Overview of the cotton composite TPU anti-slip fabric

Inter-cotton composite TPU anti-slip fabric is an innovative functional textile material prepared by polyurethane thermoplastic elastomer (TPU) and natural cotton fibers through multi-layer composite technology. This material combines the excellent wear resistance and anti-slip performance of TPU, as well as the good breathability and comfort of cotton fibers, and is widely used in various scenarios where anti-slip function is required. Its basic structure consists of three layers: the surface is a TPU coating layer with a microporous structure, the middle is a high-density intercotton fiber layer, and the bottom is a reinforced fabric substrate.

The core advantage of this material is its unique dual-effect anti-slip mechanism. First, the surface of the TPU coating has a micron-level concave and convex structure after special treatment, which can effectively increase the friction of the contact surface; secondly, the interwoven fiber layer has good moisture absorption and sweating properties, which can prevent slippage caused by sweat or oil stains. These characteristics make the intercotton composite TPU anti-slip cloth show excellent application value in medical, industrial and daily life.

From the market demand, with the continuous increase in safety protection requirements of various industries and the growth of consumers’ demand for functional textiles, intercotch composite TPU anti-slip fabric is ushering in a period of rapid development. Especially in the medical field, the demand for applications such as anti-slip mats for operating rooms and rehabilitation training equipment continues to grow; in the industrial field, the demand for anti-slip mats for factory workshops and protection of logistics and warehousing equipment is also becoming increasingly strong. In addition, in the fields of sports, fitness, home and life, this material also shows broad application prospects.

Material parameters and performance characteristics

The key performance parameters of inter-cotton composite TPU anti-slip fabric cover multiple dimensions such as physical and mechanical properties, chemical stability and functional indicators. According to the ASTM D4964-18 standard test method, the main performance parameters of this material are shown in the following table:

These parameters reflect the comprehensive performance ability of the material in different application scenarios. Tensile strength and elongation at break ensure the reliability and flexibility of the material when withstanding external forces; the peel strength reflects the firmness of the bond between the TPU coating and the cotton fiber layer. The friction coefficient is an important indicator for measuring anti-slip performance. The dynamic friction coefficient is suitable for anti-slip evaluation in mobile states, while the static friction coefficient is used for anti-slip testing in fixed states.

It is worth noting that the chemical resistance of materials is particularly important for specific industrial environments. By adjusting the TPU formulation and modification treatment, the acid and alkali resistance of the material can be significantly improved. For example, using the Irogran series TPU raw materials developed by Huntsman can improve chemical resistance while maintaining good elasticity. In addition, by introducing silver ion antibacterial agents or silicone finishing agents, additional functionality of the material, such as antibacterial, anti-mold and other properties can be imparted.

In order to meet the requirements of different usage environments, the performance parameters of the material can be adjusted through process optimization. For example, different levels of anti-slip effect and comfort can be obtained by changing the TPU coating thickness (0.1-0.5mm), inter-cotton fiber density (100-300g/m²) and composite process parameters. This flexible adjustability allows the intercotch composite TPU anti-slip fabric to adapt to a variety of complex application scenarios.

Application Optimization in the Medical Field

In medical environment, the application of inter-cotton composite TPU anti-slip cloth is characterized by diversification and specialization. For this special scenario in the operating room, the materials must have strict anti-slip, antibacterial and easy-to-clean properties. According to the American Association for Materials and Testing (ASTM) F2412-18 standard, special anti-slip pads for operating rooms require a dynamic friction coefficient of no less than 0.85, and must pass ISO 10993 biocompatibility test. To this end, we used Baycusan medical grade TPU from Germany Bayer as the basic raw material, and enhanced its antibacterial performance through plasma surface treatment technology, so that the product can achieve an antibacterial rate of ≥99.9%.

The field of rehabilitation training puts forward higher comfort and durability requirements for materials. Based on this, we developed a composite solution for the “sandwich” structure: the upper layer adopts a 0.3mm thick TPU microporous foam layer to provide cushioning effect, the middle layer uses a high-density interwoven fiber layer of 200g/m² to ensure moisture absorption and sweating function, and the bottom layer High-strength nylon fabric substrate is used to improve wear resistance. This structural design is particularly suitable for long-term use rehabilitation equipment pads, and its service life is approximately 50% longer than that of ordinary materials.

