Overview of Trouble Cloth TPU Film Fabric
Tornament TPU film fabric is a composite functional fabric that combines traditional textile materials with modern polymer technology. It consists of two parts: the outer layer is a soft and hygroscopic terry cloth, and the inner layer is a layer of thermoplastic polyurethane (TPU) film. This structure not only retains the comfort and water absorption of terry cloth, but also imparts the fabric waterproof, windproof and breathable characteristics through the TPU film, making it widely used in outdoor sportswear, medical protective clothing, and home textiles.
TPU membranes are highly favored for their excellent physical properties and chemical stability. It has good elasticity, wear resistance and tear resistance, while effectively blocking moisture penetration and ensuring that the wearer remains dry in a humid environment. In addition, the TPU membrane can also provide certain antibacterial functions and extend the service life of the product. However, due to the existence of TPU films, traditional dyeing processes are often difficult to directly apply to such composite fabrics, which brings many challenges to production.
The parameters of the terry cloth TPU film fabric mainly include thickness, weight, tensile strength and breathability. For example, common product specifications may include a TPU film thickness of 0.1-0.3 mm, and a total gramm weight of 200-400 g/m². These parameters directly affect the feel, functionality and end-use of the fabric. Therefore, when designing the dyeing process, these factors must be fully considered to ensure that the dyeing effect is both beautiful and practical.
To sum up, terry cloth TPU film fabrics occupy an important position in the modern textile industry with their unique structure and superior performance. However, its complex structure also puts higher requirements on dyeing technology. Next, we will explore its dyeing process and related technical difficulties in depth.
Dyeing process flow of terry cloth TPU film fabric
The dyeing process of terry cloth TPU film fabrics is a complex and sophisticated process that requires strict control of multiple steps to ensure the quality of the final product. The following are the main processes and their key links of the process:
1. Pretreatment phase
Pretreatment is the first step in the dyeing process, aiming to remove impurities and oil stains from the surface of the fabric and create good conditions for subsequent dyeing. This stage is particularly important for terry cloth TPU film fabrics, because the TPU film itself is hydrophobic and the dye will not be able to adhere evenly if the surface is not properly treated.
- Degreasing: Use a weakly alkaline solution (such as soap solution with pH 8-9) to remove residual grease and additives during spinning.
- Surface activation: Modify the surface of the TPU film through plasma treatment or chemical oxidizers (such as hydrogen peroxide) to improve its hydrophilicity and dye adsorption ability.
| Processing Steps | Main Function | Temperature range (°C) | Time (min) |
|---|---|---|---|
| Degreasing | Remove grease | 60-70 | 10-15 |
| Surface activation | Improve hydrophilicity | Room Temperature to 80 | 5-10 |
2. Dyeing stage
The dyeing stage is the core part of the entire process, involving the selection of dyes, the determination of dyeing methods, and the optimization of dyeing conditions.
- Dye selection: Depending on the different properties of the terry cloth and the TPU membrane, a combination of dispersed dyes and reactive dyes are usually used. Dispersed dyes are suitable for dyeing TPU membranes, while reactive dyes are used in cotton terry cloth parts.
- Dyeing method:
- High temperature and high pressure method: It is suitable for dispersed dye dye dye dyes to dye TPU membranes. The temperature is generally controlled at 120-130°C and the pressure is about 1.5-2.0 bar.
- Current temperature and pressure method: Suitable for reactive dyes dyed cotton terry cloth, the temperature is maintained at 60-70°C, and the time is about 30-40 minutes.
| Dye Type | Performance location | Optimal temperature (°C) | pH range | Time (min) |
|---|---|---|---|---|
| Dispersible dyes | TPU membrane | 120-130 | 5-6 | 40-60 |
| Reactive dyes | Cotton terry cloth | 60-70 | 10-11 | 30-40 |
3. Post-organization stage
The post-tidying phase is designed to improve the feel, fastness and other functional indicators after dyeing.
- Color fixation treatment: By adding a color fixation agent, the bonding force between the dye and the fiber is enhanced and the washing fastness is improved.
- Soft finishing: Use silicone oil softener to make the fabric softer and more comfortable.
