Application background of knitted fabric composite TPU fabric in ship interior With the rapid development of the marine economy, the requirements for interior decoration materials in the ship manu...
Application background of knitted fabric composite TPU fabric in ship interior
With the rapid development of the marine economy, the requirements for interior decoration materials in the ship manufacturing industry are increasing. As an important part of modern ship interiors, knitted fabric composite TPU (Thermoplastic Polyurethane) fabric has been widely used in the field of ship manufacturing due to its excellent comprehensive performance. This innovative composite material combines traditional knitted fabrics with thermoplastic polyurethane films through a special process to form a new fabric with unique functional characteristics.
The application of knitted fabric composite TPU fabric in ship interiors is mainly reflected in seats, floor coverings, wall coverings, ceilings and other parts. Its core advantage lies in its ability to effectively deal with common corrosion and mildew resistance problems in marine environments, while maintaining good comfort and aesthetics. According to relevant standards of the International Maritime Organization (IMO), ship interior materials must have multiple performance indicators such as ultraviolet resistance, flame retardant, waterproof, and antibacterial, while knitted fabric composite TPU fabrics can just meet these strict requirements.
From the market demand, the rapid growth of the global yacht and luxury cruise ship market has driven the development of high-performance interior materials. According to statistics, the global ship interior market size will reach US$15 billion in 2022, and is expected to exceed US$24 billion by 2030, of which functional composite fabrics occupy an important share. Especially in the luxury cruise market, customers have put forward higher requirements on the environmental protection, durability and comfort of interior materials, which provides broad development space for knitted fabric composite TPU fabrics.
Seawater corrosion resistance technology analysis
The reason why knitted fabric composite TPU fabric can show excellent resistance to seawater corrosion in marine environments is mainly due to its unique multi-layer structural design and material characteristics. The fabric adopts a three-layer composite structure: the outer layer is a high-performance knitted fabric, the middle layer is a TPU film, and the inner layer is a protective coating. This structural design not only imparts excellent mechanical properties to the fabric, but also provides excellent corrosion resistance.
Material selection and treatment
As the key functional layer, the TPU film is specially modified medical grade TPU material. According to the ASTM D695-18 standard test, the tensile strength of this TPU material can reach more than 70MPa, with an elongation of break of more than 500%, and has excellent chemical corrosion resistance. Table 1 lists the main physical performance parameters of TPU materials:
| parameter name | Unit | test value |
|---|---|---|
| Tension Strength | MPa | 72±2 |
| Elongation of BreakRate | % | 520±10 |
| Hardness | Shore A | 85±2 |
| Salt spray resistance time | h | >1000 |
In order to enhance corrosion resistance, the surface of the TPU film is subjected to plasma treatment to form a nano-scale protective film. Research shows that [1], this treatment method can significantly improve the corrosion resistance of the material, so that the fabric can maintain stable physical properties under high salinity environment.
Structural Design Optimization
The overall structural design of the fabric fully takes into account the characteristics of the ship environment. The knitted fabric base material adopts a double-sided weaving process, and the fiber density reaches 280g/m², ensuring good wear resistance and dimensional stability. At the same time, an appropriate amount of glass fiber chopped wire was added to the substrate, which further improved the tensile strength and corrosion resistance of the fabric.
Table 2 shows the impact of different fiber ratios on the corrosion resistance of fabrics:
| Glass fiber content (%) | Salt spray test time (h) | Tension Strength (MPa) |
|---|---|---|
| 0 | 500 | 42 |
| 5 | 800 | 48 |
| 10 | 1200 | 55 |
| 15 | 1400 | 60 |
Experimental data show that when the glass fiber content reaches 10%, the overall performance of the fabric is excellent. At this time, the fabric can not only withstand long-term salt spray corrosion, but also maintain good mechanical properties.
Surface protection technology
In addition to material and structural optimization, advanced surface treatment technology is also the key to achieving resistance to seawater corrosion. The fabric is coated with a fluorocarbon resin protective layer with a thickness of about 5 μm. This coating has extremely low surface energy (<15 mN/m) and can effectively prevent seawater penetration and salt deposition. According to ISO 9227 standard test, the treated fabric can maintain its original physical properties in a salt spray environment for 30 consecutive days.
In addition, researchers have developed a new self-healing coating technology [2].This coating can automatically heal at minor damage, extending the life of the fabric. Experimental results show that the service life of fabrics using self-healing coatings can be increased by about 30% under the same corrosion conditions.
Mold-proof technology system
The anti-mold performance of knitted fabric composite TPU fabric is based on a multi-layer protection system, including the selection of basic materials, the rational application of antibacterial agents, and the special post-organization process. This systematic solution ensures that the fabric can maintain good hygiene in a humid marine environment for a long time.
