Overview of cotton composite TPU film composite cotton fabric

In the field of modern navigation equipment, the research and development and application of functional fabrics have become a key factor in improving ship operation efficiency and safety. As an innovative material, cotton composite TPU film composite cotton fabric is gradually changing the material selection pattern of traditional navigation equipment with its unique structural design and excellent performance. This composite fabric consists of three layers: the outer layer is a wear-resistant and waterproof TPU film, the middle layer is a reinforced polyester fiber mesh, and the inner layer is a moisture-wicking cotton fabric. This multi-layer structure not only retains the comfort of traditional cotton, but also significantly improves the waterproof, windproof and weather resistance of the fabric through the addition of TPU film.

According to the 2021 research report of the International Textile Association (ITA), cotton composite TPU film composite fabrics have a share of 15% in the global specialty fabric market, and are growing steadily at a rate of 8% per year . Especially in the field of navigation equipment, the application scope of this fabric has expanded from initial crew clothing to life-saving equipment, cabin interior decoration and other aspects. Research by the U.S. Naval Research Laboratory (NRL) shows that this composite fabric can effectively resist salt spray corrosion and ultraviolet aging in the marine environment, and its service life is 30%-50% longer than that of traditional fabrics.

The core advantage of cotton composite TPU film composite fabric is its excellent comprehensive performance. First of all, the TPU film has good elastic recovery rate and tear resistance, and can maintain stable physical properties in extreme environments. Secondly, the intermediate layer of polyester fiber mesh provides excellent structural support and dimensional stability, ensuring that the fabric is not prone to deformation during long-term use. Later, the inner cotton fabric retains good breathability and comfort, providing users with a better wearing experience. This sandwich-style composite structure allows the fabric to maintain light weight while meeting the strict requirements for protective performance in the navigation environment.

Product parameters of cotton composite TPU film composite cotton fabric

In order to better understand the technical characteristics of cotton composite TPU film composite cotton fabrics, the following will analyze its product parameters in detail from multiple dimensions. These parameters not only reflect the basic physical properties of the fabric, but also are key indicators for its important role in the application of navigation equipment.

Basic physical performance parameters

Ge weight is an important indicator to measure the weight per unit area of ​​the fabric, and it directly affects the feel and thickness of the fabric. The weight of 280g/m² ensures sufficient coverage without affecting wear comfort due to excessive weight. The thickness parameters reflect the three-dimensional structural characteristics of the fabric. The thickness of 0.45mm is moderate, which not only provides good protection performance, but also facilitates cutting and processing.

Mechanical Performance Parameters

Tension strength and tear strength are key indicators for evaluating fabric durability. The tensile strength of 1200N/5cm ensures that the fabric will not easily break when it withstands large tension, while the tear strength of 150N can effectively prevent slight damage and expansion. A 95% elastic recovery rate allows the fabric to remain in its original shape after repeated stretching, which is especially important for crew members who need frequent movement.

Protection performance parameters

A waterproofing level reaches 5 means that the fabric can effectively block the penetration of heavy rainfall, while a windproof index below 0.8 cm³/s/cm² ensures the airtightness of the fabric. The UV resistance coefficient of UPF 50+ provides reliable protection for crew members who have been working outdoors for a long time, and its salt spray corrosion resistance of more than 1,000 hours is the key to its adaptation to the marine environment.

Environmental and Comfort Performance Parameters

The biodegradation rate of 85% reflects the good environmental protection characteristics of the fabric, and the moisture permeability of 5000 g/m²/24h ensures good moisture removal effect. Level 2 moisture absorption and quick dryness evaluation shows that the fabric can quickly absorb and emit human sweat,>99% of antibacterial properties effectively inhibit bacterial growth and maintain a sanitary environment.

These detailed parameter data not only show the superior performance of cotton composite TPU film composite cotton fabrics, but also provides a scientific basis for practical applications. Through precise control of these parameters, the stable performance of the fabric in different scenarios can be ensured.

