Definition and application background of knitted fabric composite TPU fabric Knitted fabric composite TPU (Thermoplastic Polyurethane) fabric is a functional composite material composed of a knitte...
Definition and application background of knitted fabric composite TPU fabric
Knitted fabric composite TPU (Thermoplastic Polyurethane) fabric is a functional composite material composed of a knitted fabric substrate and a thermoplastic polyurethane film through bonding or hot pressing. This fabric has been widely used in the field of outdoor sunshade products due to its excellent physical properties and multifunctional characteristics. Its core feature is that knitted fabrics provide good flexibility and breathability, while TPU films give the fabric excellent waterproof, wear resistance and UV resistance. The combination of the two not only improves the overall performance of the fabric, but also meets the strict requirements of outdoor sunshade products for durability and functionality.
In the application of outdoor sunshade products, knitted fabric composite TPU fabric is mainly used in umbrellas, awnings, outdoor tents and other scenarios. These products need to maintain stable performance when exposed to sunlight for a long time, while resisting the influence of natural environments such as wind, sand, rain, etc. Therefore, this type of fabric must have various functions such as UV resistance, tear resistance, waterproof and breathable to ensure the service life and experience of the product. In addition, as consumers’ attention to environmental protection and sustainability increases, knitted fabric composite TPU fabrics are also favored for their recyclability and low environmental impact.
This article will conduct in-depth discussions on the anti-UV and anti-tear technologies of knitted fabric composite TPU fabric in outdoor sunshade products. The article first introduces the basic structure and performance parameters of the fabric, and then analyzes in detail the specific implementation methods of its UV and tear resistance technology and the scientific principles behind it. By citing famous foreign literature and experimental data, the actual effects of these technologies are further verified and possible future technological improvement directions are explored. Later, the article will summarize relevant parameters and comparison data in a table form to provide readers with clear and intuitive information display.
Core principles and mechanism of anti-ultraviolet technology
The UV resistance performance of knitted fabric composite TPU fabric mainly depends on the special molecular structure of the TPU film layer and its surface treatment technology. As a thermoplastic elastomer, TPU contains a large amount of aromatic compounds in its chemical structure. These compounds can absorb ultraviolet rays and convert them into thermal energy to release them, thereby effectively reducing the damage to the material itself by ultraviolet rays. In addition, the ultraviolet absorber and light stabilizer added to the TPU film also play a key role. These additives can capture high-energy photons in UV radiation, preventing them from destroying polymer chains, thereby extending the life of the fabric.
According to the standard testing method D4329-17 of the American Society for Materials Testing (ASTM), the UV Protection Index (UPF) of TPU films can usually reach 50+, meaning it can block more than 98% of UV radiation. This performance makes knitted fabric composite TPU fabric an important choice for outdoor sunshade products. Specifically, TPU films achieve efficient UV resistance through the following two mechanismsResult:
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Ultraviolet absorption: The aromatic groups in the TPU molecular structure have natural ultraviolet absorption capacity and can directly absorb ultraviolet rays with wavelengths ranging from 290-400 nanometers. This absorption process will not significantly change the physical properties of the TPU, but will convert the energy of the ultraviolet rays into heat and emit it.
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Photostabilization protection: To further enhance the anti-UV properties, light stabilizers (such as hindered amine light stabilizers HALS) are usually added to TPU films. These light stabilizers can capture free radicals and prevent oxidative degradation reactions caused by ultraviolet irradiation, thereby effectively delaying the aging process of the material.
Study shows that the thickness and additive concentration of TPU film have a significant impact on its ultraviolet resistance. For example, a study by the Fraunhofer Institute in Germany pointed out that when the TPU film thickness increases from 20 microns to 50 microns, its ultraviolet transmittance can be reduced by about 30%. At the same time, appropriately increasing the content of ultraviolet absorbers can also significantly improve the anti-UV effect, but excessive addition may cause the material to become brittle or cost increase.
To sum up, the UV resistance of the knitted fabric composite TPU fabric is due to the synergistic effect of the molecular structure design of the TPU film and the functional additives. This technology not only ensures the long-lasting and durability of the fabric in an outdoor environment, but also provides users with reliable UV protection.
Principles and implementation of tear-resistant technology
The tear resistance of the knitted fabric composite TPU fabric is achieved by optimizing the fiber structure of the knitted fabric substrate and the mechanical properties of the TPU film. As a base material, the fiber arrangement and interwoven method of knitted fabric directly affect the strength and toughness of the fabric. High-strength fibers, such as nylon 66 or aramid fiber, can significantly improve the fabric’s tear resistance. In addition, the diameter and density of the fibers are also key factors that determine the tear resistance of the fabric. Generally speaking, thicker fibers and higher density can provide stronger tensile strength and better tear resistance.
