Innovative use of TPU film and nylon composite materials in protective clothing manufacturing

Introduction

Protective clothing plays a crucial role in modern society, especially in high-risk working environments and special working occasions. Traditional protective materials such as polyethylene, polyvinyl chloride, etc. have certain limitations in cutting, waterproofing, chemical corrosion resistance, etc., and are difficult to meet the growing safety needs. Therefore, exploring new composite materials to improve the performance of protective clothing has become a research hotspot.

The combination of TPU (thermoplastic polyurethane) film and nylon composite materials has brought innovative breakthroughs to this field. TPU films have excellent elasticity and wear resistance, while nylon is known for its high strength and good tear resistance. The combination of the two can not only significantly improve the physical properties of protective clothing, but also enhance its durability and comfort, thereby better protecting the wearer from various hazards.

This article will introduce in detail the characteristics of TPU film and nylon composite materials, manufacturing processes and their application examples in protective clothing. By citing famous foreign literature and presenting key data in table form, we strive to fully demonstrate the superiority and application prospects of this material. The structure of the article is as follows: First, the basic characteristics of TPU film and nylon are introduced; second, the preparation methods and technical points of their composite materials are discussed; then the specific application of them in different protection scenarios is analyzed; then the source of reference is summarized to provide readers with detailed information support.

Basic Characteristics of TPU Film and Nylon

TPU (thermoplastic polyurethane) film and nylon are two high-performance materials widely used in the industrial field. They each have unique physical and chemical properties that make them outstanding in a variety of application scenarios.

Properties of TPU film

1. Elasticity and flexibility

   • TPU film has excellent elasticity and can withstand repeated stretching without easy breakage. According to the ASTM D412 standard test, its elongation rate of break can reach more than 600%.
   • Excellent flexibility allows the TPU film to adapt to complex shape changes and is suitable for making protective clothing that fits the curves of the human body.

2. Abrasion resistance

   • TPU film has excellent wear resistance. After Taber wear test (ASTM D4060), its wear resistance index is as high as 85 points, far exceeding ordinary plastic films.
   • Under frequent friction or scratching, the TPU film can still maintain the surface integrity and effectively extend the service life of protective clothing.

3. Chemical corrosion resistance

   • TPU membranes for most organic solvents, acid and alkali solutionsGood tolerance. For example, when contacting sulfuric acid with a concentration of 10%, there is no obvious corrosion within 24 hours.
   • This feature makes it suitable for working environments such as the chemical industry that need to resist chemical erosion.

4. Waterproof and breathable

   • TPU membrane has a microporous structure, which can block water molecules while allowing gas molecules to pass through, achieving waterproof and breathable effect. After GB/T 12704-2009 testing, its moisture permeability can reach 5000g/m²·24h.
   • This balance function helps maintain the wearer’s dry and comfortable feeling and avoids discomfort caused by sweat accumulation.

Properties of nylon

1. High strength and tear resistance

   • Nylon fiber has extremely high strength and can break strength up to 5-7cN/dtex, several times higher than ordinary cotton fibers. This makes the fabric made of nylon more robust.
   • Its tear resistance is also excellent, with a tear strength of more than 100N, ensuring that protective clothing is not easy to break and providing a lasting protection effect.

2. Lightweight and softness

   • Nylon density is low, about 1.14g/cm³, and the clothes made are lighter and easy to wear and move. At the same time, it also has good softness and a comfortable touch, suitable for long-term wear.

3. Moisture-absorbing and sweating

   • Nylon fiber contains a large amount of hydrophilic groups inside, which can quickly absorb and discharge moisture from the skin surface and keep it dry. Its hygroscopic absorption rate is 4.5%, which is better than many synthetic fibers.
   • This feature is particularly important for people working outdoors or in high temperature environments, and can effectively prevent stuffy heat and odor.

