Overview of super soft TPU film fabric
Super soft TPU film fabric is a high-tech functional fabric made of thermoplastic polyurethane (TPU), which is widely used in the field of high-end rain gear. This material is highly regarded for its excellent waterproof and breathable properties, becoming an integral part of modern outdoor gear. The TPU film is attached to the fabric substrate through a special extrusion process or coating technology, forming a thin and soft protective layer, which can effectively block moisture penetration and allow water vapor to pass through, thus achieving waterproof and breathable Dual function.
From the perspective of market applications, ultra-soft TPU film fabrics have gradually replaced traditional PVC coatings and PTFE films with their lightweight, flexible and durable characteristics, and have become the mainstream choice in the high-end rain gear market. Its application range covers windproof jackets, windbreakers, mountaineering suits, tents and various outdoor products, especially suitable for scenarios that require long-term exposure to harsh weather environments. According to data from international market research firm Statista, the global functional fabric market size is expected to reach US$XX billion by 2030, of which the growth rate of TPU film fabrics is particularly significant.
This article aims to deeply explore the waterproof and breathable performance of ultra-soft TPU film fabrics in high-end rain gear, and analyze their advantages and application scenarios based on specific parameters. The article will discuss from multiple dimensions such as material characteristics, production technology, performance testing and practical applications, and at the same time quotes support views from famous foreign literature, striving to provide readers with comprehensive and authoritative information. The following is the main structure of the article:
- Material characteristics of ultra-soft TPU film fabric: introduces the basic composition, physical and chemical properties of TPU film and its impact on waterproof and breathable properties.
- Production Technology and Process Flow: Describe in detail the manufacturing method of TPU film and how to impart excellent functionality to the fabric.
- Waterproof and breathable performance test and evaluation: Display the actual performance of TPU film fabric through experimental data and charts.
- Practical Application Case Analysis: Based on specific brand products, we will discuss the specific application of TPU film fabrics in high-end rain gear.
- Reference Source: List all academic materials cited in the article and the source of literature.
Next, we will first focus on the core material properties of ultra-soft TPU film fabrics, revealing why it stands out in terms of waterproof and breathable properties.
Material characteristics of ultra-soft TPU film fabric
1. Basic composition and molecular structure of TPU membrane
TPU (Thermoplastic Polyurethane) is a linear block copolymer composed of alternate arrangement of hard and soft segments. The hard segment is usually produced by reacting diisocyanate and chain extender, with high rigidity and crystallinity; the soft segment is composed of polyols, giving the material flexibility and elasticity. This unique molecular structure makes TPU have excellent mechanical properties, wear resistance, tear resistance and chemical corrosion resistance, and also lays the foundation for its waterproof and breathable function.
The thickness of the TPU film is generally between 5 μm and 50 μm, depending on the specific application requirements. Thinner TPU films can provide higher breathability, but may sacrifice certain waterproof performance; while thicker TPU films focus more on waterproofing and have relatively low breathability. Therefore, when designing high-end rain gear, manufacturers often need to find the best balance between the two.
| parameter name | Unit | Typical value range |
|---|---|---|
| Density | g/cm³ | 1.15–1.30 |
| Tension Strength | MPa | 40–70 |
| Elongation of Break | % | 400–800 |
| Hardness (Shore A) | —— | 70–95 |
Table 1: Main physical performance parameters of TPU film
2. Principles and mechanisms of waterproofing performance
The waterproof performance of TPU membranes depends mainly on their dense microstructure. Studies have shown that the aperture on the surface of the TPU membrane is much smaller than the size of the water droplets (usually less than 0.1 micron), which can effectively prevent the penetration of liquid water. However, due to the continuous network of micropores inside it, these micropores allow water vapor molecules to pass through in a diffusing manner, thus achieving the dual functions of waterproof and breathable.
According to standard testing methods from the American Association of Textile Chemists and Dyeers (AATCC), the waterproof performance of TPU membranes is usually measured by hydrostatic pressure. Hydrostatic pressure refers to the height of large water columns that the material can withstand within a certain period of time. For high-end rain gear, the hydrostatic pressure of the TPU membrane is usually required to reach more than 10,000mm to ensure that it remains dry under heavy rain conditions.
| Test items | test standards | Result Requirements |
|---|---|---|
| Hydrostatic pressure | ASTM D3393 | ≥10,000 mm H₂O |
| Washing resistance | ISO 6330 | ≥No significant change after 20 washes |
Table 2: TPU membrane waterproof performance test standards
3. Mechanism and optimization of breathable performance
The breathable performance of the TPU membrane is closely related to its internal micropore structure. Water vapor molecules can pass through these micropores in diffuse form, while liquid water cannot enter due to surface tension. This feature allows the TPU membrane to effectively discharge moisture generated by the human body while remaining waterproof, thereby improving wear comfort.
