Overview of four-sided composite TPU fleece fabric

Four-sided composite TPU fleece fabric is a new type of textile material that integrates functionality and comfort. In recent years, it has attracted much attention in the fields of high-end sportswear and outdoor equipment. The fabric achieves excellent multi-directional tensile properties and durability by combining thermoplastic polyurethane (TPU) film with a shaky fleece base cloth and adopting advanced elastic fiber technology. Its core advantage is its ability to provide all-round elastic support while maintaining excellent warmth and breathability, making it an ideal choice for high-performance clothing.

From the perspective of market application, this fabric is widely used in ski suits, yoga suits, running equipment and other scenarios that require high elasticity and good protective performance. Especially in cold climates, its unique warm structure and waterproof performance provide reliable guarantees for outdoor activities. According to data from international market research institutions, the global functional textile market size is expected to grow at an average annual rate of 8.5% in the next five years. Four-sided composite TPU fleece fabric, as an important part of the high-end market segment, shows that Strong development potential.

This study aims to deeply explore the high elasticity and durability characteristics of four-sided elastic composite TPU fleece fabric, analyze its performance in different application scenarios, and reveal its performance advantages through experimental data and theoretical analysis. The research content will cover multiple dimensions such as material structure, production process, performance testing, etc., and strive to provide comprehensive technical reference for relevant practitioners. It is particularly noteworthy that as consumers’ requirements for environmental protection and sustainable development increase, this study will also focus on the possibility of the fabric in terms of recycling and eco-friendliness.

Analysis of high elasticity characteristics

The high elastic properties of four-sided elastic composite TPU fleece fabrics are mainly derived from their unique structural design and material combination. The fabric consists of three layers: the outer layer is made of high-strength nylon or polyester fiber, the middle layer is TPU film, and the inner layer is made of soft fleece. This sandwich-style composite structure not only imparts excellent elasticity to the fabric, but also ensures good durability and comfort.

Elastic Parameter Indicators

From the above parameter table, it can be seen that the four-sided composite TPU fleece fabric shows significant elastic characteristics in all directions. The elastic ranges of warp and weft directions reach 120%-150% and 140%-180% respectively, which is far higher than the 70%-100% level of ordinary knitted fabrics. In particular, its diagonal elasticity reaches 80%-110%, which is due to the special molecular structure of the TPU film, which can provide uniform elastic support in multiple directions.

From the microstructure, the urethane segment in the TPU film has excellent elastic recovery ability, and can quickly deform and restore its original state under the action of external forces. At the same time, the fluffy structure of the inner layer of the fleece also provides additional support for overall elasticity. Studies have shown that in the repeated tensile test, the fabric can still maintain more than 95% of its initial elasticity after 1,000 cycles, showing excellent fatigue resistance (Smith et al., 2021).

In addition, the elasticity of the fabric is also affected by the ambient temperature. Under low temperature conditions, the activity of the TPU molecular chain decreases, resulting in a slight decrease in elasticity; while in high temperature environments, although the elasticity is enhanced, it may be accompanied by a certain degree of creep. Therefore, in practical applications, the temperature change factors of the use environment need to be comprehensively considered. Experimental data show that when the ambient temperature is in the range of -20°C to +50°C, the elastic properties of the fabric are stable.

Durability evaluation and testing methods

The durability of four-sided composite TPU fleece fabric is an important indicator to measure its long-term use value, involving multiple key performance parameters such as wear resistance, tear resistance and wash resistance. These characteristics directly affect the service life and maintenance cost of the fabric. According to the provisions of international standard ISO 12947, durability testing mainly includes the following three aspects:

Abrasion resistance test

Taber wear resistance test found that after the four-sided composite TPU fleece fabric has only slightly gloss changes on the surface after 50,000 rpm friction, and there is no obvious fiber breakage or shedding. Martindale edge wear tests show that the fabric remains intact structural integrity after 20,000 cycles, better than the 10,000-time standard for traditional knitted fabrics. The results of the lint resistance test show that its lint level reaches 4, ensuring the cleanliness of appearance after long-term use.

Tear resistance strength

Experimental data show that the tear resistance strength of this fabric reaches 75N, far exceeding the industry average standard. This is mainly due to the polymer cross-linking density of the TPU film and the three-dimensional mesh structure of the fleece-based cloth, which together form a strong internal support network. Dynamic tear test further verifies that it has excellent energy absorption capacity during stress.

Wash resistance

The water washing resistance test results show that after 20 standard washing procedures, the fabric size change rate is controlled within 1.5%, the color fastness reaches 4 levels, and the elastic retention rate reaches 92%. These data show that the fabric can maintain stable physical properties and appearance quality during repeated cleaning.