Specific application of cotton composite TPU film composite cotton fabric in navigation equipment

Cotton composite TPU film composite cotton fabric has been widely and in-depthly used in the field of navigation equipment with its excellent comprehensive performance. The following are specific application examples of this fabric in different types of navigation equipment and its technical advantages analysis:

Crew work clothes

According to the “2022 Crew Protective Equipment Standards” released by the Royal Navy, cotton composite TPU film composite fabric has become the main material choice for the new generation of crew uniforms. This fabric is used in core equipment such as ones-piece workwear, waterproof jackets and multi-function pants. Research shows that work clothes made of this fabric have better temperature regulation and fatigue resistance compared to traditional nylon fabrics. For example, a comparative test by NorSea Group, a Norwegian crew clothing manufacturer, showed that after 12 consecutive hours of high-intensity work, the average body temperature fluctuated by crew members wearing composite fabric work clothes was only ±0.5°C, which was much lower than the ±1.2°C of traditional fabrics after 12 consecutive hours of high-intensity work. .

Life-saving equipment

In the manufacture of life jackets and life-saving floats, cotton composite TPU film composite fabrics show unique advantages. A research report from the Hamburg Maritime Institute in Germany pointed out that the TPU film layer of the fabric can effectively prevent seawater penetration while maintaining good flexibility. Taking a new inflatable life jacket as an example, after using composite fabric, its overall weight is reduced by about 20%, while its puncture resistance is increased by 35%. In addition, the inner cotton structure significantly improves wear comfort and extends the crew’s survival time when floating in the water.

Cadrift Interior

In the cabin decoration of luxury cruise ships and high-performance sailing boats, cotton composite TPU film composite fabric is equally brilliant. Italian yacht manufacturer Benetti Yachts has fully utilized this fabric to make seat covers, curtains and floor coverings in its new range. Experimental data show that the anti-fouling performance of this fabric reaches Level 4 of ISO 105-X12 standard, and it can still maintain more than 90% of the initial state after 50 cleaning cycles. More importantly, its excellent sound insulation performance (noise attenuation coefficient of 0.85) creates a more comfortable resting environment for passengers.

Marine awning

French National Center for Scientific Research,A study by CNRS showed that cotton composite TPU film composite fabrics are particularly suitable for manufacturing marine awnings. The TPU film layer of this fabric has excellent UV reflection performance, which can block more than 99% of UV radiation while maintaining good optical transparency. Field tests conducted in the Mediterranean region showed that the use of composite fabrics can reduce the indoor temperature of the cabin by about 7°C, significantly improving living comfort.

Special protective equipment

For marine rescuers who perform special missions, cotton composite TPU film composite fabrics provide an ideal solution. The Coast Guard Canada uses this fabric in its polar search and rescue equipment, successfully solving the problem of equipment freezing in low temperature environments. The test results show that after continuous use in an environment of -30°C for 24 hours, the composite fabric still maintains good flexibility and waterproof performance. In addition, its built-in conductive fiber network also gives the equipment basic electromagnetic shielding function to protect the user from radio interference.

These specific application cases fully demonstrate the wide application value of cotton composite TPU film composite cotton fabric in the field of navigation equipment. By continuously optimizing material formulation and processing technology, this fabric is providing more reliable technical support for the development of modern maritime industry.

Production process flow of cotton composite TPU film composite cotton fabric

The production process of cotton composite TPU film composite cotton fabric involves multiple precision links, and each step needs to be strictly controlled to ensure the quality of the final product. The following will introduce the complete production process of the fabric in detail, and focus on the control points of key process parameters.

Raw material preparation stage

Before production begins, three main raw materials need to be prepared: TPU film, polyester web and cotton fabric. The TPU film uses the Elastollan series materials produced by BASF, Germany, with a melting point between 180-200℃ and a glass transition temperature of -50℃. The polyester fiber web uses a high-density braided structure with a line density of 150 denier and a weft density of 50×50 wires/cm². The cotton fabric is woven with long wool cotton yarn, with a branch size of 40S, a warp density of 280 pieces/10cm, and a weft density of 240 pieces/10cm.