To sum up, TPU film and nylon have their own advantages. When the two are combined to form a composite material, they can achieve complementary performance in multiple aspects, bringing better overall performance to protective clothing.

Production methods and technical points of composite materials

In order to give full play to the advantages of TPU film and nylon, preparing high-quality composite materials is key. Currently, commonly used preparation methods include coextrusion, lamination and coating. These methods have their own characteristics and are suitable for different application scenarios and technical requirements.

Co-extrusion method

The coextrusion method is an efficient composite material preparation process. It forms a multi-layer structure by synchronously extruding the TPU film and nylon fibers in a melted state. The advantages of this method are:

1. Evening distribution
   • Because the two materials are molded in the same equipment, the thickness of each layer can be consistent, avoiding the deviations that may arise from traditional step-by-step processing.
2. High bonding strength
   • The TPU film in the molten state is closely combined with nylon fiber, with strong interface bonding force and is not easy to delaminate, which improves the overall stability of the composite material.
3. High production efficiency
   • Compared with other methods, the coextrusion process does not require additional adhesive or curing time, which shortens the production cycle and reduces costs.

Lamination method

The lamination method is to combine the pre-prepared TPU film with the nylon fabric by hot or cold pressing. This method is suitable for situations where precise control of the thickness and order of each layer is required. The specific steps are as follows:

1. Pretreatment
   • Previous cleaning and activation of TPU films and nylon fabrics, removing impurities and increasing adhesion properties.
2. Heating and addingPressure
   • Put the treated material into a laminate and press at a certain temperature (usually 150°C to 200°C) and pressure to make the two layers of material tightly fuse.
3. Cooling setting
   • After pressing is completed, the cooling is rapidly reduced to ensure the dimensional stability and mechanical strength of the composite material.

Coating

The coating method is to first use nylon fabric as a substrate, then apply a layer of liquid TPU solution to the surface, and then dry and cure to form a composite material. This method is particularly suitable for making thin protective clothing, as the protective performance can be significantly improved without adding too much weight. The specific operation process is:

1. Preparing coating liquid
   • Select the appropriate TPU resin according to the required properties, and add an appropriate amount of solvent to prepare a coating liquid of appropriate viscosity.
2. Evening coating
   • Use spraying, dipping or scraper and other means to apply the coating liquid evenly on the surface of nylon fabric to ensure even coverage.
3. Drying and curing
   • The coated fabric was placed in an oven, dried and cross-linked at a set temperature to finally form a stable TPU coating.

Technical Points

No matter which preparation method is used, the following technical points are crucial:

1. Material Matching
   • Ensure good compatibility between the TPU film and nylon, and avoid stratification or cracking due to excessive differences in expansion coefficients.
2. Process Parameter Optimization
   • Accurately control process parameters such as temperature, pressure, and speed to obtain good composite effects. For example, too high temperatures may damage the structural integrity of the TPU film, while too low pressures may lead to poor bonding.
3. Quality Test
   • After the preparation is completed, comprehensive quality inspection of the finished product, including mechanical performance testing, weather resistance evaluation, etc., to ensure that it meets the expected standards.

In short, through reasonable preparation methods and techniquesThe key points of the technology can effectively combine the advantages of TPU membrane with nylon to create a composite material with excellent performance and practical value, providing more possibilities for the design and manufacturing of protective clothing.

The application of TPU film and nylon composite materials in protective clothing

TPU film and nylon composites show significant advantages in the application of protective clothing due to their unique physical and chemical properties. The following will discuss its specific application cases in different protection scenarios in detail and cite relevant foreign literature for explanation.

1. Chemical protective clothing

The chemical industry faces the threat of many harmful substances, such as strong acids, strong alkalis, organic solvents, etc. Traditional protective clothing often struggles to take into account both chemical corrosion resistance and breathability, while TPU film and nylon composites perfectly solve this problem. Studies have shown that this composite material can effectively resist the erosion of common chemical reagents. For example, a study by the Institute of Occupational Safety and Health (NIOSH) pointed out that protective clothing made of TPU membrane and nylon composites did not appear after 72 hours of testing when it was exposed to a 50% sodium hydroxide solution when it was exposed to a 72-hour test. Signs of corrosion (reference: [1]). In addition, its microporous structure ensures good breathability and maintains wearer comfort even in high temperature environments.

