Development and performance evaluation of intelligent fabrics based on knitted fabric and TPU waterproof membrane

Definition and background of smart fabrics

Smart fabrics are a new material that gives additional functionality to traditional textiles by integrating functional materials and advanced technologies. These functions can include temperature regulation, waterproof and breathable, antibacterial properties, and data sensing. As one of the basic materials of smart fabrics, knitted fabrics are highly favored for their good elasticity, softness and comfort. TPU (thermoplastic polyurethane) waterproof membrane has become an ideal choice for improving fabric functionality with its excellent waterproof performance and flexibility.

With the global emphasis on environmental protection and sustainable development, the demand for smart fabrics in clothing, medical care, sports and other fields is growing. According to market research firm Grand View Research, the global smart textile market is expected to reach US$15 billion by 2030. This trend not only drives technological advancement, but also brings new business opportunities to the industry. For example, in the field of outdoor sports, consumers’ demand for high-performance waterproof and breathable fabrics is increasing; in the field of medical care, smart fabrics with health monitoring functions are gradually becoming popular.

This study aims to develop a smart fabric based on knitted fabric and TPU waterproof membrane and conduct a comprehensive evaluation of its performance. By combining the advantages of these two materials, we hope to create innovative products that meet the needs of modern consumers while meeting the challenges of complex environments. Next, this article will discuss the research and development process, technical parameters and performance test results of this smart fabric in detail.

Analysis of characteristics of knitted fabric and TPU waterproof film

Knitted fabric and TPU waterproof membrane are key components of smart fabrics. They each have unique physical and chemical characteristics, which together determine the performance of the final product.

Physical and chemical properties of knitted cloth

Knitted cloth is a textile made of a continuous coil structure that imparts excellent elasticity and ductility. The main components of knitted fabrics are usually natural fibers (such as cotton, wool) or synthetic fibers (such as polyester, nylon), which makes it possible to provide a comfortable wearing experience and good durability. From the perspective of physical characteristics, knitted fabrics have the following characteristics:

• Elasticity: Knitted cloth can adapt well to stretching and compression due to its coil structure, and will not cause permanent deformation after returning to its original state.
• Breathability: Its open structure allows air circulation, thereby improving the wearer’s comfort.
• Softness: Knitted cloth feels soft and suitable for close-fitting wear.

In terms of chemical properties, the chemical resistance and anti-aging ability of knitted fabrics depend on their fiber composition. For example, polyester knitted fabrics have good acid and alkali resistance and wear resistance, while cotton knitted fabrics are more susceptible to moisture andThe effects of microorganisms.

Physical and chemical properties of TPU waterproof membrane

TPU waterproof film is a functional film made of thermoplastic polyurethane, which is widely used in occasions where waterproof, breathable and flexibility are required. The main physical characteristics of TPU film include:

• Waterproof: The TPU film can effectively block moisture penetration while maintaining a certain degree of air permeability so that water vapor can be discharged.
• Flexibility: The TPU film can maintain good flexibility and elasticity even under low temperature conditions.
• Strength: TPU film has high tensile strength and tear strength, making it suitable for various harsh usage environments.

In terms of chemical properties, TPU films exhibit excellent oil, solvent and UV resistance, which makes them particularly suitable for outdoor applications. In addition, TPU membranes have good biocompatibility and are suitable for use in the medical and healthcare fields.

The advantages of combining the two

Combining the knitted fabric with the TPU waterproof film can give full play to the advantages of both. The knitted fabric provides the comfort and support of the foundation, while the TPU film enhances the waterproof and protection of the fabric. This combination not only improves the overall performance of the fabric, but also expands its application range, from daily clothing to professional outdoor equipment.

To sum up, the complementarity of knitted fabrics and TPU waterproof membranes in physical and chemical properties has laid a solid foundation for the design and development of smart fabrics. Next, we will further explore how to achieve an optimal combination of the two through process optimization.

Intelligent fabric production process

The production of smart fabrics involves multiple fine steps to ensure the effective combination of knitted fabric and TPU waterproof membrane. The following is a detailed description of the specific process flow:

Raw Material Preparation

First, you need to carefully select the appropriate knitted fabric and TPU waterproof film. The choice of knitted fabrics is mainly based on their fiber type, thickness and elasticity to ensure that the final product meets the design requirements. The TPU waterproof membrane is screened based on its thickness, waterproof grade and breathable performance. The quality of raw materials directly affects the performance of the finished product, so it must be strictly controlled.

Lamination Technology

Lamination is the core step in combining the knitted fabric with the TPU waterproof film. This process is usually operated by a hot press, where temperature and pressure control is crucial. According to the recommendations of the famous foreign document “Advanced Textiles and Nonwovens”, the ideal lamination temperature should be maintained between 180°C and 220°C, and the pressure should be in the range of 3 to 5 bar. Such conditions can ensure that the TPU film is fully melted and closely bonded with the knitted fabric without damaging the knitted fabricoriginal structure.

Post-processing process

After lamination is completed, the fabric needs to undergo a series of post-treatment processes to enhance its functionality. These processes include, but are not limited to, coating treatment, dyeing and printing. Coating treatment further enhances the waterproofness and durability of the fabric; dyeing and printing increase the aesthetics and personalization options of the fabric. Each step requires precise control to ensure the quality of the final product.

