Overview of Knitted Cloth Composite TPU Fabrics in Industrial Filtration Field Industrial filtration technology plays a crucial role in modern manufacturing, especially in areas such as air purific...
Overview of Knitted Cloth Composite TPU Fabrics in Industrial Filtration Field
Industrial filtration technology plays a crucial role in modern manufacturing, especially in areas such as air purification, water treatment and dust control. Knitted fabric composite TPU (thermoplastic polyurethane) fabrics have attracted widespread attention as a new high-efficiency filter material for their excellent performance. This material is made by combining knitted fabric with TPU films, which not only has high strength and flexibility, but also has excellent corrosion resistance and chemical resistance, making it an ideal choice in the field of industrial filtration.
The main applications of knitted fabric composite TPU fabric include but are not limited to: industrial waste gas treatment, liquid filtration, particulate matter capture, and corrosive substance filtration in the chemical industry. Its unique structural design can effectively intercept tiny particles while maintaining high breathability, thereby improving filtration efficiency and reducing energy consumption. In addition, the high wear resistance and tear resistance of TPU materials ensures its long-term stability in harsh environments.
This article aims to deeply explore the efficient filtration and corrosion resistance technology of knitted fabric composite TPU fabrics in the field of industrial filtration. The article will be divided into several main parts for detailed explanation: first, introduce the basic characteristics of the material and its specific application in different industrial scenarios; second, analyze its efficient filtration mechanism and corrosion resistance principle; then discuss the key parameters that affect its performance , and verified through experimental data; later, based on research results in famous foreign literature, the possibilities and potential challenges of future technological development are explored. Through these contents, readers can fully understand the technical advantages of knitted fabric composite TPU fabrics and their wide application prospects in the field of industrial filtration.
Physical and chemical properties of knitted fabric composite TPU fabric
Knitted fabric composite TPU fabric is a highly engineered material whose physical and chemical properties are key factors in its success in the field of industrial filtration. First of all, from the perspective of physical characteristics, the TPU itself has excellent mechanical strength and elastic modulus, which allows the composite material to maintain its structural integrity when withstanding high pressure or stretching. According to ASTM D412 standard test, the tensile strength of TPUs is usually between 20-80 MPa and has an elongation of break of up to 500%-600%, which means that the material can maintain its shape and function even under extreme conditions.
In terms of chemical properties, TPU is known for its excellent chemical resistance and corrosion resistance. TPU shows extremely high resistance to a variety of chemicals such as acids, alkalis, salt solutions and organic solvents. For example, in a study conducted by Smith et al. (2019), TPU samples showed no significant degradation or performance losses after soaking in a solution with a pH range of 2 to 12 for more than 30 days. In addition, the molecular structure of TPU gives it good antioxidant capacity, which is crucial to extend the service life of the material.
The following table summarizes some key physical and chemical parameters of knitted fabric composite TPU fabricsNumber:
| parameters | Description | Testing Standards | Typical |
|---|---|---|---|
| Tension Strength | The high stress that the material can withstand before breaking | ASTM D412 | 20-80 MPa |
| Elongation of Break | Percent extension of material when it breaks | ASTM D412 | 500%-600% |
| Chemical resistance | Resistance to various chemical reagents | ISO 9227 | pH 2-12 |
| Antioxidation | The ability to maintain stability in an oxygen environment | ASTM D3803 | >1000 hours |
These characteristics make knitted fabric composite TPU fabrics ideal for use in industrial filtration, especially in cases where corrosive or high temperature environments are required. By combining the porous structure of the knitted fabric and the protective layer of the TPU, this composite material can provide excellent protection while ensuring efficient filtration.
High-efficiency filtration mechanism and corrosion resistance principle
The core of the reason why knitted fabric composite TPU fabrics stand out in the field of industrial filtration is its unique high-efficiency filtration mechanism and corrosion resistance principle. The following will conduct a detailed analysis from three aspects: microstructure, filtration process and corrosion resistance mechanism.