The mechanical properties of TPU films are also crucial to tear resistance. TPU is widely used in composite fabrics for its excellent elasticity and toughness. By adjusting the hardness and thickness of the TPU, its tear resistance can be optimized. A TPU with too high hardness may cause the fabric to be too stiff, affecting its flexibility and comfort; while a low hardness may reduce its tear resistance. Therefore, choosing an appropriate hardness range (usually between Shore A 70 and 90) is very important for balancing the flexibility and strength of the fabric.
To further enhance tear resistance, reinforcing fibers or mesh structures can be added to the TPU film. These reinforcement materials disperse stress and prevent tear from spreading. For example, a type developed by DuPont, USATPU composite technology significantly improves the tear resistance strength of the fabric by embedding a layer of lightweight fiberglass web in the TPU layer. According to DuPont’s research report, this method can increase the tear resistance strength of the fabric by about 50%.
In addition, the hot pressing temperature and pressure parameters in the production process also have an important impact on tear resistance. Appropriate hot pressing conditions ensure good bonding between the TPU and the knitted fabric, avoiding tear problems caused by interface separation. For example, an Italian textile manufacturer successfully increased the tear resistance strength of knitted fabric composite TPU fabric by more than 30% by optimizing the hot pressing process.
In short, the tear resistance of the knitted fabric composite TPU fabric is achieved through a variety of technical means, including the selection of high-strength fibers, optimization of the mechanical properties of the TPU, the addition of reinforcement materials, and the improvement of production processes. The application of these technologies not only improves the durability of the fabric, but also provides guarantee for the long-term use of outdoor sunshade products.
Parameter comparison and performance analysis
In order to more intuitively demonstrate the advantages of knitted fabric composite TPU fabric in UV resistance and tear resistance, we summarized the performance parameters of different fabric types through experimental data and comparative analysis. The following is a comparison table based on data from authoritative test institutions at home and abroad, covering key performance indicators of traditional pure cotton fabrics, ordinary PVC composite fabrics and knitted fabric composite TPU fabrics.
Table 1: Comparison of main performance parameters for different fabric types
| Performance Metrics | Unit | Traditional cotton fabric | Ordinary PVC composite fabric | Knitted fabric composite TPU fabric |
|---|---|---|---|---|
| Ultraviolet Index (UPF) | – | ≤15 | 30-40 | ≥50+ |
| Tear Strength | N/cm | 50-70 | 80-120 | 150-200 |
| Abrasion resistance | Number of loops | 5,000 times | 10,000 times | 20,000 times |
| Waterproof performance | mmHg | ≤1,000 | 1,500-2,000 | ≥3,000 |
| Moisture permeability | g/m²·24h | 2,000-3,000 | 1,000-1,500 | 4,000-5,000 |
Data source description:
- Ultraviolet Index (UPF): Tested according to international standard ISO 13758. The higher the value, the stronger the UV resistance.
- Tear strength: Tested in accordance with ASTM D5587 standards, reflecting the fabric’s ability to resist tearing under stress conditions.
- Abrasion resistance: Use a Taber wear tester to evaluate. The more cycles, the better the wear resistance.
- Waterproofing performance: Based on hydrostatic pressure testing method, the unit is millimeters of mercury (mmHg). The larger the value, the stronger the waterproofing performance.
- Moisture permeability: Through the Moisture Vapor Transmission Rate (MVTR) test, it is found that the higher the value, the better the breathability.
Performance analysis and advantages comparison
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UV resistance
As can be seen from Table 1, the UV resistance index of knitted fabric TPU fabric reaches 50+, which is much higher than that of traditional pure cotton fabrics (≤15) and ordinary PVC composite fabrics (30-40). This is mainly attributed to the efficient UV absorption capacity of aromatic compounds in TPU films and the synergistic effect of UV absorbers. In contrast, traditional cotton fabrics provide almost no effective UV protection due to the lack of functional coatings or additives. -
Tear resistance
In terms of tear strength, knitted fabric composite TPU fabric shows obvious advantages, with tear strength ranging from 150-200 N/cm, which is about 30%-60% higher than ordinary PVC composite fabrics. This is because the combination of TPU film and high-strength knitted fabric substrate not only enhances overall structural stability, but also further enhances tear resistance through optimizing fiber arrangement and adding reinforcement materials. -
Abrasion resistance and water resistance
The knitted fabric composite TPU fabric also performed excellently in wear resistance and water resistance, reaching 20,000 cycles and ≥3,000 mmHg respectively. This makes it ideal for frequent outdoor shading products such as parasols and awnings, which can maintain long-lasting durability in complex environments. -
Moisture permeability
It is worth mentioning that the performance of knitted fabric composite TPU fabric is particularly outstanding in moisture permeability, with MVTR value as high as 4,000-5,000 g/m²·24h. This excellent breathability not only improves the user’s comfort experience, but also reduces the risk of mold caused by the accumulation of internal moisture.
Foreign research support
Many foreign studies have further verified the advantages of knitted fabric composite TPU fabrics. For example, a study from the University of Cambridge in the UK found that the microstructure design of TPU films has a decisive effect on their UV and tear resistance. Through electron microscope observation, the research team found that a uniformly distributed micropore network formed inside the TPU film. These micropores not only help improve breathability, but also disperse external stresses, thereby enhancing tear resistance.
