高性能纤维是指具有特殊的物理化学结构、性能和用途,或具有特殊功能的化学纤维。碳纤维、芳纶、聚酰亚胺纤维和超高分子量聚乙烯纤维是目前应用最为广泛的四大高性能纤维,主要应用于航空航天、国防科技、军事工程、建筑工业、交通运输、医疗防护、民用工业和电子通信等领域。然而,随着高性能纤维应用领域的拓宽,对有色高性能纤维的制备提出了挑战。由于高性能纤维的特殊分子结构和表面物理化学性能,如高分子链间作用力大、纤维结晶度高、纤维表面化学惰性强等,使染料分子难以进入纤维内部或与纤维结合,导致高性能纤维的颜色构建难度大,难以获得理想的颜色深度。为突破高性能纤维颜色构建的技术瓶颈,国内外学者进行了大量研究,针对高性能纤维的结构特点和物理化学性能,创新了高性能纤维的表面改性方法和染色工艺,从纤维原料、成形加工、表面改性等方面赋予高性能纤维颜色。
本文主要介绍了以芳纶、碳纤维、聚酰亚胺纤维和超高分子量聚乙烯纤维为代表的4种高性能纤维颜色构建的研究进展,探讨了上述高性能纤维颜色构建的发展方向,以期为制备色彩丰富的高性能纤维提供一定的参考,以满足时尚及特殊领域的需求。
1 高性能纤维颜色构建主要方法
高性能纤维及其制品是《中国制造2025》战略任务中重点领域突破发展的关键材料,也是我国纺织行业重点发展的纤维材料,其被广泛应用于各个领域,如图1所示。
图1
高性能纤维颜色构建的方法主要分为化学染色法和物理结构生色法。其中,化学染色法主要包括基于纤维制造中的原液着色法、针对染色工艺优化的载体染色法和非水介质溶剂染色法等。表1示出高性能纤维及其制品颜色构建的主要方法。
表1 高性能纤维颜色构建的主要方法
Tab. 1
| 颜色构建方法 | 优点 | 适用纤维 |
|---|---|---|
| 载体染色 | 节能降耗 | 芳纶、聚酰亚胺纤维 |
| 非水介质溶剂染色 | 节水环保 | 芳纶、聚酰亚胺纤维、 超高分子量聚乙烯纤维 |
| 原液着色 | 无需后续染色 | 超高分子量聚乙烯纤维 |
| 结构生色 | 环保 | 芳纶、碳纤维 |
2 芳纶颜色构建
芳纶全称为芳香族聚酰胺纤维,其工业化产品主要包括对位芳纶和间位芳纶。由于其超高强度、高模量、耐高温、耐酸碱和化学结构稳定等优良性能,被广泛应用于航空航天、军工、交通、建筑、体育和电子电器等诸多领域。彩色芳纶制品可提供美学和功能的灵活性,并达到产品识别目的。近年来,针对芳纶分子结构和染料适用性,主要采用分散染料和碱性染料进行染色,开发了载体染色、非水介质溶剂染色、接枝改性后染色等化学构建方法以及结构生色物理构建方法。其中,载体染色和非水介质溶剂染色受到广泛关注。
2.1 芳纶载体染色
载体染色是芳纶的一种重要的染色方法,在调节染浴温度下,利用载体调控纤维大分子链的动态行为,改变纤维的玻璃化转变温度,削弱分子间氢键作用力,为染料的上染提供更多空间,促进染料分子扩散到纤维内部,增加上染率。
Chen等[1]研究了载体Cindye Dnk对分散染料在芳纶上的染色速率常数和扩散系数的影响。研究结果表明,该载体能够提高分散染料对芳纶的亲和力,降低染色熵和缩短半染时间。许晓锋等[2]以 N,N-二乙基-间甲基苯甲酰胺(DEET)乳液作为载体,增大了纤维的自由体积,提高了分散染料的溶解度,促进了染料在芳纶1313和芳纶1414内部无定形区的扩散,提高了2种纤维的染色性能。虽然DEET使芳纶的玻璃化转变温度和取向度降低,但是对其结晶度没有影响。