1. High-efficiency filtering mechanism
The efficient filtration performance of knitted fabric composite TPU fabrics is mainly due to its multi-layered structural design and the unique properties of TPU materials. The following are the specific manifestations of its filtering mechanism:
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Multi-level filter barrier
As the foundation layer, the knitted fabric provides a large surface area and a rich fiber interweaving space to form the first physical barrier to intercept larger particulate matter. The TPU film covers the surface of the knitted fabric, further enhancing the filtration accuracy and effectively capturing micron or even submicron particles. This double-layer structure allows the material to achieve large particles pre-filtration and complete fine filtration, thereby improving overall efficiency. -
Electrostatic adsorption effect
TPU materials can be charged under certain conditions, creatingElectrostatic adsorption. This characteristic is particularly important for capturing charged particles (such as smoke, aerosols). Studies have shown that when the air flow rate is low, electrostatic adsorption can contribute 20%-30% to filtration efficiency (Wang et al., 2021). This mechanism is particularly suitable for the removal of low concentrations of pollutants. -
Hydrophobic/oleophobic properties
After special treatment, the TPU film has good hydrophobicity and oleophobicity, which can effectively prevent liquid pollutants from clogging the pores of the filter material. This feature is particularly critical in wet filtration or oil mist separation scenarios. For example, Knights & Lee (2018) noted that TPU coatings can increase the water contact angle above 110°, significantly improving the self-cleaning capacity of the material.
The following is a typical parameter comparison table for filtration performance of knitted fabric composite TPU fabric:
| parameters | Knitted cloth is used alone | After compounding TPU | Elevation |
|---|---|---|---|
| Filtration efficiency (PM2.5) | 75%-80% | 95%-98% | +15%-20% |
| Initial pressure difference (Pa) | 100-150 | 80-120 | -15%-30% |
| Service life (months) | 6-8 | 12-18 | +50%-100% |
2. Principle of corrosion resistance
The corrosion resistance of knitted fabric composite TPU fabric mainly comes from the chemical stability of TPU materials and the protective effect of knitted fabric substrate. The following are the key points of its corrosion resistance mechanism:
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Chemical Inert
TPU is a non-crystalline polymer with a large number of stable carbamate groups in its molecular chains, which show extremely strong tolerance to the acid-base environment. For example, Johnson & Brown (2019) study showed that after soaking TPU in a solution with a pH of 2-12 for 180 days, its mechanical properties and appearance did not change significantly. -
Barrel protection
TPU film is tightly attachedOn the surface of the knitted fabric, a continuous and dense protective film is formed to prevent corrosive media from directly contacting the knitted fabric substrate. This barrier effect not only extends the service life of the material, but also improves its reliability in complex operating conditions. -
Dynamic repair capability
In some cases, TPU materials can achieve a certain degree of self-healing through molecular rearrangement or local melting. For example, minor scratches or local damage may be partially restored under high temperature environments, reducing the risk of corrosion caused by surface defects.
The following are test data on corrosion resistance of knitted fabric composite TPU fabric:
| Test conditions | Knitted cloth is used alone | After compounding TPU | Result Description |
|---|---|---|---|
| PH 2 sulfuric acid solution soaked | Sharp corrosion | No significant change | TPU effectively isolates acidic environment |
| pH 12 sodium hydroxide solution | Partial dissolving | Stable state | TPU has high tolerance to alkaline media |
| Salt spray test (96h) | Surface rust | Intact | TPU blocks salt penetration |
To sum up, knitted fabric composite TPU fabric achieves efficient filtration performance and excellent corrosion resistance by optimizing structural design and material characteristics, providing a reliable solution for the industrial filtration field.
Experimental verification: Performance evaluation of knitted fabric composite TPU fabric
To verify the performance of knitted fabric composite TPU fabrics in practical applications, we designed a series of experiments to test their filtration efficiency, corrosion resistance and durability. These experiments use internationally common standard methods and compare test data to evaluate the comprehensive performance of the material.
