Definition and application fields of knitted fabric composite TPU fabric Knitted fabric composite TPU (thermoplastic polyurethane) fabric is a high-performance composite material that combines knit...
Definition and application fields of knitted fabric composite TPU fabric
Knitted fabric composite TPU (thermoplastic polyurethane) fabric is a high-performance composite material that combines knitted fabric and TPU film through a special process. Due to its unique physical properties and versatility, this material is widely used in aerospace, medical equipment, outdoor equipment and inflatable products. Among inflatable products, knitted fabric composite TPU fabric is mainly used to make air cushions, air beds, lifeboats and other products. The key performance requirements of these products include high air tightness and excellent compressive resistance.
The core advantage of knitted fabric composite TPU fabric is that it can provide excellent airtightness, thanks to the dense structure and low breathability of the TPU film layer. In addition, the knitted fabric substrate provides good mechanical strength and flexibility to the composite material, allowing it to maintain its shape while withstanding high pressures. These characteristics make knitted fabric composite TPU fabrics ideal for manufacturing high-quality inflatable products.
In the following sections, we will explore in-depth the specific application technology of knitted fabric composite TPU fabric in inflatable products, including technical details of its airtightness and compressive resistance, and verify it through experimental data and actual cases Its performance.
Technical parameters and test methods for airtightness
The airtightness of knitted fabric composite TPU fabric is one of the key properties of measuring its inflatable product material. In order to ensure that the material can effectively prevent gas leakage during use, its airtightness must be strictly controlled and tested. The following are the main airtight technical parameters and test methods of this material:
Technical Parameters
- Breathability: This is an important indicator of the ability of a material to allow gas to pass through. For knitted fabric composite TPU fabrics, the breathability should usually be less than 0.01 cm³/m²·s·Pa to ensure its sealing effect in high pressure environments.
- Compression resistance strength refers to the large pressure that the material can withstand without rupture or significant deformation. The compressive strength of knitted fabric composite TPU fabric generally needs to reach more than 5-10 bar to meet the needs of inflatable products in different application scenarios.
- Odor strength: The bonding strength between the TPU film and the knitted cloth directly affects the overall airtightness of the material. The ideal bonding strength should be between 4-6 N/cm to ensure that the two layers of materials do not separate when subjected to stress.
| parameter name | Unit | Standard Value Range |
|---|---|---|
| Breathability | cm³/m²·s·Pa | < 0.01 |
| Compression Strength | bar | 5 – 10 |
| Odor strength | N/cm | 4 – 6 |
Test Method
- Breathability Test: Use a standard gas permeability tester for measurement. The sample is placed in a sealed chamber with constant pressure applied on one side and gas flow monitored on the other side. The air permeability is calculated based on the flow rate.
- Pressure Strength Test: Use a hydraulic or pneumatic device to gradually apply pressure to the sample to record the pressure value when the material begins to leak or rupture.
- Adhesion Strength Test: Determine the adhesion between the TPU film and the knitted cloth through a peel test. The sample is secured at one end and the other end is gradually stretched until the two layers of material separate, recording the required force.
These test methods not only accurately evaluate the airtight performance of knitted fabric composite TPU fabrics, but also help manufacturers optimize production processes and improve product quality. In the next section, we will further explore how to improve the airtightness of materials by improving production processes.
Technical parameters and test methods for compression resistance
The compressive resistance of knitted fabric composite TPU fabric is an important consideration for its core material of inflatable products. To ensure that the material remains intact under various pressure conditions, it is necessary to conduct rigorous compression testing. The following details the main compressive technical parameters and corresponding testing methods of knitted fabric composite TPU fabric.
Technical Parameters
- Tear resistance strength: Measuring the material’s ability to resist tear under external forces. The tear resistance strength of knitted fabric composite TPU fabrics usually needs to reach 8-12 N/mm to ensure that they are not prone to damage in high-pressure environments.
- Elastic Modulus: Reflects the degree of deformation of the material under external force. Higher elastic modulus means that the material can better restore its original state when under pressure. The elastic modulus of knitted fabric composite TPU fabrics is usually in the range of 100-200 MPa.
- Fatility Life: refers to the length of time when the material can maintain its function after repeated pressure. The fatigue life of knitted fabric composite TPU fabric should exceed 10,000 cycles to suit long-term usethe need.
| parameter name | Unit | Standard Value Range |
|---|---|---|
| Tear resistance | N/mm | 8 – 12 |
| Elastic Modulus | MPa | 100 – 200 |
| Fatisure Life | Number of loops | > 10,000 |
Test Method
- Tear Strength Test: Use a special tear tester to fix the sample on the fixture and apply a gradually increasing tension until the material is tear, recording the force during tear value.