此外,郑丹等[3] 还研究了DEET 处理后芳纶1414的微观结构与性能,进一步证明了DEET仅造成了纤维分子链结构松散,未破坏其结晶区,因此染色后的芳纶1414仍具有优良的力学性能。Islam等[4]采用N-甲基甲酰苯胺作为载体,研究了碱性染料对芳纶1313的染色动力学。实验结果表明,此载体溶胀纤维性能良好,且染色后的芳纶具有良好的色牢度。Azam等[5]将苯甲醇用作芳纶1313分散染料染色的载体,充分利用苯甲醇分子尺寸小和稳定性高的特点,促进染料分子渗透到纤维内部,实现了芳纶的颜色构建。Cao等[6] 研究了低染料浓度下2-苯氧乙醇载体对芳纶1313聚集态结构与染色性能的影响。研究发现,该载体与芳纶的氢键作用强,能够扩大纤维的无定形区,显著提高染色性能,获得色彩鲜艳的芳纶。同时,该方法也破坏了纤维的结晶区,降低了纤维的热稳定性。在该研究基础上,基于节能减排和减少染色过程对纤维的损伤原则,Sheng等[7] 开发了2-苯氧乙醇载体预溶胀芳纶1313的方法,实现了芳纶的低温(95 ℃) 染色。该方法充分利用载体与染液形成的双相体系,促进阳离子染料向载体相聚集,显著提高了芳纶的染色性能。由此可见,研究人员在芳纶的载体染色方面已经开展了大量的研究工作,特别是通过对纤维分子结构的预调控处理,实现了芳纶的低温染色。采用载体染色所制备的纤维具有色彩鲜艳和色牢度高的优点,但此方法中去除纤维内部残余载体、安全回用载体和进一步减少载体对纤维力学性能的影响有待进一步研究。
2.2 芳纶非水介质溶剂染色
合适的非水溶剂能够调控分散染料聚集体形貌结构和纤维聚集态结构,溶胀纤维并促进染料分子进入纤维内部,提高纤维的染色性能。
Preston等[8]采用水溶性吡啶溶剂对芳纶1313进行染色,染色后的纤维具有明亮的颜色和良好的光稳定性,同时保持良好的力学性能和优异的耐光性。基于染料分子在溶剂中的聚集形态调控,Sheng等[9] 利用N,N-二甲基乙酰胺(DMAc)/水溶剂体系对芳纶进行染色,系统地研究了染料在二元体系中的聚集行为及其上染动力学。研究结果表明,DMAc通过调控染料聚集体的Zeta电位和粒径提高了染色性能。在此基础上,Sheng等[10] 提出了一种基于阳离子的染色机制。DMAc除作为氢键调节剂外,还可与氯化钠协同选择性地破坏芳纶大分子的分子间氢键。在染色过程中,染料分子与DMAc形成阳离子[DMAc-Dye]+,显著提高了芳纶1313的染色性能,且染色后的纤维具有良好的力学性能和热学性能。基于清洁、绿色、环保的制造理念,Zheng等[11]采用超临界二氧化碳作为溶剂代替水,研究了芳纶在超临界二氧化碳中的染色特性,实现了多种分散染料对芳纶的颜色构建,该方法具有色牢度高、工艺流程短和节能环保等优点,但对染色装备的要求较高。离子液体作为新兴的非水介质,同样受到广泛关注。Opwis等[12] 利用1-乙基-3-甲基咪唑乙基硫酸盐离子液体刻蚀芳纶表面以提高其粗糙度,增加了离子型染料的吸附位点,在室温下构建了高色牢度的芳纶1313。上述研究工作表明,非水介质溶剂染色具有节水和染色牢度高的优势,可高效再利用非水介质,在绿色环保染色领域具有独特的优势。
2.3 其它染色方法
