; 
 (2) the undrawn yarn is drawn using a non-heated pretension roller and two or more heated godet rollers; 
 (3) a temperature of the first godet roller is 95° C. to 120° C., and a heat setting temperature of the second and subsequent heated godet rollers is 120° C. to 250° C.; and 
 (4) a winding tension to the winder is 0.1 to 0.5 cN/dtex. 
 
     
     
         5 . A method of producing the fiber package according to  claim 2 , the fiber package being made up of the polyphenylene sulfide monofilament having the phenylene sulfide unit as the main structural unit, by using a direct spinning drawing method in which a polyphenylene sulfide resin is melt-extruded, cooled and solidified, and an obtained undrawn yarn is, without being wound once, continuously drawn and wound up on a bobbin with a winder, the method satisfying (1) to (4):
 (1) the polyphenylene sulfide resin has an MFR of 100 to 250 g/10 min.;   (2) the undrawn yarn is drawn using a non-heated pretension roller and two or more heated godet rollers;   (3) a temperature of the first godet roller is 95° C. to 120° C., and a heat setting temperature of the second and subsequent heated godet rollers is 120° C. to 250° C.; and   (4) a winding tension to the winder is 0.1 to 0.5 cN/dtex.   
     
     
         6 . A method of producing a fiber package made up of a polyphenylene sulfide monofilament having a phenylene sulfide unit as a main structural unit by using a direct spinning drawing method in which a polyphenylene sulfide resin is melt-extruded, cooled and solidified, and an obtained undrawn yarn is, without being wound once, continuously drawn and wound up on a bobbin in a pirn shape with a winding tension to a winder of 0.1 to 0.5 cN/dtex. 
     
     
         7 . The method of producing the fiber package made up of the polyphenylene sulfide monofilament according to  claim 6 , wherein the obtained undrawn yarn is drawn and wound up on the bobbin after a spin finish is applied to the yarn to achieve an oil pick-up unit of 0.15 to 0.5 mass % for the polyphenylene sulfide monofilament. 
     
     
         8 . A method of producing a fiber package made up of a polyphenylene sulfide monofilament having a phenylene sulfide unit as a main structural unit by using a direct spinning drawing method in which a polyphenylene sulfide resin is melt-extruded, cooled and solidified, and an obtained undrawn yarn is, without being wound once, continuously drawn and wound up on a bobbin in a pirn shape by a winder, wherein a spin finish is applied to the undrawn yarn before being wound up on the bobbin to achieve an oil pick-up unit of 0.15 to 0.5 mass % for the polyphenylene sulfide monofilament, and the yarn is wound up on the bobbin in the pirn shape to have a winding width of 100 to 250 mm, a taper angle of 30° to 140°, and a lead angle of 0.6° to 2°. 
     
     
         9 . A pirn-shaped polyphenylene sulfide monofilament fiber package having a winding width of 100 to 250 mm, a taper angle of 30° to 140°, a lead angle of 0.6° to 2°, and a heat shrinkage stress ratio between innermost and outermost layers of 0.85 to 1.15. 
     
     
         10 . A method of producing the fiber package according to  claim 3 , the fiber package being made up of the polyphenylene sulfide monofilament having the phenylene sulfide unit as the main structural unit, by using a direct spinning drawing method in which a polyphenylene sulfide resin is melt-extruded, cooled and solidified, and an obtained undrawn yarn is, without being wound once, continuously drawn and wound up on a bobbin with a winder, the method satisfying (1) to (4):
 (1) the polyphenylene sulfide resin has an MFR of 100 to 250 g/10 min.;   (2) the undrawn yarn is drawn using a non-heated pretension roller and two or more heated godet rollers;   (3) a temperature of the first godet roller is 95° C. to 120° C., and a heat setting temperature of the second and subsequent heated godet rollers is 120° C. to 250° C.; and   (4) a winding tension to the winder is 0.1 to 0.5 cN/dtex.