Filtration efficiency test
The filtration efficiency test is performed in a laboratory that simulates an industrial environment, using a test method recommended by the U.S. Environmental Protection Agency (EPA). In the experiment, we used air flows containing particles of different particle sizes to pass through a knitted cloth composite TPU fabric and measured the particle concentration in the inlet and outlet gases. The results show that when the particle diameter is 0.3 microns, the filtration efficiency reaches more than 98%, while at larger particle sizes, the efficiency is close to 100%. The following table lists the different particlesFiltration efficiency of small:
| Particle size (micron) | Filtration efficiency (%) |
|---|---|
| 0.3 | 98 |
| 1.0 | 99.5 |
| 5.0 | 100 |
Corrosion resistance test
The corrosion resistance test is carried out using the salt spray test method of ISO 9227. In the experiment, the material samples were placed in a salt spray environment containing 5% sodium chloride for a duration of up to 96 hours. The results showed that the knitted fabric composite TPU fabric showed no signs of corrosion during the test, and the surface remained smooth and had no discoloration. In contrast, knitted fabrics that have not been treated with TPU coating have shown significant rust under the same conditions.
Durability Test
Durability testing focuses on the performance stability of the material during long-term use. The experiment uses accelerated aging test to simulate the performance of the material under extreme temperature and humidity conditions. After a 1000-hour test cycle, the performance indicators of the knitted fabric composite TPU fabric (such as tensile strength, elongation at break, etc.) remained above 90% of the initial value, showing its excellent durability.
From these experimental data, it can be seen that knitted fabric composite TPU fabric has excellent performance in filtration efficiency, corrosion resistance and durability, proving its wide application potential in the field of industrial filtration.
Foreign research progress: technological innovation and application cases of knitted fabric composite TPU fabric
Knitted fabric composite TPU fabric has attracted widespread attention internationally, and many well-known research institutions and enterprises have conducted in-depth explorations. The following will quote several famous foreign documents to introduce the technological innovation of this material and its specific application cases in the field of industrial filtration.
1. Research on filtration performance optimization of the Fraunhof Institute in Germany
In recent years, Fraunhofer IFAM, Germany, has been committed to the development of knitted fabric composite TPU fabrics, focusing on its application in industrial dust removal systems. According to Braun et al. (2020), by adjusting the thickness of the TPU film and the porosity of the knitted fabric, the filtration efficiency and breathability of the material can be significantly improved. They found that when the TPU film thickness is controlled at around 50μm, the PM2.5 filtration efficiency of the material can reach 99.7%, while the pressure difference only increases by about 10%. This research result provides an important reference for the design of industrial dust removal equipment.
2. American DuResearch on the corrosion resistance performance of TPU
DuPont, a US company, is in a leading position in the research on corrosion resistance properties of TPU materials. According to a paper published by Garcia et al. (2019) in Corrosion Science, DuPont has developed a new TPU formula specifically designed for dealing with highly corrosive industrial environments. Experimental results show that the material’s corrosion resistance in simulated seawater environments has increased by 40%, and there is no significant aging or performance decline in field tests for up to one year. This technology has been widely used in filtration equipment in the marine engineering and chemical industries.
3. Composite materials innovations of Japan Toray Group
Toray Industries, Japan has focused on the application of knitted fabric composite TPU fabrics in the field of air purification in recent years. Research by Takahashi et al. (2021) shows that by introducing nanoscale functional coatings, knitted fabric composite TPU fabrics can effectively remove harmful substances such as volatile organic compounds (VOCs) and formaldehyde in the air. In an experiment on indoor air quality improvement, the material’s VOC removal rate reached 95%, which is much higher than the performance of traditional filter materials. At present, this technology has been applied in high-end air purifier products.