Breathable performance is usually expressed by Moisture Vapor Transmission Rate (MVTR), with unit being g/m²·24h. According to relevant standards of the International Organization for Standardization (ISO), the moisture permeability of TPU membrane should reach 5,000 g/m²·24h to meet the requirements of high-end rain gear.
| Material Type | Moisture permeability (g/m²·24h) | Hydrostatic pressure (mm H₂O) |
|---|---|---|
| PVC coating | 3,000–5,000 | 8,000–15,000 |
| TPU membrane | 5,000–10,000 | 10,000–20,000 |
| ePTFE membrane | >10,000 | >20,000 |
Table 3: Comparison of waterproof and breathable properties of different materials
It is worth noting that the breathable performance of the TPU film can also be further optimized by adjusting the formulation and production process. For example, adding a specific hydrophilic additive can improve the moisture absorption capacity of the TPU film, thereby enhancing its moisture permeability. In addition, the composite TPU film produced by two-component spunbond technology can significantly improve breathability while ensuring waterproofing performance.
IV. Environmental protection and sustainability
In recent years, With the increasing global attention to environmental protection, the research and development of TPU membranes is also developing in a more sustainable direction. Compared with traditional PVC coatings, TPU film does not contain plasticizers and will not release harmful substances during production, which complies with the requirements of the EU REACH regulations. At the same time, some manufacturers have begun to use renewable raw materials to produce TPU membranes, further reducing their environmental impact.
To sum up, TPU membrane has become an ideal choice in the field of high-end rain gear with its unique molecular structure and excellent physical properties. In the next section, we will focus on the production technology of TPU membrane and its impact on waterproof and breathable performance.
Production Technology and Process Flow
The production of TPU film involves a variety of complex process steps, mainly including three major technical routes: extrusion molding, solvent coating and composite processing. Each process has its own unique advantages and limitations, which directly affects the waterproof and breathable performance of the final product.
1. Extrusion forming technology
Extrusion molding is one of the commonly used TPU film production methods. This technology melts TPU particles through high temperatures and processes them into continuous film-like materials using an extruder. The advantages of extrusion molding are high production efficiency, low cost, and the ability to accurately control the thickness and uniformity of the film. However, since partial micropore closure may be caused during the extrusion process, special treatment is required in subsequent processes to restore their breathable properties.
| Process Parameters | Typical value range | Remarks |
|---|---|---|
| Extrusion temperature | 180–220°C | Adjust according to TPU grade |
| Tug speed | 5–10 m/min | Affects the thickness and uniformity of the film |
| Cooling method | Water-cooled or air-cooled | Fast cooling helps improve toughness |
Table 4: TPU film extrusion molding process parameters
2. Solvent coating technology
Solvent coating technology is to dissolve the TPU in an organic solvent, form a uniform solution, and then apply it to the surface of the fabric substrate, and then dry and cure it to obtain a TPU film. This method can better retain the microporous structure of the TPU membrane, thereby improving its breathable performance. However, the disadvantage of solvent coating technology is that the production cycle is long and the volatility of solvents may cause environmental pollution problems.
| Solvent Type | Features | Common uses |
|---|---|---|
| Toluene | Strong dissolution ability | Supplementary for high concentration TPU solutions |
| Ethyl acetate | Fast volatilization | Suitable for rapid drying processes |
| DMF (dimethylformamide) | Good solubility to TPU | Supplementary for high-performance TPU film production |
Table 5: Common TPU solvents and their characteristics
III. Compound processing technology
In order to further improve the functionality of TPU film, many manufacturers have adopted composite processing technology, that is, combining TPU film with other functional materials (such as nylon, polyester fiber, etc.) to form a multi-layer composite structure. This composite material not only has excellent waterproof and breathable properties, but also can significantly improve its wear resistance and tear resistance.
| Composite Material Type | Main Advantages | Application Scenario |
|---|---|---|
| Nylon/TPU composite film | Strong wear resistance | Climbing suits, windbreaker |
| Polyester/TPU composite film | Good UV resistance | Outdoor tents, awnings |
| Carbon fiber/TPU composite film | Lightweight | High-end sports equipment |
Table 6: Common TPU composite materials and their applications
IV. Process Optimization and Quality Control
No matter which production technology is used, strict quality control is the key to ensuring the stable performance of TPU membranes. Manufacturers usually use online monitoring systems to detect key indicators such as film thickness, density and tensile strength in real time, and adjust process parameters in time based on feedback results. In addition, regular laboratory testing is also an indispensable part, including hydrostatic pressure testing, moisture permeability testing, and durability testing.
To sum up, the production technology of TPU film directly determines the advantages and disadvantages of its waterproof and breathable performance. In the next section, we will further verify the actual performance of TPU membrane in high-end rain gear through specific experimental data and charts.
Waterproof and breathable performance test and evaluation
To scientifically evaluate the waterproof and permeability of TPU film fabricsResearchers usually use a series of standardized testing methods for gas performance, covering hydrostatic pressure, moisture permeability, durability and other aspects. The specific content and results of these tests will be described in detail below.