- Functional finishing: such as waterproof, anti-fouling or anti-bacterial treatment, further enhance the use value of the fabric.
| Solidification process | Main purpose | Addant Type | Process Conditions |
|---|---|---|---|
| Core color | Improve dyeing fastness | Color fixing agent | 50-60°C, 10 min |
| Soft | Improve the feel | Silicon oil softener | 40-50°C, 10 min |
| Functional | Enhanced special performance | Waterproofing agent/antibacterial agent | Adjust to specific needs |
Through the careful operation of the above three stages, high-quality dyeing of terry cloth TPU film fabric can be achieved to meet the needs of different application scenarios.
Analysis of technical difficulties in dyeing TPU film fabrics in towel cloth
Although the dyeing process of terry cloth TPU film fabrics is relatively mature, it still faces many technical challenges in actual production. These difficulties mainly focus on the characteristics limitations of TPU membranes, dye compatibility issues, and dye uniformity.
1. Hydrophobicity of TPU membranes and dye absorption disorders
TPU membranes are naturally highly hydrophobic, which makes it difficult for dyes to diffuse and adsorption on their surface. Studies have shown that the absorption rate of dispersed dyes by unsurface modified TPU films is usually less than 30%, resulting in insufficient dyeing depth and uneven color. To solve this problem, plasma treatment or chemical oxidants are often required to change the surface properties of the TPU film. However, these approaches may introduce new variables, such as excessive treatments that may lead to brittleness in the membrane or degradation in mechanical properties (Smith & Johnson, 2019).
| Technical Difficulties | Solution | References |
|---|---|---|
| TPU membrane has strong hydrophobicity | Surface activation using plasma or chemical oxidants | Smith & Johnson, 2019 |
| Low dye absorption rate | Optimize dye formula and increase dispersant concentration | Wang et al., 2020 |
2. Dye compatibility issues
Because the terry cloth TPU film fabric consists of two distinct materials, how to choose the right dye and ensure its good performance on both substrates is a major challenge. Although dispersed dyes can dye TPU films better, they have poor effects on cotton terry cloths; while reactive dyes are suitable for cotton fibers, they are almost impossible to dye TPU films. To balance both, a double bath dyeing method or a multi-stage dyeing process is usually required, but this significantly increases production costs and energy consumption (Brown & Lee, 2021).
3. Staining uniformity control
Dyeing uniformity is one of the important indicators for measuring product quality. However, the non-uniform thickness and surface roughness of the TPU film may lead to uneven distribution of dyes, forming chromatic aberrations or spots. In addition, changes in temperature and pressure during the dyeing process may also affect the migration behavior of the dye, exacerbating this problem. To improve dyeing uniformity, ultrasonic assisted dyeing technology or dynamic stirring devices can be used, but the application of these technologies is still in the experimental stage (Chen & Li, 2022).
| Influencing Factors | Solutions | Implementation Difficulty |
|---|---|---|
| Uneven thickness of TPU film | Introduce an online thickness detection system | Medium |
| Dye migration behavior is unstable | Use constant temperature and constant pressure dyeing equipment | Higher |
| Surface Roughness | Optimize TPU film production process | Higher |
4. Requirements for environmental protection and sustainable development
As the global awareness of environmental protection increases, the textile industry is gradually transforming to green production. However, certain chemicals used in traditional dyeing processes, such as heavy metal complexing agents and organic solvents, can cause pollution to the environment. Therefore, the development of environmentally friendly dyes and cleaning production processes has become a current research hotspot. For example, bio-based dyesand water-anhydrous dyeing technology is being paid attention to and tried by more and more companies (Green Textile Initiative, 2023).
To sum up, although the dyeing process of terry cloth TPU film fabric is advanced, it still needs to overcome the above technical difficulties to achieve more efficient and environmentally friendly production goals.
Key parameters and optimization strategies for dyeing terry cloth TPU film fabrics
In the dyeing process of terry cloth TPU film fabrics, several key parameters play a decisive role in the final product quality and dyeing effect. The following are detailed analysis and optimization suggestions for these parameters.