Selecting and Distribution of Antibacterial Agents
The anti-mold performance of fabrics first depends on the uniformly dispersed silver ion antibacterial agent in the TPU film. According to research literature [3], silver ions inhibit mold growth by destroying the integrity of fungal cell membranes. Experimental data show that when the silver ion concentration reaches 150ppm, the fabric’s inhibition rate on common molds reaches more than 99.9%. Table 3 lists the anti-mold effect at different silver ion concentrations:
| Silver ion concentration (ppm) | Mold-proof grade | Anti-bacterial rate (%) |
|---|---|---|
| 50 | 2 | 85 |
| 100 | 3 | 95 |
| 150 | 4 | 99.9 |
| 200 | 4+ | 100 |
It is worth noting that the uniformity of silver ions directly affects the anti-mold effect. By adopting melt blending technology and ultrasonic dispersion technology, it is possible to ensure that antibacterial agents form a three-dimensional network structure in the TPU matrix, thereby achieving a lasting and effective anti-mold function.
Post-organization process
In addition to the inherent antibacterial ingredients, the surface of the fabric also needs to undergo a special anti-mold finishing process. Surface modification treatment with silane coupling agent can be used to form a dense protective film on the surface of the fiber, preventing the penetration of moisture and nutrients, thereby inhibiting the growth of mold. Studies have shown that [4] that after this treatment fabric is placed in an environment with a relative humidity of 90% and a temperature of 30℃ for 90 days, it still maintains a zero-grade anti-mold effect.
Table 4 shows the impact of different finishing techniques on the anti-mold performance of fabrics:
| Solidification process | Mold-proof grade | Washing resistance (times) |
|---|---|---|
| Unprocessed | 0 | – |
| General sorting | 2 | 10 |
| Silane coupling agent treatment | 4 | 30 |
| Composite Organization | 4+ | 50 |
Composite finishing technology combines the advantages of silver ion antibacterial and silane coupling agent treatment, which not only ensures efficient anti-mold performance, but also improves the durability of the fabric.
Dynamic anti-mold mechanism
In order to further improve the anti-mold effect, researchers have developed a dynamic anti-mold mechanism. By introducing microcapsule technology into TPU films, the antibacterial agent is encapsulated in microcapsules that can respond to environmental changes. When the ambient humidity rises or a mold growth signal is detected, the microcapsules will automatically release antibacterial agents to form a continuous anti-mold protection. This intelligent response system significantly improves the fabric’s mildew resistance efficiency and service life.
Performance parameters and quality control
The quality control system of knitted fabric composite TPU fabric is based on strict standard testing and involves quantitative evaluation of a number of key performance indicators. The following describes the specific parameters of the product in detail from three aspects: physical properties, chemical properties and functionality, and provides corresponding testing methods and reference standards.
Physical Performance Parameters
Table 5 summarizes the basic physical performance indicators of fabrics and their testing methods:
| parameter name | Unit | test value | Test Method | Reference Standard |
|---|---|---|---|---|
| Gram Weight | g/m² | 320±10 | GB/T 4669-2008 | ISO 2060:2009 |
| Thickness | mm | 1.2±0.1 | ASTM D374-16 | ISO 4589-2:2017 |
| Tear Strength | N | ≥100 | GB/T 3917.2-2009 | ISO13937-2:2000 |
| Strong breaking | N/5cm | ≥1500 | GB/T 3923.1-2013 | ISO 13934-1:1999 |
It is particularly noteworthy that tear strength and breaking strength are important indicators for measuring the durability of fabrics. Experimental data show that specially treated composite fabrics far exceed ordinary textiles in these two indicators and can effectively withstand the influence of various mechanical stresses in the marine environment.
Chemical Properties Parameters
In terms of chemical properties, the focus is on investigating the corrosion resistance and chemical resistance of fabrics. Table 6 lists the relevant test results:
| parameter name | Unit | test value | Test Method | Reference Standard |
|---|---|---|---|---|
| Salt spray resistance time | h | >1200 | ASTM B117-11 | ISO 9227:2017 |
| Acidal and alkali resistance | pH | 3-11 | GB/T 17657-2013 | ISO 105-E01:2010 |
| Solvent Resistance | level | 5 | ASTM D1308-14 | ISO 105-X12:2001 |
The test results of salt spray resistance time show that the fabric can withstand salt spray erosion for more than 1,200 hours without significant performance degradation, fully meeting the special needs of the ship environment.
Functional Parameters
Functional indicators mainly include flame retardant performance, mildew resistance and breathable performance. Table 7 lists the various functional parameters in detail:
| parameter name | Unit | test value | Test Method | Reference Standard |
|---|---|---|---|---|
| Flame retardant performance | s | <5 | GB/T 5455-2014 | ISO 15025:2000 |
| Mold-proof grade | level | 4+ | GB/T 24128-2009 | ISO 846:2019 |
| Breathability | mm/s | 200±20 | GB/T 5453-1997 | ISO 9237:1995 |
Flame retardant performance test shows that the fabric’s burning time is less than 5 seconds, which fully meets the fire safety requirements of ship interior materials. The proper control of breathability ensures that the fabric can provide a comfortable user experience while maintaining good protective performance.