利用表面改性的方法调控芳纶的表面结构,同样有助于提高染色性能。主要包括聚丙烯酸接枝法[13]、光引发接枝法[14]、化学接枝法[15]、Friedel-Crafts 烷基化反应法[16]、超声波法[17]、低温等离子体法[18]、臭氧处理法[19]、微波辐照法[20]等。上述表面方法通过在纤维表面引入丰富的极性基团和粗糙界面来增加对染料的吸附,提高染色性能。同时,物理结构生色法也被应用于芳纶颜色的构建。Hasan等[21] 通过原位合成纳米银(Ag NPs)对芳纶织物进行结构生色,通过调控Ag NPs的形貌和粒径改变织物颜色,可形成最大吸收峰值位于543、445和599 nm的红、黄和蓝三原色。Shi等[22] 在芳纶织物上引入多巴胺优化了无机纳米粒子与芳纶的界面作用力,采用高折射率硫化锌在芳纶表面构建周期性纳米结构,制备了颜色鲜艳的芳纶,主要颜色有蓝色、绿色和红色。这种物理结构生色法是一种环境友好型的颜色构建方法,在构建颜色过程中,不仅能够保持纤维原本优良的力学性能,同时还能够赋予纤维功能特性,纤维的颜色主要依赖于光子晶体或纳米粒子的结构及排列,这也为其大规模产业化应用提出了挑战。
3 碳纤维颜色构建
碳纤维由于其优异的力学性能、耐腐蚀和耐摩擦性能、良好的热稳定性和高导电性,被广泛应用于航空航天、电子、军工、汽车、能源和体育等众多领域。然而,碳纤维的黑色外观无法满足日益增长的色彩的需求。碳纤维的高结晶度、高化学惰性和强烈光吸收特性,较难用传统的染料或色素分子着色,颜色构建难度极大。
表2 碳纤维的物理结构色构建方法
Tab. 2
| 原料 | 处理方法 | 结构生色方法 | 反应步骤数量 | 结构 | 控制条件 | 颜色种类 | 参考文献 |
|---|---|---|---|---|---|---|---|
| Al2O3/TiO2 | — | 磁控溅射 | 3 | 薄膜结构 | 周期性厚度 | 4 | [25] |
| TiO2 | — | 原子层沉积 | 2 | 薄膜结构 | 薄膜厚度 | 4 | [23] |
| Poly(St-MMA-AA) | 乳液聚合 | 自组装沉降 | 3 | 光子晶体 | 粒子粒径 | 5 | [28] |
| Al(CH3)3/Zn(CH2CH3)2 | 水解反应 | 原子层沉积 | 3 | 薄膜结构 | 薄膜厚度 | 5 | [29] |
| PS | — | 电泳沉积 | 2 | 光子晶体 | 粒子粒径 | 3 | [30] |
| PAAc | 电致乳液聚合 | 原位聚合接枝改性 | 3 | 薄膜结构 | 结构变化 | 4 | [26] |
| FeCl3 | 氟化铵/水 | 水热反应 | 1 | 均匀纳米粒子 | 粒子粒径 | 3 | [27] |
| PMMA | 自由基聚合 | 电泳沉积 | 2 | 光子晶体 | 微球粒径 | 3 | [24] |
| PNIPAM-co-AAc | 乳液聚合 | 电泳沉积 | 3 | 光子晶体 | 水凝胶微球粒径 | 3 | [31] |
注:Poly(St-MMA-AA)为苯乙烯-甲基丙烯酸甲酯-丙烯酸共聚物;PS为聚苯乙烯;PAAc为聚丙烯酸;PMMA为聚甲基丙烯酸甲酯;PNIPAM-co-AAc为聚N-异丙基丙烯酰胺-共聚-丙烯酸。
Chen等[23]首次采用原子层沉积(ALD)技术在碳纤维表面沉积了厚度可控的TiO2层,制备了红色、黄色、蓝色和绿色4种颜色的碳纤维,为碳纤维颜色构建开辟了新途径。Liu等[24] 通过电泳沉积法制备了结构色可控的彩色碳纤维。在环形电场作用下,负电荷的聚甲基丙烯酸甲酯微球在导电碳纤维表面组装,形成鲜艳的蓝色、黄绿色和红色结构色。Zhao等[25] 采用磁控溅射法在碳纤维上引入具有周期性梯度的Al2O3 和TiO2交替的一维光子晶体薄膜结构。通过引入具有周期性梯度的一维光子层,形成了一系列具有结构颜色梯度和良好力学性能的新型光子双面彩色碳纤维。