It is worth noting that factors affecting durability also include external environmental conditions and frequency of use. For example, in high humidity environments, TPU films may cause slight performance degradation due to hygroscopic expansion; while under frequent friction conditions, special attention should be paid to the wear of edges. To extend the life of the fabric, it is recommended to take appropriate maintenance measures such as regular cleaning and avoiding excessive stretching.

Material composition and production process

The production process of four-sided composite TPU fleece fabric is a complex and sophisticated process involving the selection of a variety of materials and the application of processing technologies. Its basic structure includes three main materials: the outer layer is made of high-strength polyester fiber, the middle layer is a thermoplastic polyurethane (TPU) film, and the inner layer is made of soft fleece. Each layer of materials is combined together through a special composite process to form a composite fabric with excellent performance.

Material selection and characteristics

The COCOON® series of polyester fibers selected from the outer layer are known for their excellent wear resistance and UV resistance, and can effectively resist the erosion of the external environment. The ELASTOLLAN® TPU film used in the middle layer has excellent elastic recovery and waterproof and breathable properties, ensuring that the fabric can maintain a comfortable wearing experience in all weather conditions.The POLARTEC® fleece material used in the inner layer provides the user with an ideal close-fitting feeling due to its excellent warmth and soft touch.

Production process

1. Pretreatment phase: First, pre-shrink the outer polyester fiber to remove stress in the fabric and ensure dimensional stability during subsequent processing. At the same time, the TPU film is surface-activated to improve its adhesive properties with other materials.

2. Composite molding: Use double-sided coating technology to combine the TPU film with the outer polyester fiber and the inner fleece base cloth. In this process, it is crucial to precisely control the coating thickness and bonding temperature. Infrared heating systems are usually used to melt the TPU film within the range of 180-220°C and closely bond with the base cloth.

3. Standing and Curing: The composite semi-finished product enters the shaping machine for thermal setting treatment to ensure a firm combination between the materials of each layer. The setting temperature is set between 140-160°C and the time is controlled between 30-60 seconds to obtain good physical performance.

4. Post-organization and processing: After completing the composite process, the fabric will be cleaned up after water splashing, stain-proofing, etc. Nano-grade fluorocarbon coating technology is used to impart excellent water and oil repellency to the fabric without affecting its breathability.

5. Quality Test: Each batch of products needs to undergo rigorous performance testing, including inspection of multiple indicators such as tensile strength, tear strength, wear resistance, and breathability to ensure the final product The quality meets the design requirements.

The design of this multi-layer composite structure not only improves the overall performance of the fabric, but also provides greater flexibility for its use in different application scenarios. For example, in winter outdoor activities, the thickness of the TPU film can be adjusted to optimize the warmth effect; in summer sports equipment, the breathable performance of the fabric can be strengthened.

Performance comparison and application scenario analysis

Four-sided composite TPU fleece fabric shows significant advantages in multiple key performance indicators compared with other similar materials. By comparing and analyzing the three mainstream functional fabrics – traditional fleece, one-way elastic TPU composite fabric and four-sided elastic TPU composite fleece fabric, we can understand its uniqueness more clearly.

Performance comparison analysis

From the data, it can be seen that the four-sided composite TPU fleece fabric is in the leading position in all performance indicators. Especially in terms of elastic range and wear resistance, its advantages are particularly prominent. This superiority is derived from its unique three-layer composite structure and advanced production processes, allowing the fabric to withstand higher mechanical loads while maintaining lightweight.

Application Scenario Analysis

Depending on different usage needs, four-sided composite TPU fleece fabric can be flexibly applied to a variety of professional fields:

1. High-end sportswear: In sports equipment such as yoga clothes and running clothes that require high elasticity and comfort, this fabric can provide all-round support and good breathability. Research shows that wearing sportswear made of such fabrics can significantly improve athletic performance and reduce muscle fatigue (Johnson & Lee, 2022).

2. Outdoor Adventure Equipment: For use scenarios such as ski suits and mountaineering suits, their excellent waterproofness and cold resistance have become key selling points. Experimental data show that under low temperature conditions of -30°C, the fabric can still maintain an elastic recovery rate of more than 95%, ensuring the wearer’s freedom of movement.

3. MedicalRehabilitation supplies: Due to its excellent elasticity and comfort, this fabric is also widely used in rehabilitation auxiliary products such as pressure clothing and knee pads. Its uniform pressure distribution characteristics help promote blood circulation and accelerate tissue repair.

4. Special protective equipment: In the fields of fire suits, rescue suits, etc., the high-strength wear resistance and flame retardant properties of this fabric have been fully utilized. By adding special coatings, the protection level can be further improved to meet the demanding working environment requirements.