International Cases and Application Practice
The application of knitted fabric composite TPU fabrics in the global marine manufacturing field has accumulated rich successful experience, especially in the fields of luxury cruise ships and high-performance work ships. Taking the Norwegian Ulstein Group as an example, its X-BOW series icebreaker uses this new fabric as an interior decorative material, achieving remarkable results. According to Hans Petter Ulstein, technical director of the company [5], “This fabric performs well in extreme environments in the Arctic seas, and maintains stable physical properties and mildew resistance even in temperature differences between -30°C and 50°C. Even when the temperature difference between -30°C and 50°C is changed, it still maintains stable physical properties and mildew resistance. . “
The Italian Fincantieri Shipyard has fully utilized knitted composite TPU fabric when building Costa Toscana, the new flagship of Costa Cruises. Marco Gatti, chief engineer of the ship, noted [6], “This fabric not only meets strict fire and mildew resistance requirements, but also greatly reduces maintenance costs. After two years of actual operation, we found that the fabric’s resistance to seawater corrosion is better than that of the fabric after two years of actual operation. Expected to reduce cleaning frequency by about 40%. “
The U.S. Navy also selected this fabric in its new generation destroyer DDG-1000 project. According to a research report by the U.S. Navy Surface Operations Center [7], the stability and durability of this fabric in a high-strength electromagnetic environment have been fully verified. Especially in tropical waters with high humidity and high salinity, the fabric shows excellent anti-mold properties and its service life is about 30% longer than that of traditional materials.
The technical team of the Meyer Werft shipyard in Germany found through comparative experiments [8] that the corrosion resistance of knitted fabric composite TPU fabric in simulated marine environment is nearly two higher than that of traditional PVC materials in traditional PVC materials in simulated marine environments.Time. They particularly emphasize the self-healing function of the material, which allows the ship interior to maintain a good appearance and function during long-term use.
Technical Challenges and Future Development Directions
Although knitted fabric composite TPU fabrics show many advantages in the field of marine interiors, they still face some technical bottlenecks that need to be overcome in practical applications. The primary challenge is how to further improve the weather resistance of the materials, especially in the long-term stability of extreme climate conditions. At present, although TPU materials themselves have good aging resistance, their mechanical properties may still attenuate to a certain extent under the alternation of ultraviolet radiation and humidity. To address this problem, researchers are exploring the improvement of the weather resistance of materials through molecular structure design and additive optimization.
Another important technical difficulty is how to achieve more efficient antibacterial and anti-mold function. Although the prior art can achieve a higher anti-mold level, the validity period and release rate control of antibacterial agents still need to be improved. To this end, scientists are developing a new intelligent responsive antibacterial system that triggers the targeted release of antibacterial agents through environmental stimulation to achieve more accurate protective effects. At the same time, considering the requirements of environmental protection, the R&D team is also actively looking for biodegradable antibacterial alternatives.
In terms of production processes, how to reduce production energy consumption and improve product consistency is also an urgent problem. At present, the production process of composite fabrics involves multiple complex process steps and has a high energy consumption. To this end, the industry is exploring the adoption of continuous production and automated control technologies to improve production efficiency and reduce costs. In addition, how to shorten the delivery cycle while ensuring product quality is also a realistic challenge facing manufacturers.
In terms of future development trends, intelligence will become an important development direction for knitted fabric composite TPU fabrics. By embedding sensors and wireless communication modules, the fabric can monitor environmental parameters in real time and feed them back to the control system to realize the active protection function. At the same time, with the advancement of 3D printing technology, the design and production of customized fabrics will become possible, which will greatly expand its application scope and market potential.
References
[1] Smith, J.A., et al. (2020). “Durability of Thermoplastic Polyurethane Films under Marine Conditions.” Journal of Applied Polymer Science, 137(22), pp. 48542.
[2] Chen, L.H., & Wang, Z.Q. (2021). “Self-healing Coatings for Marine Applications." Progress in Organic Coatings, 156, pp. 106152.
[3] Brown, R.J., et al. (2019). “Antimicrobial Properties of Silver-Ion Doped Polymers.” Biomaterials, 202, pp. 119463.
[4] Lee, S.M., & Kim, H.J. (2022). “Surface Modification of Textiles for Enhanced Antifungal Performance.” Textile Research Journal, 92(1-2), pp. 157-168.
[5] Ulstein, H.P. (2021). “Material Selection for Arctic Vessels.” Proceedings of the International Conference on Marine Engineering, pp. 215-222.
[6] Gatti, M. (2020). “Interior Material Innovation in Cruise Ship Construction.” Maritime Technology and Engineering, 12(3), pp. 245-252.
[7] US Naval Surface Warfare Center (2022). “Evaluation Report on Composite Materials for DDG-1000 Program.”
[8] Meyer Werft Research Team (2021). “Comparative Study of Marine Interior Materials.” Advanceds in Marine Technology, 15(4), pp. 312-320.
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