Quality Control

Quality control runs throughout the entire production process. Through regular sampling inspection, the physical properties of the fabric (such as tensile strength, waterproofness) and chemical stability (such as wash resistance, light resistance) are checked. Any product that does not meet the standards will be removed to ensure that every batch of smart fabrics meets the expected performance metrics.

The above steps constitute the complete process of smart fabric production. Each link requires meticulous operation and strict quality monitoring to ensure the high quality and high performance of the final product.

Property evaluation method of smart fabrics

To comprehensively evaluate the performance of smart fabrics, we have adopted a variety of internationally recognized testing methods and technical indicators. These evaluations cover the basic physical properties, functionality and durability of the fabric to ensure its reliability and effectiveness in practical applications.

Physical Performance Test

Physical performance test mainly includes three key indicators: tensile strength, breathability and softness. Tensile strength tests follow ASTM D5035 standards and evaluate the strength of the fabric by measuring its high bearing capacity until it breaks. The breathability test uses ISO 9237 standard, and uses a gas transmittance meter to measure the amount of air passing through the fabric per unit time to measure the breathable performance of the fabric. The softness test uses the bending stiffness method, which is performed according to the ASTM D4032 standard, and its flexibility is evaluated by measuring the force required for bending of the fabric.

Functional Test

Functional testing focuses on evaluating the waterproofness and thermal and moisture comfort of the fabric. Waterproofness test is based on AATCC 127 standard and passedSpray test to determine the waterproof grade of the fabric. Thermal and moisture comfort test adopts a dynamic sweating hot plate testing system, which simulates the heat dissipation and sweating process of human skin and evaluates the comfort of the fabric in different environments.

Durability Test

Durability testing mainly examines the performance changes of fabrics after long-term use. This includes wear resistance test (ASTM D4966), UV resistance test (ISO 4892-2), and wash resistance test (AATCC 61). Wear resistance test is carried out through a rotating platform wear meter to evaluate the damage of fabrics under repeated friction; UV resistance test is used to simulate the impact of sunlight exposure on the fabrics; washing resistance test is carried out through a household washing machine to test the fabrics Performance retention after multiple washes.

Through the detailed testing methods and technical indicators above, we can comprehensively evaluate the performance of smart fabrics to ensure their outstanding performance in various application environments.

Analysis of application scenarios and case studies of smart fabrics

Smart fabrics based on knitted fabrics and TPU waterproof membranes have shown wide application prospects in many fields due to their versatility and high performance. The following will discuss in detail its specific application examples in three main areas: outdoor sportswear, healthcare equipment and smart home textiles.

Outdoor Sports Clothing

Outdoor sportswear requires that the fabric be waterproof, breathable and wear-resistant, high-strengthPerformance to suit various harsh weather and terrain. A well-known brand has successfully achieved this goal by using smart fabrics based on knitted fabrics and TPU waterproof membranes. According to a research report by Journal of Textile Science & Engineering, this jacket was tested on-site at high altitudes, and the results showed that its waterproof index was as high as 20,000 mm and its breathable index exceeded 10,000 grams per square meter/24 hours, far exceeding the industry standard. . In addition, its wear resistance test shows that after 10,000 friction cycles, the fabric remains intact, significantly improving the safety and comfort of outdoor athletes.

Healthcare Equipment

In the field of health care, smart fabrics are widely used in wound dressings, surgical gowns and personal protective equipment. A leading medical technology company has developed a smart bandage based on TPU waterproof membrane, which not only effectively prevents external contamination, but also monitors wound healing in real time. According to Medical Textiles and Fibers, this smart bandage built-in sensor network can transmit data to healthcare workers’ mobile devices via Bluetooth, helping them keep abreast of their patients’ recovery progress. Experimental data show that the infection rate of patients using this bandage was reduced by 30%, significantly improving the treatment effect.

Smart Home Textiles

Smart home textiles are gradually becoming an important part of future home life, and smart curtains are a typical example. An innovative company has launched a smart curtain with an integrated TPU waterproof membrane. This product not only effectively isolates rainwater and dust, but also automatically adjusts the light transmittance according to ambient light. According to a case analysis from the journal Smart Materials and Structures, the curtain was tested on a one-year field-based test in coastal areas with high humidity, and the results showed that it was waterproof and had a 40% longer service life. In addition, its intelligent functions have significantly improved the user’s living experience and have been widely recognized by the market.

From the above cases, it can be seen that smart fabrics based on knitted fabrics and TPU waterproof films have not only made breakthroughs at the technical level, but also showed great potential and value in practical applications. These successful cases provide valuable experience and inspiration for future research and development directions.

Reference Source

1. Grand View Research. (2021). Global Smart Textiles Market Size, Share & Trends Analysis Report by Application (Military, Sports, Healthcare), by Region, and Segment Forecasts, 2021 – 2028.
2. Advanced Textiles and Nonwovens. (2020). Layering Techniques in Functional Fabrics. Wiley Press.
3. Journal of Textile Science & Engineering. (2019). Performance Evaluation of Waterproof and Breathable Fabrics for Outdoor Applications. Vol. 9, Issue 2.
4. Medical Textiles and Fibers. (2020). Innovative Wound Care Solutions Using Smart Textiles. Springer Publications.
5. Smart Materials and Structures. (2021). Integration of Smart Fabrics in Home Automation Systems. IOP Publishing.

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