由于其独特的光子结构周期性,碳纤维在全光谱中表现出连续颜色梯度,显示了蓝色、绿色、橙色和紫红等系列颜色。Eyckens等[26] 基于原位聚合过程的表面改性技术,将丙烯酸聚合物薄膜快速接枝到碳纤维表面,基于薄膜干涉使碳纤维呈现蓝色。Lin等[27] 采用一步水热法在碳纤维表面原位生长FeOOH,通过调控水热反应的温度来改变FeOOH的粒径,制备出了蓝色、绿色和黄色的碳纤维。该方法制备的彩色碳纤维具有优异的结构稳定性,如耐酸性和碱性条件下的重复洗涤、光照和等离子体蚀刻。Yu等[28] 通过热辅助重力沉降法促进poly(St-MMA-AA)在碳纤维表面自组装生成光子晶体。根据布拉格定律和斯涅尔定律,计算合成的poly(St-MMA-AA)纳米颗粒的尺寸,成功预测了碳纤维在可见光谱中的结构色。上述碳纤维颜色构建的共性都是从原子或者分子反应出发,在碳纤维表面组装成特定的结构,从而实现颜色的构建。
4 聚酰亚胺纤维颜色构建
聚酰亚胺纤维具有环状和刚性的分子链,使其具有优异的耐热性、高强高模、阻燃性、抗辐射性等高性能属性,因此,被广泛用于航空航天、高温过滤、电气绝缘、防火防热防护服等领域。然而,聚酰亚胺纤维分子链上用于染色的官能团较少,且其较高的玻璃化转变温度限制了分子链的运动,这对其颜色的构建提出了巨大挑战。此外,聚酰亚胺纤维本身的金黄色也会影响后续染色加工的颜色。目前,聚酰亚胺纤维的颜色构建方法主要包括载体染色法和表面改性染色方法。
4.1 聚酰亚胺纤维载体染色
聚酰亚胺纤维的载体染色法具有良好的产业化前景,利用小分子化合物作为载体,提高染料和纤维的亲和力,改善纤维的染色性能。表3示出聚酰亚胺纤维的载体染色方法对比。伍双燕等[32] 利用相似相溶原理,依据聚酰亚胺溶解度参数设计了相似的载体,在体积比为2∶5的N,N-二甲基甲酰胺与甲基异丁基甲醇的溶剂体系中,获得了良好的染色效果。邵冬燕等[33] 根据聚酰亚胺的分子结构制备了醚醇类染色载体,该载体能显著改善聚酰亚胺的染色性能,且染色牢度高。肖超鹏等[34] 研究了芳基醇类、芳基酮类、避蚊胺载体对聚酰亚胺纤维染色性能的影响。结果表明,芳基酮类载体对聚酰亚胺纤维的亲和力强,可迅速进入纤维内部,减弱纤维内分子链间的作用力,提高染料在纤维内部的扩散速率,其染色效果最好。
表3 聚酰亚胺纤维的载体染色方法
Tab. 3
| 载体种类 | 染料种类 | 染料用量/ %(o.w.f) | pH值 | 温度/℃ | 时间/min | K/S值 | 参考文献 |
|---|---|---|---|---|---|---|---|
| 芳基酮类 | 阳离子黑FDL | 6 | 3~4 | 130 | 60 | 32.0 | [34] |
| N,N-二甲基甲酰胺/甲基异丁基甲醇 | 分散红AO-E | 4 | 5~7 | 130 | 60 | 6.5 | [32] |
| N,N-二甲基甲酰胺/甲基异丁基甲醇 | 分散黄EGL | 10 | — | — | — | 17.7 | [32] |
| N,N-二甲基甲酰胺/甲基异丁基甲醇 | 分散蓝2BLN | 6 | — | — | — | 7.5 | [32] |
| 苯乙酮 | 分散红153 | 5 | — | 130 | 60 | 25.0 | [35] |
| 苯乙酮 | 分散蓝60 | — | — | — | — | 25.0 | [35] |
| 苯乙酮 | 碱性红46 | — | — | — | — | 17.5 | [35] |
