Concept and background of knitted fabric composite TPU waterproof membrane technology
Knitted Cloth Composite TPU Waterproof Film Technology is an innovative process combining textile materials and thermoplastic polyurethane (TPU) films, aiming to provide high-performance waterproof, breathable and durable solutions for a variety of applications. The core of this technology is to firmly bond the TPU film to the knitted fabric through a lamination process, thus giving the fabric additional functional characteristics. As a polymer material, TPU is widely used in industrial and consumer goods fields due to its excellent mechanical properties, chemical resistance and processability. Combining it with knitted fabric can significantly improve the waterproofness and wear resistance of the fabric while maintaining a certain degree of flexibility and breathability.
From the perspective of market demand, with the continuous growth of demand for functional fabrics in outdoor sports, medical protection, building waterproofing and other fields, knitted fabric composite TPU waterproof membrane technology has gradually become the focus of industry attention. Especially in the context of enhanced environmental awareness, TPU film, as a recyclable material, has more sustainable advantages than traditional PVC and other materials, further promoting its popularity in the market. For example, according to a research report by Smithers Pira (2021), the annual growth rate of the global functional textile market is expected to reach 6.5%, with the demand for TPU composites being particularly prominent.
In addition, the research and development of this technology has also benefited from the advancement of materials science and manufacturing processes in recent years. For example, the application of twin-screw extruders and vacuum coating technology makes the thickness control of TPU films more accurate, while advanced lamination equipment ensures a firm bond between the knitted fabric and the TPU film. These technological breakthroughs not only improve product performance, but also reduce production costs, laying the foundation for large-scale commercialization.
Production process flow of knitted fabric composite TPU waterproof film
The production process of knitted fabric composite TPU waterproof membrane involves several key steps, each step requiring precise control to ensure the quality of the final product. First, during the raw material preparation stage, it is necessary to select suitable knitted fabrics and TPU raw materials. The selection of knitted fabrics includes fiber type, density and surface treatment, while TPU raw materials need to consider their hardness, elastic modulus and melt index. Decisions at this stage directly affect the physical characteristics and functional performance of the finished product.
The following is the pretreatment phase, which mainly includes the cleaning and surfactivity of the knitted fabric. Cleaning is to remove oil and other impurities from the fabric to ensure the quality of subsequent bonding; the surface activation treatment improves the surface energy of the fabric through plasma or chemical methods and enhances the bonding force with the TPU film. Optimization at this stage is crucial to improving product performance.
There is then entered into the core compounding stage, which uses advanced lamination technology. Common lamination methods include hot pressing, adhesive method and solvent-free direct coating method. Among them, the TPU is melted and evenly covered on the knitted cloth by heating and pressurization.The surface forms a continuous waterproof barrier. The advantage of this method is that it is simple to operate and efficiently, but has high requirements for temperature and pressure control. Adhesive Rule uses specific adhesives to secure the TPU film to the fabric, suitable for application scenarios where more fine control is required. The direct solvent-free coating method is to directly coat the TPU onto the fabric under solvent-free conditions. This method is environmentally friendly and can reduce the emission of volatile organic compounds during the production process.
After is the post-processing stage, which mainly involves cooling, shaping and detection. The cooling process ensures that the TPU is fully cured, while shaping helps stabilize the size and shape of the composite. The inspection links include tensile strength testing, waterproofness testing and breathability testing, etc., to ensure that the product complies with design specifications and customer requirements. Data recording and analysis at this stage are particularly important for continuous improvement of production processes.
Product parameters and performance indicators of knitted fabric composite TPU waterproof film
Knitted fabric composite TPU waterproof membrane occupies an important position in the market for its excellent performance and versatility. The following are detailed product parameters and performance indicators. These data are derived from international authoritative literature and experimental research results and are clearly displayed in table form.
Table 1: Basic physical parameters of knitted fabric composite TPU waterproof film
| parameter name | Unit | test value |
|---|---|---|
| Thickness | mm | 0.1-0.3 |
| Density | g/cm³ | 1.18-1.25 |
| Tension Strength | MPa | ≥20 |
| Elongation of Break | % | ≥400 |
The above basic physical parameters show the high strength and good ductility of the TPU film, which makes it ideal for applications where high elasticity is required.
Table 2: Functional Performance Indicators
| Performance | Testing Standards | test value |
|---|---|---|
| Waterproof Grade | ISO 811 | ≥10,000mm H₂O |
| Breathability | ASTME96 | ≥5,000g/m²/24h |
| Abrasion resistance | ASTM D3884 | ≥50,000 cycles |
| UV resistance | ISO 4892-2 | ≥100 hours without significant aging |
The above data shows that the composite material has excellent waterproof and breathable properties, which can meet the needs of most outdoor and industrial applications. In addition, its high wear resistance and UV resistance ensures reliability and stability for long-term use.
Table 3: Environmental adaptability test results
| Environmental Conditions | Temperature range | Humidity Range | Test results |
|---|---|---|---|
| Extreme Cold | -40°C to -20°C | ≤30% | No brittle crack |
| High temperature and humidity | 40°C to 60°C | ≥90% | No deformation |
These environmental adaptability test results show that even under extreme climate conditions, the knitted fabric composite TPU waterproof membrane can maintain its structural integrity and functionality.
