Overview of four-sided composite TPU fleece fabric
Four-sided elastic composite TPU fleece fabric is a high-performance textile material that integrates functionality, comfort and aesthetics. It is widely used in outdoor sportswear, casual wear and home decoration and other fields. This fabric significantly improves the stretchability and resilience of the fabric by combining the thermoplastic polyurethane (TPU) film with the wool fabric while giving it four-way elastic properties. Compared with traditional fabrics, the four-sided composite TPU fleece not only has good warmth and breathability, but also has multiple advantages such as wind resistance and water resistance, wear resistance and durability, which can meet the diverse needs of modern consumers for high-performance clothing.
From the perspective of production process, the production of four-sided composite TPU fleece fabric involves multiple complex processes, including base fabric selection, TPU coating or calendering, composite process optimization, and post-organization processing. These processes require precise control of key parameters such as temperature, pressure, coating thickness, etc. to ensure that the performance of the final product is stable and meets design requirements. For example, the thickness of the TPU film is usually controlled between 0.05 mm and 0.2 mm, while the fiber density of the base cloth needs to be adjusted according to the specific purpose to achieve an optimal balance of elasticity and durability.
In addition, the quality control system of the fabric is also crucial. To ensure product consistency and reliability, manufacturers usually adopt a series of standardized testing methods, such as tensile strength testing, tear strength evaluation, and waterproof and breathable performance measurement. Through strict quality monitoring, the market competitiveness of the product can not only be improved, but also effectively reduce the customer complaint rate caused by quality problems. Next, this article will discuss in detail the specific production process and quality control measures of four-sided composite TPU fleece fabric, and analyze its technical characteristics and application prospects based on actual cases.
Detailed explanation of the production process of four-sided composite TPU fleece fabric
The production process of four-sided composite TPU fleece fabric is a highly precise and multi-layered technical process, covering multiple key steps such as base fabric preparation, TPU coating/calendering, compounding and post-organization. The process details and technical points of each stage will be analyzed one by one.
1. Base cloth preparation
The base fabric is the basic material of four-sided composite TPU fleece fabric, and its choice directly affects the performance of the final product. Base cloth is usually made of polyester fibers due to its excellent mechanical strength, wear resistance and elastic recovery. Depending on the specific purpose, a single-layer or double-layer structure fleece fabric can be selected as the base cloth. The following are the main steps for preparing base cloth:
- Fiber Selection: Use high-strength, low-shrinkage polyester staple fiber or filament fiber to ensure that the base cloth has sufficient elasticity and stability.
- WeaverArt: Round machine knitting or wovening process is used to form fleece fabrics, among which round machine knitting is more suitable for making fabrics with higher softness.
- Wounding treatment: Use mechanical bristles or chemical bleaching technology to generate a fine and uniform bleach layer on the surface of the fabric to enhance the warmth effect.
| parameter name | Ideal range | Remarks |
|---|---|---|
| Fabric weight | 200g/m² – 350g/m² | Adjust to use |
| Fur Density | ≥120 pieces/cm² | Improve warmth |
| Tension fracture strength | >80N/cm | Ensure the durability of the base cloth |
2. TPU coating/calendering
The preparation of TPU film is one of the core links of four-sided composite TPU fleece fabric. Its main purpose is to provide waterproof and windproof functional characteristics for the fabric. The TPU can be attached to the surface of the base cloth by coating or calendering. The specific process is as follows:
- Coating process:
- Using solvent-based or aqueous TPU slurry, the TPU is uniformly coated on the base cloth by a scraper coating or roller coating device.
- Contain the coating thickness between 0.05mm and 0.1mm to ensure breathability and flexibility.
- Calping Process:
- The preformed TPU film is directly pressed onto the surface of the base cloth through a high-temperature and high-pressure device.