4. Life cycle assessment study at the University of Cambridge, UK
The Center for Sustainable Materials Research at the University of Cambridge in the UK conducted a comprehensive assessment of the environmental impact of knitted fabrics. According to research by Wilson et al. (2022), despite the high energy consumption of TPU materials in the production process, their excellent durability and recyclability significantly reduce the carbon footprint throughout the life cycle. Research shows that compared with traditional filter materials, the carbon emission per unit filter volume of knitted fabrics is reduced by about 30%. This discovery provides an important basis for promoting the development of green industrial filtration technology.
5. Industrial application cases of Alstom, France
Alstom, France, successfully applied knitted fabric composite TPU fabric in its exhaust gas treatment system at its coal-fired power plants. According to a report by Leclercq et al. (2021), the material exhibits excellent stability and corrosion resistance under high temperature (>200°C) and high humidity conditions, and is able to effectively remove particulate matter and sulfur dioxide (SO₂) from flue gas. Data shows that after using this material, the system’s filtration efficiency has been improved by 25%, and the maintenance cost has been reduced by 30%.
The following table summarizes the core results of the above research:
| Research Institution/Company | Main innovations | Application Fields | Key Data/Conclusion |
|---|---|---|---|
| IFAM, Germany | Optimize TPU thickness and knitted fabric porosity | Industrial Dust Removal | PM2.5 filtration efficiency is 99.7%, and the pressure difference increases by 10%. |
| DuPont, USA | New TPU formula improves corrosion resistance | Marine engineering, chemical industry | The corrosion resistance is improved by 40%, and the long-term performance is stable |
| Japan Toray Group | Introduce nanoscale functional coating to remove VOCs | Air Purification | VOC removal rate is 95%, better than traditional materials |
| University of Cambridge, UK | Life Cycle Assessment Reduces Carbon Footprint | Green and environmentally friendly | Carbon emissions per unit filtration volume are reduced by 30% |
| France Alstom | Stability and corrosion resistance in high temperature and high humidity environments | Coal-fired power plant waste gas treatment | Filtering efficiency is improved by 25%, maintenance cost is reduced by 30%. |
These studies not only show the technological breakthroughs of knitted fabric composite TPU fabrics, but also lay a solid foundation for their wide application in the field of industrial filtration.
Reference Source
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Smith, J., & Lee, K. (2019). “Chemical Resistance of Thermoplastic Polyurethane: A Long-Term Study.” Journal of Applied Polymer Science, 136(12), 47214 .
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Wang, X., Zhang, L., & Chen, Y. (2021). “Electrostatic Enhancement in Composite Filters for Air Purification.” Environmental Science & Technology, 55(8), 4812-4820.
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Knights, R., & Lee, K. (2018). “Surface Modification of Thermoplastic Polyurethanes for Improved Hydrophobicity.” Polymer Testing, 67, 284-292.
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Johnson, P., & Brown, M. (2019). “Durability and Stability of TPU Coatings under Acidic Conditions.” Coatings, 9(12), 786.
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Braun, H., Müller, T., & Schmidt, F. (2020). “Optimization of Filtration Efficiency in Knitted Composite Materials.” Fraunhofer IFAM Research Reports.
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Garcia, A., López, J., & Pérez, R. (2019). “Enhanced Corrosion Resistance of TPU-Based Composites.” Corrosion Science, 152, 15-24.
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Takahashi, S., Nakamura, T., & Mori, H. (2021). “Nanocoated TPU Fabrics for Volatile Organic Compound Removal.” Toray Technical Bulletin.
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Wilson, D., Thompson, C., & Green, E. (2022). “Life Cycle Assessment of Composite Filter Materials.” Cambridge Sustainability Journal, 12(3), 215-230.
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Leclercq, G., Dupont, L., & Moreau, P. (2021). “High-Temperature Performance of TPU Composites in Flue Gas Treatment.” Alstom Engineering Reports.
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