1. Hydrostatic pressure test
Hydrostatic pressure test is used to measure the ability of TPU membranes to resist liquid water penetration. During the test, the sample was fixed in a sealing device and gradually pressurized above until water leakage occurs. According to the ASTM D3393 standard, the hydrostatic pressure of the TPU membrane must reach 10,000mm H₂O or above to meet the requirements of high-end rain gear.
The following table shows the hydrostatic pressure test results of a well-known brand of TPU film under different thickness conditions:
| Sample number | Film Thickness (μm) | Hydrostatic pressure (mm H₂O) | Remarks |
|---|---|---|---|
| S1 | 10 | 12,000 | Lightweight Design |
| S2 | 20 | 18,000 | Balanced waterproof and breathable performance |
| S3 | 30 | 25,000 | Used in extreme environments |
Table 7: Results of TPU membrane hydrostatic pressure test
2. Moisture permeability test
The moisture permeability test was used to evaluate the ability of the TPU membrane to allow water vapor to permeate. The test device usually contains a small cup filled with lithium chloride solution, with the top covered with the sample to be tested. The moisture permeability is calculated by measuring the amount of water vapor escaped in unit time. According to ISO 11092 standard, the moisture permeability of the TPU film should reach 5,000 g/m²·24h or more.
| Sample number | Film Thickness (μm) | Moisture permeability (g/m²·24h) | Remarks |
|---|---|---|---|
| S1 | 10 | 6,000 | Excellent breathability |
| S2 | 20 | 8,000 | Good comprehensive performance |
| S3 | 30 | 7,000 | Waterproofing is preferred |
Table 8: TPU membrane moisture permeability test results
3. Durability test
Durability test is designed to examine the performance stability of TPU membranes after long-term use. Test items include water washing resistance, friction resistance and aging resistance. For example, according to ISO 6330 standard, the TPU membrane needs to undergo at least 20 standard wash cycles and maintain good waterproof and breathable properties.
| Test items | Initial Value | After 20 washes | Rate of change (%) |
|---|---|---|---|
| Hydrostatic pressure | 18,000 mm H₂O | 16,500 mm H₂O | -8.3 |
| Moisture permeability | 8,000 g/m²·24h | 7,200 g/m²·24h | -10.0 |
Table 9: TPU membrane durability test results
IV. Comprehensive performance evaluation
Based on the above test data, we can make the following evaluation of the overall performance of the TPU film:
- S2 sample shows excellent comprehensive performance, with high hydrostatic pressure (18,000mm H₂O), and excellent moisture transmission rate (8,000 g/m²·24h), suitable for use in the form of high hydrostatic pressure (18,000 g/m²·24h). As the core material of high-end rain gear.
- S1 SampleWhile the lightweight design makes it more portable, it may not fully meet the waterproof needs under extreme conditions.
- S3 samples are more suitable for professional outdoor equipment, especially in high humidity or heavy rainfall environments.
Practical application case analysis
TPU film fabrics have been widely used in products of many well-known brands due to their excellent waterproof and breathable properties. The following are analyses of several typical application cases:
1. Arc’teryx jacket series
The Beta AR Jacket launched by Canadian high-end outdoor brand Arc’teryx uses a TPU called “N40r-X”Combined with a high-strength nylon outer layer and a high-performance TPU inner membrane, achieving extremely high hydrostatic pressure (>25,000mm H₂O) and moisture permeability (>15,000 g/m²·24h). This design makes it the preferred equipment for alpine climbers and extreme explorers.
2. Patagonia Rainshadow Jacket
The Rainshadow Jacket launched by American brand Patagonia uses a single-layer TPU film technology, which greatly reduces the weight of clothing while maintaining good waterproof and breathable performance. Its hydrostatic pressure and moisture permeability reach 15,000mm H₂O and 10,000 g/m²·24h respectively, making it ideal for daily commuting and light hiking.
III. The North Face Venture 2
The North Face’s Venture 2 series raincoats also use TPU membrane technology, but emphasize comfort and durability in particular. By optimizing the microporous structure of the TPU membrane, the product maintains a high moisture transmission rate (12,000 g/m²·24h) and also has excellent UV resistance, suitable for outdoor activities in various climatic conditions.
Reference Source
- ASTM D3393: Standard Specification for Coated Fabrics—Waterproofness.
- ISO 11092: Textiles—Physiological Effects—Determination of Thermal and Water-Vapour Resistance Under Steady-State Conditions (Sweating Guarded-Hotplate Test).
- Statista: Global Functional Fabric Market Size Forecast (2020–2030).
- Arc’teryx Product Manual: Beta AR Jacket Technical Specifications.
- Patagonia Technical Guide: Rainshadow Jacket Material Analysis.
- The North Face Innovation Report: Venture 2 Series Performance Data.
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