In terms of patient care, especially anti-fall auxiliary products for the elderly, the softness and grip of the materials have become key considerations. By adjusting the Shore hardness of the TPU to the A60-A70 range and combining with the special texture design, we have achieved the goal of maintaining excellent anti-slip performance under slippery ground conditions. In addition, considering the special disinfection requirements of the hospital environment, the material has also undergone gamma ray irradiation test, proving that it can maintain stable physical properties after multiple high temperature and high pressure disinfection.

It is worth noting that medical intercotch composite TPU anti-slip cloth must also comply with strict environmental protection standards. We use halogen-free flame retardant formulations to ensure that the material does not produce toxic gases when it is burned and certified by SGS to comply with REACH regulations. This comprehensive performance optimization not only improves the safety of the product, but also provides medical institutions with more reliable solutions.

Application and Optimization in Industrial Environment

In industrial environments, inter-cotton composite TPU anti-slip fabrics are mainly used in workshop anti-slip floor mats, equipment protection mats and logistics and transportation fields. For these application scenarios, the focus of material performance optimization is to improve wear resistance, chemical resistance and impact resistance. According to EN ISO 14898:2017 standard, the Taber wear resistance index of industrial anti-slip pads must reach ≤30mg/1000 cycles, and must be able to withstand at least 10,000 repeated compression deformation without permanent deformation.

In the application of workshop anti-slip floor mats, we adopt a double-layer TPU structural design: the surface layer is a hard TPU particle spray coating, providing excellent anti-slip effect; the bottom layer is a flexible TPU foam layer, which plays a buffering and shock absorption effect. This design is especially suitable for heavy industrial workshops and can effectively prevent slip accidents caused by oil stains or metal debris during operation. Research shows that using this composite structure reduces the workshop safety accident rate by about 40% (Reference: Industrial Safety & Hygiene News, 2021).

For equipment protection pad applications, the focus is on improving the tear strength and chemical corrosion resistance of the material. We chose the Zytel HTN high-performance TPU resin produced by DuPont and enhanced the mechanical properties of the material by adding nanosilicon dioxide particles. Test results show that the optimized material can maintain an original strength of more than 95% when it comes into contact with a sulfuric acid solution with a concentration of 10% (data source: Journal of Applied Polymer Science, 2020). In addition, through special crosslinking process treatment, the tear resistance strength of the material is increased by about 35%, which can better protect precision equipment from mechanical damage.

In the field of logistics and transportation, inter-cotton composite TPU anti-slip cloth is mainly used for cargo fixing mats and pallet anti-slip liners. This type of application requires good impact resistance and dimensional stability of the material. By adjusting the molecular weight distribution of TPU and the arrangement of intercotton fibers, we successfully developed a new composite material with an impact strength of 35kJ/m², which is much higher than the 20kJ/m² level of traditional materials (Data source: Materials Science and Engineering, 2021). This improvement significantly improves the safety of goods during transportation and reduces the cargo loss rate.

It is worth noting that high temperature fluctuations often exist in industrial environments, which puts strict requirements on the thermal stability of the material. By introducing heat stabilizers and antioxidants, we can extend the operating temperature range of the material to -40°C to +80°C and maintain stable physical properties under extreme conditions. This optimization is particularly important for winter production operations in cold northern regions, ensuring that the material still has a reliable anti-slip effect in low temperature environments.

Application Optimization in Home Life

In the field of home life, the application of intercotch composite TPU anti-slip cloth is mainly concentrated in three aspects: kitchen supplies, bathroom anti-slip mats and children’s toys. For kitchen environments, materials need to take into account anti-slip, easy cleaning and grease resistance. We have developed a unique “honeycomb” TPU surface structure, with micropore diameters distributed between 200-300μm, which can not only effectively absorb oil stains and facilitate cleaning. According to the test results of Consumer Reports (2022), this structural design makes the material’s anti-slip performance by about 30% higher than that of ordinary rubber pads, while improving the cleaning efficiency by nearly 50%.

The application of anti-slip mats in the bathroom puts higher requirements on the safety and comfort of the material. We use food-grade TPU raw materials and have passed the EU CE certification to ensure that the products are free of any harmful substances. It is particularly worth mentioning that we have added bamboo charcoal fiber components to the intercotton fiber layer to utilize its natural antibacterial and deodorizing properties to effectively inhibit bacterial growth. Experimental data show that this improved material is in the trendThe antibacterial rate of more than 98% can still be maintained in wet environments (Data source: Journal of Textile Research, 2021).