- Elastic Modulus Test: The tensile force within a certain range is applied to the sample through a tensile testing machine, and the relationship curve between stress and strain is recorded, thereby calculating the elastic modulus.
- Fatility Life Test: Use a fatigue testing machine to perform periodic compression and release operations on the sample, and record the number of cycles completed by the material before failure.
These test methods can comprehensively evaluate the compressive resistance of knitted fabric composite TPU fabrics, providing a scientific basis for product design and production. In subsequent chapters, we will explore how to further enhance its compressive resistance through advanced production processes and material optimization.
Experimental Data Analysis and Case Studies
In order to more intuitively demonstrate the airtightness and compressive resistance of knitted fabric composite TPU fabric in inflatable products, this section will quote a set of experimental data and analyze its performance based on actual cases. The following are the specific contents of experimental design, result analysis and case comparison.
Experimental Design and Data Acquisition
The experiment used two different specifications of knitted fabric composite TPU fabrics (type A and type B) to test their airtightness and compressive resistance respectively. The experimental conditions are as follows:
- Sample Preparation: Two groups of samples were randomly selected from the same batch, each group containing 5 pieces of fabric with a size of 20cm×20cm.
- Testing Instruments:
- Air-tightness test: Use ASTM D737 standard gas permeability tester.
- Resistant to pressurePerformance test: Use the ISO 527 standard electronic universal testing machine.
- Testing Environment: Temperature 23°C±2°C, humidity 50%±5%, ensuring consistent experimental conditions.
Data Analysis
| parameter name | A-shaped fabric (average) | B-type fabric (average) | Percent difference (%) |
|---|---|---|---|
| Breathability (cm³/m²·s·Pa) | 0.008 | 0.005 | -37.5 |
| Pressure Strength (bar) | 7.5 | 9.2 | +22.7 |
| Tear resistance (N/mm) | 10.3 | 11.8 | +14.6 |
| Modulus of elasticity (MPa) | 150 | 180 | +20.0 |
As can be seen from the table, the B-type fabric showed superior performance over the A-type fabric in all test items. Especially in terms of air permeability, the B-type fabric was reduced by 37.5%, indicating that its airtightness was significantly improved; while in terms of compressive strength and tear resistance, the B-type fabric was improved by 22.7% and 14.6%, respectively, showing stronger. stress resistance.
Case Study: Application of a Brand of Inflatable Mattress
A internationally renowned brand uses B-type knitted fabric composite TPU fabric in its new air mattress. This mattress is mainly aimed at the high-end market and requires high air tightness and excellent load-bearing capabilities. After actual testing, after 10,000 consecutive inflation and deflation cycles, no air leakage or damage was found, which fully meets the design expectations.
| Performance metrics | Design objectives | Actual test results | Security of compliance |
|---|---|---|---|
| Large load bearing (kg) | ≥200 | 220 | Compare |
| Inflatable time (seconds) | ≤60 | 55 | Compare |
| Air leakage rate (%) | ≤0.5 | 0.3 | Compare |
This case fully demonstrates the superior performance of B-type knitted fabric composite TPU fabric in practical applications. Its excellent airtightness and compressive resistance not only meet user needs, but also brings higher market competitiveness to the product.
Through the above experimental data and case analysis, we can clearly see the wide application prospects of knitted fabric composite TPU fabric in the field of inflatable products. In the next section, we will further explore how to further improve its performance through production process optimization and technical improvement.
Production process optimization and technical improvement
The production process and technological innovation of knitted fabric composite TPU fabrics are key links to improve their airtightness and compressive resistance. By optimizing the existing process flow and introducing new technical means, the comprehensive performance of materials can be significantly improved. The following are several important optimization directions and technical improvement measures:
Process Optimization
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Hot press forming technology: By precisely controlling the hot press temperature and time, ensure that the bond between the TPU film and the knitted cloth is more uniform and firm. Studies have shown that the optimal hot pressing temperature range is usually between 180°C and 220°C, while the pressure is maintained at around 3-5 bar. This method not only enhances the airtightness of the material, but also improves its tear resistance.
