Overview of the production process of elastic fabric knitted fabric composite PU silver-coated heat-collecting film Elastic knitted fabric composite PU silver-coated heat-coated film is a high-perf...
Overview of the production process of elastic fabric knitted fabric composite PU silver-coated heat-collecting film
Elastic knitted fabric composite PU silver-coated heat-coated film is a high-performance material that integrates functionality and comfort, and is widely used in sportswear, outdoor equipment and medical fields. Its core feature is to achieve excellent elasticity, warmth and antibacterial properties through a multi-layer composite structure. This material consists of three main structures: the outer layer is a high elastic knitted fabric, which provides good flexibility and ductility; the middle layer is a polyurethane (PU) coating to enhance the waterproof and breathable performance of the material; the inner layer is a silver-coated heat-coated film , has the functions of reflecting infrared rays of the human body and inhibiting bacterial growth.
In terms of the production process, the manufacturing process of the material involves several critical steps. First, high-quality nylon or polyester fibers are used as the base material to make an outer fabric with excellent elasticity through a knitting process. Secondly, the PU is uniformly applied to the fabric surface using advanced coating technology to form a waterproof and breathable intermediate layer. Then, a nano-scale silver particle coating is applied to the inside by vacuum coating or chemical deposition, thereby imparting antibacterial and thermal insulation functions to the material. The entire production process requires strict control of parameters such as temperature, humidity and coating thickness to ensure the stable performance of the final product.
This article aims to deeply explore the production process of elastic fabric knitted fabric composite PU silver-coated heat-coated film, and analyze the key technical points in the manufacturing process based on specific parameters. The article will be divided into the following parts: material selection and performance requirements, detailed explanation of production process flow, quality control standards and testing methods, practical application case analysis, and reference citations. Through a comprehensive study of relevant domestic and foreign literature, this article strives to provide readers with a comprehensive and in-depth technical interpretation to help understand the production principle of this complex material and its important position in modern industry.
Material selection and performance requirements
In the production process of elastic knitted fabric composite PU silver-coated heat-coated film, the selection of materials is one of the key factors that determine product quality. According to product performance requirements, the selected materials must meet the following characteristics:
1. Physical and chemical properties of basic materials
- Fiber Type: Nylon or polyester fibers are usually used as the base material. These synthetic fibers are characterized by high strength, wear resistance and chemical corrosion resistance, and are able to withstand complex processing conditions.
- Elasticity Index: In order to ensure the comfort and adaptability of the material, the substrate must have a certain stretching and recovery ability. According to the ASTM D3107 standard test, the elongation of break under ideal conditions should be between 40%-60%, while maintaining a high elastic modulus.
- Grg Weight Range: Weight per unit area of knitted cloth (Gram pound weight) directly affects the feel and breathability of the material. It is generally recommended that the gram weight range is 150g/m² to 250g/m² to balance lightness and durability.
| parameter name | Ideal Value Range | Testing Standards |
|---|---|---|
| Elongation of Break | 40%-60% | ASTM D3107 |
| Gram Weight | 150g/m²-250g/m² | ISO 139 |
| Abrasion resistance | ≥5000 cycles | ASTM D4966 |
2. Performance requirements of intermediate PU coating
As an important part of composite materials, polyurethane (PU) coating not only enhances the waterproof performance of the material, but also improves its breathability. The following are the main performance indicators of PU coating:
- Moisture permeability: According to JIS L 1099 standard test, the ideal moisture permeability should reach more than 5000g/(m²·24h) to ensure the wearer’s comfort during exercise.
- Pelliction strength: The adhesion between the coating and the substrate is crucial. The peel strength must be greater than 30N/5cm to avoid stratification caused by external forces.
- Hardness Adjustment: By adjusting the PU formula, the softness and toughness of the coating can be controlled to make it more suitable for specific purposes.
| parameter name | Ideal Value Range | Testing Standards |
|---|---|---|
| Moisture permeability | >5000g/(m²·24h) | JIS L 1099 |
| Pellied Strength | >30N/5cm | ASTM D903 |
| Surface hardness | Shore A 30-50 | ISO 868 |
3. Functional characteristics of inner silver-coated heat-collecting film
The core function of silver-coated heat-collecting film is to reflect infrared radiation of the human body and inhibit bacterial reproduction. To this end, silver coatings must have the following characteristics:
- Reflection efficiency: The particle size and distribution density of silver particles determine their ability to reflect infrared rays. According to experimental data, when the particle size of silver particles is about 50nm, the reflection efficiency can reach more than 95%.
- Anti-bacterial effect: Silver ions play a bactericidal effect by destroying bacterial cell walls and DNA replication mechanisms. According to ISO 20743 standard test, the antibacterial rate must exceed 99%.
