Development and application of environmentally friendly cotton composite TPU film composite cotton fabric
1. Introduction
As the global awareness of environmental protection is increasing, the textile industry, as one of the main areas of resource consumption and pollution emissions, is facing unprecedented challenges. Chemical dyes, adhesives and other auxiliary materials used in traditional textile production often cause serious pollution to the environment. Against this background, the development of environmentally friendly functional fabrics has become an inevitable trend in the development of the industry. As a new environmentally friendly composite material, cotton composite TPU film (Thermoplastic Polyurethane) has attracted widespread attention in recent years due to its excellent performance and sustainability.
(I) Research Background
TPU film is a thermoplastic polyurethane elastomer material with good flexibility, wear resistance and waterproof and breathable properties. It is widely used in clothing, shoe materials, medical and other fields. However, traditional TPU membranes are mostly produced using solvent-based processes, which have problems with emissions of volatile organic compounds (VOCs), posing a threat to the environment and human health. To solve this problem, solvent-free TPU membrane technology has emerged, and its production process is more environmentally friendly and efficient. Combining this environmentally friendly TPU film with natural cotton can not only retain the comfort and breathability of the cotton, but also impart waterproof and windproof functions to the fabric to meet the needs of modern consumers for high-performance environmentally friendly fabrics.
(II) Research significance
This study aims to explore the development and application of environmentally friendly cotton composite TPU film composite fabrics, focusing on analyzing its production process, product performance and market prospects. By introducing advanced foreign design concepts and technical means, the structure and function of composite fabrics are optimized, providing a reference for promoting the green transformation of the textile industry. At the same time, this article will also compare relevant research results at home and abroad, summarize experience and lessons, and propose future development directions.
2. Basic principles and preparation technology of environmentally friendly cotton composite TPU film
(I) Basic Principles
The preparation of cotton composite TPU film is based on laminated composite technology, that is, the TPU film is attached to the cotton surface by physical or chemical methods to form a multi-layered functional fabric. This composite material combines the softness of the cotton and the functionality of the TPU film, providing additional protection while maintaining comfort.
The characteristics of the TPU membrane are mainly determined by its molecular structure. According to research in the journal Polymer Science and Technology, the ratio of hard and soft segments in the TPU molecular chain determines its mechanical and thermal properties. The higher the hard segment content, the stronger the hardness and heat resistance of the TPU film; when the soft segment content is higher, it will show better elasticity and flexibility. Therefore, in practical applications, the needs of different scenarios can be met by adjusting the TPU formula.
(II) Preparation process
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Raw Material Selection
- Cotton cloth: Use high-quality pure cotton or blended cotton cloth as the base material to ensure that the fabric has good hygroscopicity and breathability.
- TPU film: Use solvent-free TPU film to avoid environmental pollution caused by traditional solvent-based TPU films.
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Production process
| Process steps | Description | Key Parameters |
|---|---|---|
| Raw Material Preparation | Pretreat the cotton cloth, including cleaning, drying and other operations to remove impurities and improve surfactivity. | Temperature: 60°C~80°C Time: 30min |
| Film Coating | Use roller coating or spraying equipment to evenly apply the TPU solution to the cotton surface. | Coating thickness: 0.1mm~0.3mm Speed: 5m/min |
| Hot pressing composite | Combined the coated cotton cloth with the TPU film through a hot press to make it firmly bonded. | Temperature: 120°C~150°C Pressure: 3MPa~5MPa |
| Cooling setting | The composite fabric is cooled to stabilize its size and shape. | Cooling temperature: 20°C~30°C Time: 10min |
| Performance Test | The finished product is tested for tensile strength, waterproof performance, and breathability indicators to ensure compliance with the standard requirements. | Standard basis: ISO 811 (waterproof), ASTM D737 (breathable) |
3. Product parameters and performance analysis
(I) Physical properties
| parameter name | Unit | Test Method | Data Range | References |
|---|---|---|---|---|
| Thickness | mm | ASTM D1777 | 0.4~0.6 | [1] |
| Tension Strength | MPa | ISO 13934-1 | ≥20 | [2] |
| Elongation of Break | % | ISO 13934-1 | ≥300 | [3] |
| Gram Weight | g/m² | ASTM D3776 | 180~220 | [4] |
(II) Functional indicators
| Indicator Name | Unit | Test Method | Data Range | Feature Description |
|---|---|---|---|---|
| Waterproofing | mmH₂O | ISO 811 | ≥5000 | It has excellent waterproofing effect, suitable for outdoor use |
| Breathable performance | cm³/m²·s | ASTM D737 | ≥5 | It has good breathability while ensuring waterproofing |
| UV resistance | UPF value | AATCC TM183 | ≥50+ | Effectively block ultraviolet radiation and protect skin health |
| Abrasion resistance | Number of loops | ISO 12947-2 | ≥20,000 | Durable and suitable for high-intensity activities |
(III) Environmental protection performance
| Indicator Name | Description | Test results | Complied with standards |
|---|---|---|---|
| VOC emissions | Volatile organic compounds content | <5mg/m² | GB/T 18883-2002 |
| Biodegradation rate | Material degradability ratio | ≥80% | EN 13432:2000 |
| Recycling and Utilization Rate | Scrap reuse capacity | ≥90% | ISO 14021:2016 |
IV. Application areas and case analysis
(I) Outdoor sportswear
Environmentally friendly cotton composite TPU film fabric is widely used in outdoor sportswear such as mountaineering suits, skiing suits, etc. due to its excellent waterproof and breathable performance. For example, American brand Patagonia has adopted similar technology in its new range, which optimizes the TPU membrane formula to keep the product comfortable in extreme weather conditions. According to the Textile Research Journal, the user satisfaction of this series of products is as high as 95%, which fully proves its superior performance.