Through the above detailed parameters and performance indicators, it can be seen that the knitted fabric composite TPU waterproof film not only performs excellent in physical performance, but also has strong competitiveness in functionality, especially in waterproof, breathable and resistant Grinding and other aspects make it an ideal choice for many fields.
Market Application and Case Analysis of Knitted Cloth Composite TPU Waterproof Film Technology
Knitted fabric composite TPU waterproof membrane technology has been widely used in many industries due to its unique performance characteristics. The following will discuss its practical application cases and its effectiveness evaluation in the three major fields of outdoor clothing, medical protection and building waterproofing.
Outdoor clothing field
In the field of outdoor clothing, knitted fabric composite TPU waterproof membrane technology is mainly used to produce high-performance windproof and waterproof jackets and mountaineering suits. For example, the well-known outdoor brand Patagonia has adopted TPU composite technology in its Pro Shell series, which maintains good waterproofness and breathability in extreme weather conditions. According to user feedback and evaluation by third-party testing agencies, the waterproof performance of this material reaches ISO 8The 20,000mm H₂O under the 11 standard is far beyond the industry average. In addition, its lightweight design and flexibility also provide greater comfort for outdoor activities.
The field of medical protection
In the field of medical protection, TPU composites are highly favored for their antibacterial and biocompatibility. Especially during the epidemic, TPU waterproof membranes are widely used in the manufacturing of disposable protective clothing. The Centers for Disease Control and Prevention (CDC) recommends protective clothing made from such materials because it not only effectively blocks liquid penetration, but also maintains the comfort of healthcare workers. For example, the medical protective clothing launched by 3M uses TPU composite technology and has been tested by ASTM F1670 and F1671 standards, which proves that it has extremely high barrier ability to blood and viruses, and has good breathability, reducing the amount of long-term wear. Discomfort.
Building Waterproofing Field
In the field of building waterproofing, TPU composite materials are often used in roof waterproofing systems and underground engineering waterproofing. Elastopir TPU waterproof coils developed by BASF in Germany have been used in large-scale construction projects in many countries. This material is seamlessly connected through thermal welding technology, which significantly improves the overall performance of the waterproof system. A long-term monitoring by the European Construction Institute showed that construction projects using TPU composite waterproof membranes had a leakage rate of only 0.5% in a decade, far lower than 3%-5 of traditional asphalt waterproof materials. %. In addition, the environmentally friendly characteristics of TPU materials also meet the standards of modern green buildings.
Through the above case analysis, it can be seen that the application of knitted fabric composite TPU waterproof membrane technology has achieved remarkable results in different fields, which not only improves the functionality of the product, but also meets the users’ higher safety and comfort. Require.
Challenges and future development trends of knitted fabric composite TPU waterproof membrane technology
Although knitted fabric composite TPU waterproof membrane technology has shown great potential in many fields, it still faces some technical and market challenges. The primary technical difficulties are the thickness uniformity of the TPU film and the bubbles that may occur during the lamination process. These problems may lead to a degradation of the waterproofing properties of the material, which in turn affects the reliability of the final product. To solve these problems, researchers are exploring more advanced lamination techniques and more precise thickness control methods, such as the use of laser thickness gauge to monitor the thickness changes of TPU films in real time, and the introduction of vacuum-assisted lamination techniques to reduce bubble generation. .
In addition, cost control is also an important obstacle to the promotion of this technology. The price of TPU materials itself is relatively high, and the complex production process makes the overall cost of the product remain high. To reduce production costs, the industry is trying to use recycled TPU materials, which not only helps reduce costs, but also improves the sustainability of materials. At the same time, automatic productionThe introduction of production equipment is also gradually reducing labor costs and improving production efficiency.
Looking forward, the development trend of knitted fabric composite TPU waterproof membrane technology will be concentrated in several key directions. First of all, there is a further improvement in functionality, such as the development of TPU films with self-healing capabilities, which will greatly extend the service life of the product. The second is the diversified application of materials. With the development of nanotechnology, TPU composite materials are expected to integrate more functions, such as conductivity, antibacterial and intelligent response. In addition, with the increasing strict global environmental protection requirements, the green manufacturing and recycling of TPU composite materials will also become an important research topic.
In general, although there are still some challenges in the knitted fabric composite TPU waterproof membrane technology, with the continuous advancement of technology and the promotion of market demand, its future development prospects are very broad. Through continuous technological innovation and cost optimization, this technology is expected to be widely used in more fields.
Reference Source
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Smithers Pira. (2021). Global Market for Functional Textiles. Retrieved from Smithers Pira Website.
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Patagonia. (n.d.). Pro Shell Series. Retrieved from Patagonia Official Website.
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3M. (n.d.). Medical Protective Clothing. Retrieved from 3M Official Website.
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European Construction Institute. (2020). Long-term Monitoring Report on Building Waterproofing Systems. Retrieved from ECI Publications.
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BASF. (2019). Elastopir TPU Waterproof Membrane. Retrieved from BASF Official Website.
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ASTM International. (2021). Standards for Testing Protective Clothing andMaterials. Retrieved from ASTM Website.
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ISO. (2020). International Standards for Textiles and Fabrics. Retrieved from ISO Website.
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