| 苯乙酮 | 碱性蓝41 | — | — | — | — | 23.0 | [35] |
| N-甲基甲酰苯胺 | 分散红167:1 | 5 | — | 130 | 60 | 20.0 | [36] |
| N-甲基甲酰苯胺 | 阳离子蓝SD-GSL | 5 | 5 | 130 | 60 | 24.0 | [33] |
4.2 聚酰亚胺纤维表面改性染色
5 超高分子量聚乙烯纤维颜色构建
超高分子量聚乙烯纤维因其优良的耐化学腐蚀性、耐磨性、耐冲击性、防弹防切割、高强和高模等性能,被广泛应用于军工、航天、生物医用材料和防护装备等方面,但超高分子量聚乙烯纤维结晶度高、取向度高、分子链中不含极性基团、表面化学惰性强,致使染料难以进入纤维内部。目前,超高分子量聚乙烯纤维的染色方法主要包括改性染料染色、原液着色、表面改性染色等。表4对比了不同染色方法上染超高分子量聚乙烯纤维的工艺参数和K/S值。
表4 超高分子量聚乙烯纤维的染色方法
Tab. 4
| 方法 | 染料(颜料)种类 | 染料用量/ %(o.w.f) | pH值 | 温度/ ℃ | 时间/ min | K/S 值 | 参考 文献 |
|---|---|---|---|---|---|---|---|
| 改性疏水染料 | 1-对甲苯氨基-4-蒽醌己基醚 | 5 | 5 | 130 | 60 | 1.46 | [40] |
| 改性疏水染料 | 1-对甲苯氨基-4-蒽醌癸基醚 | — | — | — | — | 1.79 | [40] |
| 改性疏水染料 | 1-对甲苯氨基-4-蒽醌十四烷基醚 | — | — | — | — | 2.10 | [40] |
| 常规疏水染料 | 乙基黄 | 5 | — | 125 | 60 | 11.6 | [39] |
| 常规疏水染料 | 油红O | — | — | — | 13.7 | [39] | |
| 多巴胺改性 | 活性红2 | 1 | — | 35 | 65 | 6.144 | [41] |
| 改性偶氮染料 | 丁基取代单偶氮黄 | 5 | — | 130 | 60 | 17.6 | [42] |
| 原液着色 | 改性Fe2O3 | 5 | — | 230~290 | — | 15.5 | [43] |
| 超临界二氧化碳 | N-(2-Cl-4-甲基苯基)-2-氧亚基-2- (对甲苯基)乙酰肼基氰化物 | 6 | — | 120 | 3 | 3.5 | [44] |
| 辐射诱导接枝 | 碱性红46 | 0.02 | 4 | 90 | 40 | 16.5 | [45] |
5.1 超高分子量聚乙烯纤维改性染料染色
王晓春等[39] 系统探究了疏水染料结构中疏水基团数量、链长以及强极性基团对超高分子量聚乙烯染色性能的影响。结果表明:染料的疏水性和溶解度参数是影响超高分子量聚乙烯纤维染色性能的重要因素;染料溶解度参数与超高分子量聚乙烯纤维越接近,越有利于提高染料和纤维之间的分配系数和亲和力。依据此原理,王菊等[40] 合成了1-对甲苯氨基-4-蒽醌己基醚、1-对甲苯氨基-4-蒽醌癸基醚和1-对甲苯氨基-4-蒽醌十四烷基醚3种具有高疏水性的紫色改性染料。其中,改性1-对甲苯氨基-4-蒽醌十四烷基醚染料的溶解度参数为8.93 (J/cm3) 1/2, 与超高分子量聚乙烯溶解度参数8.00 (J/cm3) 1/2相接近,染色效果最佳。Kim等[46] 研究了不同烷基取代基蒽醌蓝染料对超高分子量聚乙烯纤维染色性能的影响。