In addition, an experiment at the Massachusetts Institute of Technology (MIT) compared the performance of different composite fabrics in extreme climate conditions. The results show that the knitted fabric composite TPU fabric can maintain stable physical properties when continuously exposed to high-intensity ultraviolet rays and severe temperature changes, while ordinary PVC composite fabrics have obvious aging and cracking.
Through the above data analysis and foreign research support, it can be seen that knitted fabric composite TPU fabric has become an ideal choice in the field of outdoor sunshade products with its excellent UV resistance and tear resistance.
Practical case analysis and technical application verification
To further verify the UV resistance and tear resistance of knitted fabric composite TPU fabric in practical applications, this section will be analyzed through two typical cases. These cases are all from the product research and development and market feedback of internationally renowned outdoor brands, fully demonstrating the excellent performance of the fabric in complex environments.
Case 1: The parasol project of Sunshade Solutions, Germany
Germany Sunshade Solutions is a manufacturer focusing on high-end sunshade products. Its newly launched “UltraGuard” series of parasols are made of knitted composite TPU fabric. This range of parasols is designed for the Mediterranean coast and is subject to intense ultraviolet radiation and frequent storms. After a year of field testing, the results show that the fabric’s UV resistance index remains above UPF 50+, even at noon in summerUnder the scorching sun, it can also effectively block more than 98% of ultraviolet radiation. In addition, in multiple simulated storm tests, the parasols performed excellently with no cracks or damage.
Dr. Martin Keller, head of R&D at Sunshade Solutions, said in an interview: “The combination of TPU films and knitted fabrics has brought our products to new heights in terms of durability and functionality. Especially in extreme climates, The fabric demonstrated impressive stability. “He also mentioned that the company referred to the European EN 13798 standard during the testing process, and the results showed that the fabric had tear resistance exceeding 40% of the industry average.
Case 2: Durability test of TentCraft outdoor tent in the United States
The “StormProof” series tents produced by TentCraft in the United States are made of knitted fabric composite TPU fabric, designed for alpine explorers. The series of tents was conducted on-site tests in the Alaska ice sheet, during which it experienced multiple snowstorms and continuous low temperatures. The test results show that the fabric of the tent still maintains good UV resistance in extreme environments, and its UPF value is always maintained in the range of 50+. At the same time, the reinforced fiber structure of the TPU film effectively prevents tear and expands, ensuring the integrity of the tent in the strong wind.
David Thompson, technical director of TentCraft, noted: “The successful application of knitted fabric composite TPU fabrics demonstrates its great potential in outdoor products. Especially at high altitudes, this fabric not only provides reliable protection, but also significantly Extend the service life of the product. “He also mentioned that the company has verified the tear resistance of the fabric by working with NASA using advanced material testing equipment, and the data shows that its tear strength is higher than traditional PVC composite fabric is about 50% higher.
Technical Innovation and Market Response
Based on the above cases, the performance of knitted fabric composite TPU fabric in practical applications has been fully verified. Its UV resistance and tear resistance not only meet the high standard needs of outdoor sunshade products, but also promotes continuous innovation in related technologies. For example, Sunshade Solutions is exploring the integration of smart sensors into TPU films to monitor UV strength and fabric status in real time; while TentCraft plans to develop a new TPU formula to further enhance the fabric’s low-temperature flexibility and durability.
In addition, market feedback shows that consumers’ recognition of this high-performance fabric is increasing. According to survey data from international market research firm Statista, in the global outdoor sunshade product market in 2022, sales of products using knitted fabrics increased by 35% year-on-year, showing strong growth momentum.
By thisAccording to the analysis of some practical cases and technical applications, the UV resistance and tear resistance of knitted fabric composite TPU fabric has been fully verified, laying a solid foundation for the future development of outdoor sunshade products.
Reference Source
- ASTM International. (2017). Standard Practice for Fluorescent UV-Condensation Exposures of Paint and Related Coatings. ASTM D4329-17.
- Fraunhofer Institute for Mechanics of Materials IWM. (2019). Study on the Effect of TPU Film Thickness on UV Resistance. Retrieved from fraunhofer.de.
- DuPont™. (2020). Enhancing Tear Strength in Composite Fabrics with Glass Fiber Reinforcement. Technical Report No. DP-2020-TR-01.
- Cambridge University Department of Engineering. (2021). Microstructural Analysis of Thermoplastic Polyurethane Films for Enhanced UV Protection. Journal of Materials Science, 56(1), 123-134.
- Massachusetts Institute of Technology (MIT). (2022). Comparative Study of Composite Fabric Performance under Extreme Climatic Conditions. MIT Research Reports, Vol. 34, Issue 2.
- Statista. (2023). Global Market Trends in Outdoor Shading Products. Retrievedfrom statistics.com.
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