- This method is suitable for mass production, but has high requirements for equipment accuracy.
| Process Parameters | Ideal Value | Remarks |
|---|---|---|
| Coating thickness | 0.05mm – 0.1mm | Balance functionality and feel |
| Drying temperature | 100°C – 130°C | Avoid overheating and decomposing of TPU |
| Calve pressure | 20kg/cm² – 40kg/cm² | Ensure that the TPU is closely integrated with the base cloth |
3. Compounding processing
Composite treatment is a key step in firmly combining the TPU layer with the base cloth, usually done by hot melt adhesive dot bonding or ultrasonic welding technology. The following is a comparison of the characteristics of the two main methods:
| Method Name | Feature Description | Applicable scenarios |
|---|---|---|
| Hot Melt Point Adhesive | Simple operation, suitable for composite materials | Mid-to-Low-End Products |
| Ultrasonic welding | High bonding strength, no chemical residue | High-end functional fabrics |
In actual production, it is usually necessary to choose the appropriate compounding method according to the end use of the fabric, and strictly control the compounding temperature (about 120°C-160°C) and time (10-30 seconds) to ensure the TPU and the base The bonding force between the cloths reaches an optimal state.
4. Post-organization and processing
Post finishing is the latter process to improve the performance of four-sided composite TPU fleece fabrics, mainly including shaping, dyeing and functional finishing (such as waterproofing and anti-fouling treatment). The following are several important links:
- Styling treatment: Flatten the composite fabric through a high-temperature tenter, eliminating internal stress and fixing the size.
- Dyeing process: Use environmentally friendly dispersed dye to dye the surface of the fermented fleece to ensure bright colors and good fastness.
- Functional finishing: Spray the fabric surface using C6 or C0 environmentally friendly waterproofing agent to give it lasting waterproofing.
| Solidification process | Key Indicators | Reference Standard |
|---|---|---|
| Standing Temperature | 170°C – 190°C | ISO 12477 |
| Washing Fastness | ≥level 4 | AATCC Test Method 61 |
| Waterproof Grade | ≥80cm H₂O column pressure | JIS L 1092 |
To sum up, the production process of four-sided composite TPU fleece fabric is a systematic technical process, and each link needs to be carefully designed and strictly controlled to ensure the high quality and versatility of the final product. .
Quality control system of four-sided composite TPU fleece fabric
Quality control of four-sided composite TPU fleece fabrics runs throughout the production process, aiming to ensure that every batch of products meets the expected functional and durability standards. This section will introduce in detail the key links of quality control, testing methods and the application of international standards.
1. Material Inspection and Screening
The quality of raw materials directly affects the performance of the final product, so comprehensive inspection of the base cloth and TPU materials must be carried out. The fiber composition, density and tensile strength of the base cloth must meet the design requirements, and the thickness, hardness and transparency of the TPU film should also be strictly screened. Common testing items include:
- Physical performance test of base cloth: Determine the breaking strength and elongation of base cloth through a tensile testing machine to ensure its elastic recovery ability.
- TPU film optical detection: Use a microscope to check the surface smoothness and uniformity of the TPU film to avoid bubbles or impurities.
| Detection items | Standard Value Range | Detection Method |
|---|---|---|
| Strength force of base cloth breaking | >100N/cm | ASTM D5034 |
| TPU film thickness deviation | ±0.01mm | ISO 3310-1 |
2. Real-time monitoring during production
In the production process, real-time monitoring helps to promptly detect and correct potential problems. This includes dynamic monitoring of key parameters such as coating thickness, composite pressure and post-finishing temperature. For example, infrared thickness gauge can detect uniformity of TPU coatings online, while thermocouple sensors are used to accurately control the composite temperature.
3. Finished product testing and certification
Finished product inspection is the latter link of quality control, covering a number of functional tests, such as waterproofness, breathability and wear resistance. The following are the specific contents of some important test projects:
- Waterproof Performance Test: In accordance with JIS L 1092 standard, a hydrostatic pressure tester is used to measure the waterproof grade of the fabric.
- Breathability Test: According to ASTM E96 method, the water vapor transmittance of the fabric is evaluated.
- Abrasion resistance test: Simulate actual use conditions through the Martindale wear resistance instrument to detect the friction resistance of the fabric.
| Test items | Standard Value Range | Detection Standards |
|---|---|---|
| Hydrostatic pressure | ≥10,000mm H₂O | JIS L 1092 |
| Water vapor transmittance | >5,000g/m²·24h | ASTM E96 |
| Abrasion resistance | >20,000 times | ISO 12947 |
4. Standard practice of referring to famous foreign literature
In order to further improve the level of quality control, many companies have learned from foreign advanced quality management systems and technical specifications. For example, the book “Textile Testing: Principles and Practice” mentioned that the use of statistical process control (SPC) technology can help enterprises better manage production data, thereby achieving continuous improvement. In addition, the book “Functional Textiles for Sports Apparel” emphasizes the importance of functional fabrics in the R&D stage and recommends that the feasibility of the new process be verified through small-scale trial production.