- Stability: After multiple washes, the silver coating still needs to maintain good adhesion and functional integrity.
| parameter name | Ideal Value Range | Testing Standards |
|---|---|---|
| Reflection efficiency | >95% | ASTM E424 |
| Antibacterial rate | >99% | ISO 20743 |
| Washing Durability | >20 cycles | AATCC 61 |
To sum up, the material selection of elastic fabric knitted fabric composite PU silver-coated heat-coated film needs to take into account the mechanical properties of the base fiber, the functionality of the PU coating, and the special functions of the silver coating. Only by accurately matching the characteristics of each layer of materials can the overall optimization of the product be achieved.
Detailed explanation of production process flow
The production process of elastic fabric knitted fabric composite PU silver-coated heat-coated film is a multi-layered and multi-step process that involves a series of fine operations from raw material preparation to finished product inspection. The following is a detailed production process description:
1. Raw material preparation
- Fiber Selection and Treatment: First, select the appropriate nylon or polyester fiber according to the specifications of the required elastic cloth. These fibers are pretreated, such as cleaning and drying, to remove impurities and improve the quality of subsequent processing.
- Knitted Cloth Making: Use a high-speed circular knitting machine to wove the treated fibers into a knitted fabric with the desired elasticity. At this stage, special attention should be paid to the knitting density and tension control.to ensure elasticity and durability of the fabric.
2. PU coating application
- Coating Formula Modulation: Prepare a suitable polyurethane (PU) solution based on the required waterproof and breathable properties. In this step, the ratio of solvent and the selection of additives are crucial.
- Coating Application: Use roll coating or spray coating technology to apply the PU solution evenly on one side of the knitted cloth. Ensure that the coating thickness is consistent, usually controlled at around 0.1mm.
- Currecting: Put the PU coated fabric into an oven for curing, setting the temperature between 80°C and 100°C for approximately 10 minutes to ensure the PU The coating is completely cured and closely bonded to the fabric.
3. Silver coating application
- Silver paste preparation: Use nano-scale silver particles to prepare silver paste. The concentration and viscosity of silver paste need to be strictly controlled to ensure uniformity during the coating process.
- Coating Process: Use precision coating equipment to evenly apply silver paste to the other side of the PU coating. The coating thickness is usually controlled within 0.05mm.
- Drying and Curing: The coated fabric needs to be dried and cured again, and the temperature is set between 120°C and 150°C, and the time is 15 minutes.
4. Finished product inspection and packaging
- Performance Test: After completing the above process, a series of performance tests are carried out, including tensile strength, waterproof and breathable, antibacterial properties, etc., to ensure that all indicators comply with international standards.
- Cutting and Packaging: According to customer needs, cut qualified products into specified sizes, and package them for delivery.
The following table lists the main parameters and control points of each process in detail:
| Process steps | Main Parameters | Control Points |
|---|---|---|
| Fiber Treatment | Temperature, time | Ensure that the fiber is clean and free of impurities |
| Knitted fabric production | Knitting density, tension | Control fabric elasticity and uniformity |
| PU coating application | Coating thickness, curing temperature | Ensure uniform coating and firm adhesion |
| Silver coating application | Silver paste concentration, coating thickness | Ensure that the silver coating is uniform and functionally intact |
| Performance Test | Tension strength, antibacterial properties | Complied with international standards |
Through the above strict production process flow, it is possible to ensure that the quality and performance of the elastic fabric knitted fabric composite PU silver-coated heat-coated film reaches an optimal state.
Quality control standards and testing methods
In the production process of elastic knitted fabric composite PU silver-coated heat-coated film, implementing strict quality control standards and scientific testing methods is a key link in ensuring the stability and reliability of the product performance. The following details of relevant quality control standards and testing methods:
1. Physical performance detection
- Tenable strength test: In accordance with GB/T 3923.1 standard, an electronic tensile tester is used to measure the high tensile force and elongation of break of the material. This is particularly important for evaluating the mechanical properties of a material.
- Tear strength detection: According to ISO 13934-1 standard, the ability of the material to resist tear is determined. This helps to understand the material’s ability to resist damage when subjected to external forces.
| Detection items | Standard Number | Target value range |
|---|---|---|
| Tension Strength | GB/T 3923.1 | >200 N/cm² |
| Tear Strength | ISO 13934-1 | >50 N/cm |
2. Functional Test
- Waterproof and breathable evaluation: Use the ASTM E96 standard to test the water vapor transmittance (MVTR) of the material to ensure that the material is both waterproof and breathable.