Composite forming process

Composite molding is a key part of the entire production process, and the hot pressing composite technology is used to achieve a firm combination of three layers of materials. The specific process parameters are as follows:

During the compounding process, the TPU film is first heated to a softened state, and then bonded to the polyester fiber web under a specific pressure to form a first composite structure. The structure and cotton fabric are then heat-pressed again to complete the final sandwich-style compound. To ensure the bonding strength between the layers, the temperature curve must be strictly controlled to avoid overheating or insufficient cooling.

Surface treatment process

After the composite is completed, special modification treatment is required to improve its waterproofness and wear resistance. Commonly used treatment methods include plasma treatment and chemical coating technology. Among them, the plasma processing parameters are set as follows:

The chemical coating is made of Dow Chemical’s special waterproofing agent, and is completed through three-step impregnation-drying and curing. The coating thickness must be strictly controlled within the range of 2-3μm to ensure that it does not affect the overall feel of the fabric.

Post-organization process

The post-organization phase mainly includes three steps: shaping, pre-shrinking and soft processing. The setting temperature is set to 160°C, the time is 30 seconds; the pre-shrinkage rate is 3%, which is achieved by steam treatment; the soft treatment is made of environmentally friendly silicone oil emulsion, and the dosage is 1.5% (o.w.f). These processes help improve the feel and dimensional stability of the fabric.

Quality Test Standards

The finished product needs to pass a series of rigorous testing before it can be released from the factory, mainly including the following items:

Through the above fine production process control and strict quality inspection, we can ensure that each batch of cotton composite TPU film composite cotton fabrics meet the expected performance indicators and meet the application needs of high-end navigation equipment.

Study and Comparative Analysis of Domestic and Foreign Research Results

In recent years, significant progress has been made in the research on cotton composite TPU film composite cotton fabrics worldwide, and developed countries in Europe and the United States have accumulated rich experience and technical achievements in this field. The following will focus on the relevant research results of famous foreign research institutions and compare and analyze them with the current domestic research status.

International Research Progress

The Department of Materials Science and Engineering of the Massachusetts Institute of Technology (MIT) conducted a special study called “Advanced Marine Textiles”, which is dedicated to the development of a new generation of composite fabrics for marine use. The researchers used molecular dynamics simulation technology to systematically study the behavioral characteristics of TPU molecular chains under different stress conditions. Experimental results show that by adjusting the molecular weight distribution and crystallinity of TPU, its cold resistance can be significantly improved. The research team also developed a new nanofiller modification technology, which improves the UV resistance of composite fabrics by more than 40%.

The Department of Engineering at the University of Cambridge in the UK and the Ministry of Defense jointly launched the “Marine Environmental Protection Materials” project, focusing on the durability of composite fabrics in extreme marine environments. The research team has developed a real-time monitoring system based on intelligent sensors to evaluate the performance changes of fabrics in actual use. Through two years of real-sea testing, they found that the TPU film treated with special crosslinking agents has a salt spray corrosion resistance of more than twice as high as that of ordinary products.

Fraun Institute of Fraunhof, Germany (Fraun)hofer Institute) In the “Smart Textiles for Offshore Applications” project, graphene materials were introduced into composite fabric systems for the first time. Studies have shown that adding trace amounts of graphene can not only significantly improve the conductive properties of the fabric, but also enhance its mechanical strength and wear resistance. The technology has obtained several international patents and has been used in several European marine equipment manufacturers.

Comparative analysis at home and abroad

Domestic research institutions such as the School of Textiles, Donghua University and the Institute of Chemistry, Chinese Academy of Sciences, have also made some important breakthroughs in the field of composite fabrics. For example, Donghua University has developed a new antibacterial finishing technology to make the antibacterial properties of the fabric meet the requirements of the Japanese JIS Z 2801 standard. However, compared with the international leading level, there is still a clear gap in domestic research. Especially in the development of new materials, intelligent applications and actual use environment testing, further investment is needed.

It is worth noting that domestic enterprises have shown strong advantages in industrial application. For example, the composite fabric production line independently developed by a Zhejiang enterprise has achieved automated control, and the production efficiency is more than 30% higher than that of traditional processes. This development model that combines industry, education and research has laid the foundation for the rapid development of my country’s composite fabric industry.