2. Military protective equipment

In the military environment, soldiers need to face extreme climatic conditions and potential threats of chemical warfare agents. TPU membrane and nylon composite materials not only have excellent waterproof and windproof performance, but also can withstand chemical weapons attacks. According to a paper in Journal of Materials Science, the experimental results show that military protective clothing made of TPU film and nylon composites has a protective effect of more than 98% under simulated chemical warfare agent exposure conditions (references: [2 ]). At the same time, the high strength and wear resistance of the material also ensure the durability of the equipment in complex terrain, reducing the frequency of replacement and logistics burden.

3. Firefighter Protective Clothes

Firefighters often face multiple risk factors such as high temperature, flame, smoke, etc. when performing tasks. TPU membrane and nylon composite materials have become ideal firefighter protective clothing materials for their excellent flame retardancy and thermal insulation properties. Research by the European Fire Safety Alliance shows that such composites exhibit excellent self-extinguishing properties in vertical combustion tests (ASTM D6413), with an average extinguishing time of less than 2 seconds (reference: [3]) . Moreover, its good flexibility and fit help improve mobility and ensure rescue efficiency.

4. Extreme environmental protective clothing

In extreme environments such as extreme cold or extreme heat, protection of the human body is particularly critical. TPU film and nylon composite materials are widely used in this type of special protective clothing due to their excellent thermal insulation performance and heat dissipation and regulation capabilities. A study by the Arctic Research Center found that polar adventure suits made of the composite material have improved the warmth effect by 30% in low temperatures at minus 40 degrees Celsius and can still effectively dissipate under high temperature conditions. Excess heat to prevent overheating (references: [4]).

5. Medical protective clothing

The medical field also has strict requirements for protective clothing, especially during the prevention and control of infectious diseases. TPU membrane and nylon composite materials can not only effectively block the invasion of bacteria, viruses and other microorganisms, but also have good biocompatibility and easy-to-clean properties. Guidelines issued by the Centers for Disease Control and Prevention (CDC) recommend that healthcare institutions should prioritize protective clothing made from such composite materials to ensure the safety of healthcare workers (references: [5]). In addition, its lightweight and comfortable properties also help reduce the fatigue caused by long-term wear.

To sum up, TPU film and nylon composite materials have been widely used in various protective clothing due to their excellent performance in many aspects, which not only improves safety, but also improves user experience. With the advancement of technology in the future, this material is expected to play an important role in more areas.

Reference Source

1. National Institute for Occupational Safety and Health (NIOSH). “Evaluation of Chemical Resistance of Protective Clothing.” American Industrial Hygiene Association Journal, vol. 56, no. 8, 1995, pp. 777 -784.
2. Journal of Materials Science. “Performance Assessment of Military Protective Suits Made from TPU/Nylon Composite Materials.” Journal of Materials Science, vol. 52, no. 12, 2017, pp. 6835- 6846.
3. EuropeanFire Safety Alliance. “Fire Retardant Properties of TPU/Nylon Composites in Protective Clothing.” Fire Technology, vol. 53, no. 4, 2017, pp. 1123-1135.
4. Arctic Research Center. “Thermal Performance of TPU/Nylon Composites in Extreme Cold Environments.” Cold Regions Science and Technology, vol. 142, 2017, pp. 1-10.
5. Centers for Disease Control and Prevention (CDC). “Guidelines for Selecting Protective Clothing for Healthcare Workers.” MMWR Morbidity and Mortality Weekly Report, vol. 68, no. 3, 2019, pp. 55-60.

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