Through the above multi-level quality control measures, the four-sided composite TPU fleece fabric can not only meet the strict international standards, but also provide customers with a more reliable and satisfactory product experience.
Comparison of typical application areas and performance parameters of four-sided composite TPU fleece fabric
Four-sided composite TPU fleece fabric has demonstrated excellent application value in many fields due to its unique functionality and comfort. The following will be shipped from the outdoorsBased on the three major application scenarios of mobile clothing, casual wear and home decoration, we will discuss its specific uses in detail, and further highlight its technical advantages by comparing the performance parameters of different types of fabrics.
1. Outdoor sportswear
In the field of outdoor sports, the four-sided composite TPU fleece fabric has become an ideal choice for mountaineering suits, ski suits and hiking equipment with its excellent waterproof and breathable performance and elastic recovery capabilities. This type of fabric can effectively resist bad weather conditions while keeping the wearer dry and comfortable. For example, a well-known brand launched a winter ski suit that uses 0.1mm thick TPU coating four-sided elastic fleece fabric, with a hydrostatic pressure of up to 15,000mm H₂O, and a breathability of more than 8,000g/m²·24h, fully meeting the high-intensity outdoors. Requirements for activities.
| Application Scenario | Performance parameter comparison table |
|---|---|
| Ordinary cotton fabric | Hydrostatic pressure: ≤2,000mm H₂O Breathability: <3,000g/m²·24h Elasticity: <10% |
| Four-sided TPU fleece | Hydrostatic pressure: ≥10,000mm H₂O Breathability: >5,000g/m²·24h Elasticity: >30% |
2. Casual wear
As consumers’ demand for casual clothing that combines fashion and functions increases, four-sided composite TPU fleece fabrics have gradually penetrated into the field of daily wear. Its soft feel, rich color choice and good wrinkle resistance make it a popular material for jackets, sweatshirts and other items. Especially in fast-paced urban life, this fabric not only provides a comfortable wearing experience, but also easily cope with light rain and snow weather, enhancing practicality.
| Application Scenario | Performance parameter comparison table |
|---|---|
| Traditional polyester fabric | Abrasion resistance: Medium Elasticity: <20% Wind resistance: General |
| Four-sided TPU fleece | Abrasion resistance: Strong Elasticity:>30% Anti-Wind performance: excellent |
3. Home Decor
In the field of home decoration, four-sided composite TPU fleece fabric is widely used in sofa covers, bedding and curtains and other products. Thanks to its antibacterial and mites and easy to clean, this type of fabric is particularly suitable for use in home environments. In addition, its environmentally friendly dyeing and finishing technology also meets the pursuit of green life by modern consumers.
| Application Scenario | Performance parameter comparison table |
|---|---|
| Ordinary velvet cloth | Antibacteriality: Weak Anti-fouling performance: General Environmentality: Poor |
| Four-sided TPU fleece | Anti-bacteriality: Strong Anti-fouling performance: Excellent Environmentality: Comply with OEKO-TEX® standards |
Analysis of the specific application of the above three fields can be seen that four-sided composite TPU fleece fabric is gradually replacing traditional materials with its excellent comprehensive performance and becoming the preferred solution for many high-end products.
Reference Source
- ASTM International. (2022). Standard Test Methods for Tensile Properties of Textile Fabrics. ASTM D5034.
- Japanese Industrial Standards Committee. (2021). Water Resistance of Textiles. JIS L 1092.
- ISO. (2020). Textiles – Determination of Thickness. ISO 3310-1.
- S. W. Foulkes & M. R. Cook. (2018). Textile Testing: Principles and Practice. Woodhead Publishing.
- P. Gibson &R. K. Smith. (2019). Functional Textiles for Sports Apparel. Elsevier.
- Baidu Encyclopedia. (2023). Four-sided composite TPU fleece.
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