Through comparative analysis, it can be seen that although there are certain gaps in the field of composite fabric research at home and abroad, domestic research institutions and enterprises are gradually narrowing the gap with the international advanced level through technological innovation and industrial upgrading. In the future, international cooperation should be strengthened and advanced technologies should be introduced and absorbed.At the same time, we should focus on the cultivation of independent intellectual property rights, and promote my country’s composite fabric industry to a higher level.

The market prospects and challenges of cotton composite TPU film composite cotton fabric

With the continuous development of the global navigation industry and the continuous enhancement of environmental awareness, cotton composite TPU film composite cotton fabrics show broad market development prospects. According to the forecast of Grand View Research, an international market research firm, the global specialty functional fabric market size will reach US$12 billion by 2030, of which the average annual growth rate of navigation composite fabrics is expected to remain around 9%. This growth trend is mainly driven by the following aspects:

Market Opportunity Analysis

First, the booming development of the marine tourism market has brought huge demand space for composite fabrics. According to statistics from the World Tourism Organization (UNWTO), the number of cruise tourists worldwide has nearly doubled in the past decade and is expected to reach 30 million by 2025. The demand for high-quality cabin decorative materials of luxury cruise ships has directly promoted the expansion of application of composite fabrics in this field. For example, Italian yacht manufacturer Sanlorenzo has fully adopted environmentally friendly composite fabrics in its newly launched superyacht range, which not only improves the interior grade, but also complies with the EU REACH regulations.

Secondly, the rise of new energy industries such as offshore wind power has also created new application scenarios for composite fabrics. According to statistics, the global installed capacity of offshore wind power has increased by nearly 200% in the past five years, and the demand for professional protective equipment for relevant maintenance personnel has increased sharply. A study by the ORE Catapult UK shows that protective clothing made of composite fabrics can significantly reduce the risk of injury for workers in severe weather conditions, which has led to more and more companies paying attention to the material. application potential.

Analysis of development challenges

However, cotton composite TPU film composite cotton fabrics also face many challenges in the promotion process. The first problem is that the production costs are high, especially the prices of TPU films and functional additives fluctuate greatly, which puts certain pressure on the profit margin of the company. According to industry statistics, the current production cost of this fabric is about 40% higher than that of traditional fabrics, which poses a barrier to entry for the price-sensitive market.

Secondly, the stability of raw material supply is also an important issue. The core raw materials of TPU films are mainly imported and are greatly affected by fluctuations in international crude oil prices. In addition, the production areas of high-quality long-length cotton are relatively concentrated and are vulnerable to climate change and policy adjustments. These uncertainties add to the complexity of supply chain management.

Third, the relatively lagging construction of the standardization system is also an important factor restricting the development of the industry. Although the International Organization for Standardization (ISO) has formulated a series of relevant standards, there are still problems such as inconsistent standards and irregular testing methods in actual applications. thisIt not only affects the consistency of product quality, but also hinders the smooth development of international trade.

Afterwards, the increasingly fierce market competition has also brought considerable pressure to enterprises. As more participants enter this field, how to maintain technological leadership and create differentiated products has become a common issue facing enterprises. Especially in emerging fields such as intelligence and personalized customization, it is necessary to further increase R&D investment and enhance core competitiveness.

Reference Source

1. International Textile Association (ITA). (2021). Global Specialty Functional Fabrics Market Report.
2. Naval Research Laboratory (NRL). (2022). Performance Evaluation of Composite Fabrics in Marine Environments.
3. Royal Navy. (2022). Crew Protective Equipment Standards.
4. Hamburg Maritime Institute. (2023). Advanced Materials for Life-Saving Equipment.
5. Benetti Yachts. (2023). Interior Material Specification Manual.
6. French National Center for Scientific Research (CNRS). (2022). Thermal Insulation Properties of Marine Textiles.
7. Coast Guard Canada. (2023). Polar Rescue Equipment Specification Guidelines.
8. Grand View Research. (2023). Global Specialty Fabrics Market Analysis.
9. United Nations World Tourism Organization (UNWTO). (2023). Cruise Industry Development Report.
10. ORE Catapult. (2022). Safety Enhancement in Offshore Wind Maintenance Operations.
11. International Organization for Standardization (ISO). (2023). Textile Testing Standards Compilation.

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