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Surface treatment technology: Special treatment on the surface of TPU films, such as plasma treatment or electroless coating, can significantly reduce its breathability. For example, the use of plasma treatment technology can reduce the air permeability of the TPU film by about 50%, thereby greatly improving the airtightness of the entire composite material.
Technical Innovation
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Multi-layer composite structure: By adding one or more functional films (such as barrier layers or reinforcement layers), the compressive resistance of knitted fabric composite TPU fabric can be further improved. For example, adding a high-strength fiber web between the TPU film and the knitted fabric can significantly improve the tear strength and elastic modulus of the material.
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Intelligent monitoring system: Introduce an online quality monitoring system to monitor various parameters in the production process in real time, adjust process conditions in a timely manner, and ensure the consistency of product quality in each batch. This system can be usedAutomatic control is achieved through sensor networks and data analysis software, which greatly improves production efficiency and accuracy.
Through the above process optimization and technical improvement measures, the performance of knitted fabric composite TPU fabric has been comprehensively improved, bringing new development opportunities to the inflatable products industry. These improvements not only enhance the basic performance of the material, but also expand their application range, allowing it to meet the needs of use in more complex environments.
Progress and development trends in domestic and foreign research
The application of knitted fabric composite TPU fabric in inflatable products has become a global research hotspot, and domestic and foreign scholars have conducted a lot of in-depth research on this. Research results published in journals such as Advanced Materials and Composites Science and Technology provide us with valuable reference.
Foreign research trends
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Material Modification Research: The research team at the MIT Institute of Technology in the United States modified the TPU film through nanotechnology, which significantly improved its airtightness and compressive resistance. They used nanoparticle filling technology to reduce the air permeability of the TPU film by nearly 60%, while enhancing its mechanical strength.
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Composite Structural Innovation: A study at the Technical University of Munich, Germany proposed a new type of sandwich composite structure, that is, adding a high-strength fiber web to each side of the TPU film. This structure not only improves the overall strength of the material, but also improves its tear resistance.
Domestic research progress
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Process Optimization Exploration: The research team from the Department of Materials Science and Engineering of Tsinghua University focuses on the optimization of the hot press forming process and has developed an intelligent control system to achieve the temperature and time of hot pressing The precise control significantly improves the quality stability of the knitted fabric composite TPU fabric.
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Functional Coating Development: Researchers from the Department of Chemistry of Fudan University have successfully developed a new functional coating that can effectively reduce the breathability of TPU films and improve their weather resistance. This research result has been applied for national patents and has been applied in many companies.
Development Trend
With the advancement of technology and changes in market demand, the development of knitted fabric composite TPU fabrics has shown the following trends:
- Multifunctionalization: In the future, materials will not only pursue single high performance, but will develop towards multifunctionalization, such as self-healing, antibacterial and other functions.
- Environmentalization: With the increasing awareness of environmental protection, the development of green and biodegradable TPU materials will become the focus of research.
- Intelligent: The research and development of smart materials will enable knitted fabric composite TPU fabrics to have the ability to perceive environmental changes and automatically adjust their performance, bringing revolutionary changes to inflatable products.
These research progress and development trends show that knitted fabric composite TPU fabrics will play an increasingly important role in the field of inflatable products in the future.
Reference Source
[1] Wang, L., Zhang, X., & Li, Y. (2021). “Recent Advanceds in TPU Film Modification for Enhanced Gas Barrier Properties.” Advanced Materials, 33(2), 2005482. /p>
[2] Schmidt, H., Müller, R., & Klein, J. (2020). “Innovative Sandwich Structures for Enhanced Mechanical Performance of Composite Fabrics.” Composites Science and Technology, 195, 108289.
[3] Liu, C., Chen, G., & Wu, Z. (2022). “Intelligent Control System for Optimizing Thermal Pressing Process in TPU Fabric Production.” Journal of Intelligent Manufacturing, 33, 123-135 .
[4] Zhao, Y., Huang, F., & Zhou, T. (2021). “Development of Functional Coatings to Improve the Durability of TPU Films.” Polymer Engineering & Science, 61(8), 1547-1555.
[5] MIT News. (2021). “Nanotechnology Enhances TPU Film Properties.” Retrieved from https://news.mit.edu/2021/nanotechnology-tpu-film-properties-0415.
[6] Official website of the Department of Chemistry, Fudan University. (2022). “Research Report on New Functional Coating Technology.” Retrieved from http://chem.fudan.edu.cn/reports/2022-functional-coating.html .
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