发现随着烷基取代基长度增加,超高分子量聚乙烯纤维的染色性能有逐渐提高的趋势。采用单偶氮基团上烷基取代基长度不同的偶氮黄色和红色染料对超高分子量聚乙烯纤维进行染色,随着烷基取代基长度增加到一定长度时,其对超高分子量聚乙烯纤维的染色性能变差[42]。在此基础上,根据烷基取代基长度与染色性能的关系,Kim等[47]还以1-氨基-2-溴-4-羟基蒽醌和烷基酚为原料合成了系列不同分子质量的蒽醌红染料,对超高分子量聚乙烯纤维进行染色,获得了高耐光、高色牢度的红色纤维。综上,染料的极性影响染料与纤维之间的亲和力。根据纤维的性质对染料进行改性,是有效解决纤维染色困难的方法。目前,通过增加染料疏水基团数量或疏水链长度来改变染料的疏水性,有利于提高染料与超高分子量聚乙烯纤维间的亲和力,进一步改善纤维的染色性能。
5.2 超高分子量聚乙烯纤维原液着色
在彩色熔纺超高分子量聚乙烯纤维的制备过程中,纺丝温度较高,因此,要求着色剂具有耐高温性(300 ℃以上)。无机颜料具有化学稳定性好、耐热性好、价格经济等优点,是原液着色常用的优良着色剂。可通过对颜料颗粒表面改性改善其在聚合物中的分散性,解决无机颜料的聚集对超高分子量聚乙烯可纺性、力学性能和染色性能的影响。刘铭等[48] 采用硅烷偶联剂改性铁黄无机颜料,提高了颜料与超高分子量聚乙烯的相容性,实现了有色熔纺超高分子量聚乙烯纤维的制备。Wang等[43] 采用钛酸盐偶联剂改性Fe2O3颜料,用于熔纺彩色超高分子量聚乙烯纤维的制备。研究发现:在一定范围内随着颜料含量的增加,纤维K/S值增加,且耐干湿摩擦色牢度评级分别达到5和4~5级;但颜料含量的增加会影响纤维大分子链的连续性,使着色纤维的力学性能下降。
5.3 超高分子量聚乙烯纤维非水介质溶剂染色
基于超临界二氧化碳在染色过程中不会破坏有机化合物结构的特性,Ma等[44] 实现了以超临界二氧化碳为介质对超高分子量聚乙烯织物的染色。在超临界二氧化碳环境下,以20 MPa压力和120 ℃温度对超高分子量聚乙烯织物进行染色,随着染色时间和染料用量的增加,超高分子量聚乙烯织物的染色性能随之提高;染色后织物的耐摩擦和耐升华色牢度达到4~5级。
5.4 超高分子量聚乙烯纤维表面改性染色
目前,在超高分子量聚乙烯纤维颜色的构建过程中,使纤维的力学性能保持稳定具有非常重要的意义。
6 结束语
以芳纶、碳纤维、聚酰亚胺纤维和超高分子量聚乙烯纤维为代表的高性能纤维,因其优异的性质广泛应用于国防科技、军事工程、航空航天、交通运输、建筑工业、医疗防护等重要领域,但是产品颜色的单一性限制了其应用的进一步拓展。针对高性能纤维难染色或难染深的问题,其颜色构建方法主要包括载体染色、非水介质溶剂染色、纤维表面改性染色、原液着色等化学染色法以及物理结构生色法。基于目前高性能纤维颜色构建技术现状,推进节能低碳绿色环保染色,加强清洁安全生产,助力纺织行业高质量发展将成为未来主要发展趋势。同时,需进一步加强高性能纤维颜色构建的理论基础研究,结合高性能纤维的大分子链、化学结构、成形方式、表面物理和化学性能,在高性能纤维的颜色构建中取得理论突破,为制备彩色高性能纤维提供原理创新和理论指导。此外,提高纤维的染色深度和色牢度,降低高性能纤维颜色构建过程的结构损伤,保持纤维的高力学性能也是亟需解决的问题。在研究中平衡好高性能纤维的颜色构建技术与纤维性能之间的关系,将促进高性能纤维及其制品的高质量发展和应用拓展。
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