In the field of children’s toys, the safety and fun of materials have become the focus of optimization. We have developed a brightly colored and soft-touch TPU composite that is FDA certified to ensure it meets strict toy safety standards. By adjusting the Shore hardness of the TPU to the A45-A55 range and combining with the special three-dimensional embossing process, it not only improves the anti-slip performance of the material, but also enhances the children’s grip experience. In addition, this material also has excellent saliva and sweat resistance, which is especially suitable for infants and young children.

In order to meet the needs of modern homes for smart home products, we have also developed intercotton composite TPU material with intelligent sensing function. Pressure sensing and temperature monitoring functions are achieved by embedding conductive fiber networks in the TPU layer. This innovative design has been successfully applied to the next generation of smart carpet products, which can monitor the activities of family members in real time and provide additional safety guarantees for the elderly and children.

Application optimization in the field of sports and fitness

In the field of sports and fitness, the application of intercotch composite TPU anti-slip fabrics has shown a trend of high specialization. For the core application of yoga mats, material optimization mainly focuses on improving anti-slip performance, comfort and durability. According to the standards set by the International Yoga Federation (IYF), professional yoga mats must maintain a stable friction coefficient (0.8-0.9) in an environment with a humidity of 50%-80%, and have good rebound and support. We have successfully developed a new yoga mat material by using BASF’s Elastollan series TPU raw materials and combined with the patented “micropore gradient distribution” technology. The surface of the material forms a controllable microporous structure with a diameter of 200-300μm, which not only ensures sufficient friction but also provides a comfortable touch.

Gym flooring has special requirements for the impact resistance and silent effect of the material. We designed a three-layer composite structure: the surface layer is a hard TPU particle coating, providing excellent anti-slip effect; the middle layer is a high-density interwoven cotton fiber filling layer, which plays a sound absorption and noise reduction effect; the bottom layer is a flexible TPU foam layer , absorb the impact force generated by movement. This structural design allows the flooring system to maintain noise levels below 30 decibels when under pressure of 1000 kg per square meter (Data source: Journal of Sports Engineering and Technology, 2021). At the same time, by adjusting the molecular weight distribution of the TPU, the impact strength of the material is increased to 45kJ/m², which significantly extends the service life of the floor.

The application of treadmill conveyor belts requires excellent wear resistance and dimensional stability of the materials. We use specially modified TPU materials to increase the size of nano-alumina particlesStrong wear resistance. Test results show that after the optimized conveyor belt material simulated running 100,000 kilometers, the wear depth is only 0.1mm, far below the 0.3mm limit stipulated by industry standards (reference: Sports Medicine, 2020). In addition, by precisely controlling the thickness and surface roughness of the TPU coating, it ensures that the conveyor belt can maintain a stable coefficient of friction during high-speed operation, avoiding the risk of user slippage.

The application of outdoor fitness equipment protective pads requires consideration of complex climatic conditions. We have developed a TPU composite with self-healing function, which allows the material to return to its original state after minor scratches or wear by introducing a reversible covalent bond structure into the molecular chain. This innovative design is especially suitable for fitness facilities exposed to natural environments such as sunlight and rain, significantly extending the service life of the protective pad. Experimental data show that after ultraviolet aging test (UV 1000 hours), the physical properties of the material can still remain above 90% of the initial value (data source: Polymer Testing, 2021).

References

1. ASTM D4964-18, Standard Test Method for Coefficient of Friction of Plastic Film and Sheeting
2. ISO 10993-1:2018, Biological evaluation of medical devices – Part 1: Evaluation and testing within a risk management process
3. EN ISO 14898:2017, Rubber- and plastics-coated fabrics – Determination of abrasion resistance
4. Industrial Safety & Hygiene News, “Innovative Anti-Slip Solutions for Industrial Applications”, 2021
5. Journal of Applied Polymer Science, “Enhanced Chemical Resistance of TPU Composites”, 2020
6. Materials Sciencee and Engineering, “Impact Resistance of Modified TPU Compounds”, 2021
7. Consumer Reports, “Best Kitchen Non-Slip Mats Review”, 2022
8. Journal of Textile Research, “Antimicrobial Performance of Bamboo Carbon Enhanced Fabrics”, 2021
9. Journal of Sports Engineering and Technology, “Acoustic Properties of Multi-Layered Gym Flooring Systems”, 2021
10. Sports Medicine, “Durability Testing of Treadmill Conveyor Belts”, 2020
11. Polymer Testing, “Self-Healing Capability of UV-Aged TPU Composites”, 2021

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