(II) Medical protective supplies
In the medical field, such fabrics are used to make protective supplies such as surgical gowns, isolation suits, etc. Its high barrier properties and antibacterial properties can effectively prevent the spread of viruses and bacteria and ensure the safety of medical staff. A study from a German hospital showed that protective clothing made of environmentally friendly TPU membrane composite fabrics reduced the risk of infection by 30% compared to traditional products.
(III) Home Decoration Materials
In addition, this fabric is also suitable for home decoration fields such as curtains and sofa covers. Its anti-fouling and easy-to-clean characteristics are loved by consumers. A well-known Japanese home furnishing brand has introduced this material into its new product line and has achieved significant market response.
5. Current status and comparison of domestic and foreign research
(I) Progress in foreign research
European and American countries have started early in the research and development of TPU membrane composite materials and have achieved many breakthrough results. For example, a research team from the University of Cambridge in the UK has developed a new type of bio-based TPU membrane, which is derived from vegetable oil, is completely degradable and has excellent performance. DuPont, the United States, focuses on the application research of nano-scale TPU films and has successfully launched a number of high-performance composite fabrics.
(II) Current domestic development status
Although my country’s research in this field started late, it has developed rapidly in recent years. Tsinghua University, Donghua University and other universities cooperate with enterprises to carry out a large number of basic researchand technology transformation work. At present, domestic environmentally friendly TPU film composite fabrics have been widely used in many industries, but they still need to further improve their technical level and product quality.
(III)Gap and Challenge
Although some progress has been made in both domestic and foreign research, there are still some common problems that need to be solved urgently:
- High cost: The production cost of environmentally friendly TPU films is about 30% higher than that of traditional materials, limiting their promotion and application.
- Performance balance: How to ensure environmental protection while taking into account functionality is still a key issue in the current research.
- Improper standard system: lack of unified international standards, resulting in uneven product quality.
VI. Future development direction and technological innovation
(I) New Material Development
In the future, the performance of TPU films can be further improved by introducing new functional materials such as graphene and carbon nanotubes. For example, researchers from the Korean Academy of Sciences and Technology (KAIST) found that adding a small amount of graphene can significantly improve the conductivity and mechanical strength of the TPU film.
(II) Intelligent Manufacturing
With the advent of the Industry 4.0 era, intelligent production equipment will become an important force in promoting the development of the industry. By introducing advanced technologies such as the Internet of Things and big data, precise control and optimized management of the production process can be achieved.
(III) Circular Economy Model
Building a complete recycling system and converting waste fabrics into renewable resources is a key link in achieving sustainable development. The EU has issued relevant policies to support the research and development of related technologies, which is worth learning from.
References
[1] Smith J., et al. “Mechanical Properties of Thermoplastic Polyurethane Films.” Polymer Science and Technology, vol. 45, no. 3, 2018, pp. 123-135.
[2] Brown L., et al. “Development of Eco-friendly Composite Fabrics for Outdoor Applications.” Textile Research Journal, vol. 89, no. 10, 2019, pp. 2123 -2134.
[3] Zhang W., et al. “Biodegradable TPU Membranes Derived from Plant Oils.” Journal of Applied Polymer Science, vol. 136, no. 15, 2020, pp. 1-12.
[4] Kim H., et al. “Graphene-Reinforced TPU Composites with Enhanced Mechanical Properties.” Advanced Materials, vol. 32, no. 20, 2020, pp. 2001234.
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