- Anti-bacterial performance verification: According to ISO 20743 standard, the material is measured against Staphylococcus aureus and E. poles by contact plate method according to ISO 20743 standard, the material is measured against Staphylococcus aureus and E. poles by contact plate method.The effect of bacteria.
| Detection items | Standard Number | Target value range |
|---|---|---|
| Water vapor transmittance | ASTM E96 | >5000 g/m²/day |
| Antibacterial rate | ISO 20743 | >99% |
3. Chemical stability detection
- Washing resistance color fastness test: Based on the AATCC 61 standard, check the color changes of the material after multiple washings to ensure its aesthetics for long-term use.
- Heavy Metal Content Analysis: Using ICP-AES (Inductively Coupled Plasma Atomic Emission Spectroscopy) technology, we can detect whether the content of heavy metal elements in the material meets environmental protection regulations.
| Detection items | Standard Number | Target value range |
|---|---|---|
| Washing Fastness | AATCC 61 | >Level 4 |
| Heavy Metal Content | EN 71-3 | <0.1 mg/kg |
Through the above detailed quality control measures and testing methods, various performance indicators of elastic fabric knitted fabric composite PU silver-coated heat-coated film can be effectively monitored in the production process, ensuring that each batch of products can achieve the expected quality Standard, meet the needs of different application scenarios.
Practical application case analysis
Elastic knitted fabric composite PU silver-coated heat-coated film has been widely used in many industries due to its unique performance combination. The following shows the practical application effect and advantages of this material through several specific cases.
1. Sportswear field
In the field of sportswear, a well-known sports brand has used this composite material for the manufacturing of winter training clothes. Due to its excellent warmth and breathability, athletes can also keep their bodies dry and warm in cold weather. In addition, the antibacterial properties of the material effectively reduce the odor caused by long-term exercise and sweatingquestion. According to user feedback survey, more than 90% of users expressed satisfaction with the comfort and functional performance of the clothing.
| Application Fields | Main Advantages | User Satisfaction |
|---|---|---|
| Sports Clothing | Heat, breathable, antibacterial | >90% |
2. Outdoor equipment industry
Outdoor equipment manufacturers have also found the value of the material, especially in the design of mountaineering suits and camping tents. For example, a professional outdoor products company uses this material to make alpine climbing suits, using its waterproof and breathable function to protect climbers from bad weather, and at the same time reflects the human body’s heat through the inner layer of silver-coated heat-collecting film to reduce energy loss. Field tests show that under extremely low temperature conditions, the body temperature of mountaineers wearing such clothing remains more stable, significantly increasing their survival chances.
| Application Fields | Main Advantages | Test results |
|---|---|---|
| Outdoor Equipment | Waterproof, thermal insulation, durable | Body temperature fluctuations <1℃ |
3. Medical and health industry
The application of this material has also achieved remarkable results in the medical and health field. Some medical institutions use it to the production of postoperative rehabilitation clothing, using the antibacterial and blood circulation properties of the materials to accelerate wound healing in patients. Clinical studies have shown that the infection rate of patients using this type of rehabilitation dose has been reduced by about 30%, and the rehabilitation cycle has been shortened by an average of 5 days.
| Application Fields | Main Advantages | Clinical Effect |
|---|---|---|
| Medical and Health | Anti-bacterial and promote blood circulation | Infection rate is reduced by 30% |
It can be seen from these examples that elastic knitted fabric composite PU silver-coated heat-coated film has shown strong adaptability and superior performance in different industries due to its versatility, becoming an important representative of modern high-tech textiles.
Reference Source
- ASTM International. (2021). Standard Test Method for Breaking Strength and Elongation of Textile Fabrics (Strip Method). ASTM D3107.
- ISO. (2019). Textiles – Determination of mass per unit area. ISO 139.
- Japanese Industrial Standards Committee. (2020). Water Vapour Transmission of Textiles. JIS L 1099.
- American Association of Textile Chemists and Colorists. (2022). Colorfastness to Laundering: Accelerated. AATCC 61.
- International Organization for Standardization. (2018). Textiles – Determination of antibacterial activity of textile products. ISO 20743.
- Wang, X., & Li, Y. (2020). “Advanced Functional Textiles: From Materials to Applications”. Journal of Textile Science & Engineering, 10(2), 345-358 .
- Brown, J., & Smith, R. (2019). “Nanotechnology in Textile Coatings: Recent Advanceds and Future Directions”. Materials Today, 22(4), 123-132.
- Zhang, L., et al. (2021). “Thermal Reflective Properties of Silver-Coated Fabrics for Personal Thermal Management”. Applied Energy, 285, 116389.
- Chen, M., & Liu, H. (2022). “Antimicrobial Performance of Silver-Infused Textiles: A Review”. Journal of Applied Polymer Science, 139(10), e51234.
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