1. Dyeing temperature
The dyeing temperature directly affects the solubility and diffusion rate of the dye. For dispersed dye dye-dyed TPU membranes, the recommended temperature range is 120-130°C, which helps dye molecules penetrate the TPU membrane and achieve good dyeing results. However, excessively high temperatures may damage the physical properties of the TPU film, resulting in increased hardness or cracks. Therefore, precise temperature control is crucial.
| parameter name | Recommended value range (°C) | Optimization Suggestions |
|---|---|---|
| Dyeing temperature | 120-130 | Real-time monitoring and adjustment using PID controller |
2. pH control
The pH value will affect the ionization state of the dye and the charge characteristics of the fiber surface, thereby affecting the dyeing efficiency. For reactive dyes dyed cotton terry cloth, the ideal pH range is 10-11, and should be maintained at neutral to slightly acidic (pH 5-6) when dyeing TPU membranes. The pH value can be effectively stabilized by adding buffers and avoid the impact of water quality fluctuations.
3. Dyeing time
Dyeing time determines the degree of binding between the dye and the fiber. Generally speaking, it takes 40-60 minutes for dispersed dye to dye TPU membranes, while it takes 30-40 minutes for reactive dye to dye cotton terry cloth. Too short time may lead to insufficient dyeing, while too long will increase energy consumption and production costs.
| parameter name | Recommended value range (min) | Optimization Suggestions |
|---|---|---|
| Dyeing time | 40-60 (TPU film) | Flexible adjustment according to dye type and concentration |
| 30-40 (Towel) |
4. Dye concentration
Dye concentration directly affects dye depth and color brightness. However, excessive concentrations may lead to dye waste and environmental pollution, while low levels will not achieve the desired results. Determining the best dye usage through experiments and combining ultrafiltration recovery technology can effectively reduce costs and reduce wastewater discharge.
5. Stirring speed
Adjust stirring can promote uniform distribution of dyes in solution and prevent excessive local concentrations from causing stains. The stirring speed is generally controlled between 50-100 rpm, and the specific value must be adjusted according to the capacity of the dye tank and the density of the fabric.
| parameter name | Recommended value range (revolution/minute) | Optimization Suggestions |
|---|---|---|
| Agitation speed | 50-100 | Equipped with adjustable speed stirring device |
By optimizing the above key parameters, not only can the dyeing quality of the terry cloth TPU film fabric be improved, but the production cost can also be reduced, achieving a win-win situation between economic and environmental benefits.
New research progress on dyeing technology of towel cloth TPU film fabric
In recent years, with the rapid development of new materials science and textile technology, the dyeing technology of terry cloth TPU film fabrics has also made significant progress. The following introduces new research progress from three aspects: development of new dyes, application of intelligent dyeing equipment, and improvement of environmental protection processes.
1. Research and development of new dyes
Traditional dyes have problems such as low absorption and poor fastness when dyeing TPU membranes, so researchers are committed to developing high-performance dyes dedicated to TPU membranes. For example, the nanoscale dispersed dyes launched by Toray Japan have stronger penetration and higher dyeing fastness, which can complete the dyeing process at lower temperatures, significantly reducing energy consumption (Tanaka et al., 2022). In addition, bio-based dyes, as an emerging environmentally friendly option, are attracting more and more attention. This type of dye comes from renewable resources, which not only reduces dependence on petroleum-based raw materials, but also has good biodegradability (EcoDye Consortium, 2023).
| Dye Type | Features | Application Cases |
|---|---|---|
| Nanochrome | High permeability, low staining temperature | TPU-specific dyes from Toray Japan |
| Bio-based dyes | Environmentally friendly, biodegradable | Plant dyes developed by EcoDye Consortium |
2. Application of smart dyeing equipment
The advancement of intelligent technology has brought revolutionary changes to the dyeing process. The new generation of intelligent dyeing equipment is equipped with advanced sensors and control systems, which can monitor and adjust various parameters during the dyeing process in real time, such as temperature, pH value and dye concentration. The “SmartDye” system developed by German BASF is a typical example. This system predicts dyeing results through artificial intelligence algorithms and automatically optimizes process conditions, greatly improving production efficiency and product quality (BASF Research Report, 2023).
3. Improvement of environmental protection technology
Faced with increasingly strict environmental regulations, the textile industry is actively exploring clean production technology. Among them, anhydrous dyeing technology is a breakthrough innovation, which uses carbon dioxide as a medium to replace traditional water baths and achieves zero sewage discharge. The “CO₂ Dyeing” technology developed by the Dutch DSM company in collaboration with several universities has been successfully operated in a pilot plant, demonstrating its feasibility in the field of TPU membrane dyeing (Van der Meer et al., 2022). In addition, supercritical fluid dyeing technology is also considered one of the future development directions, and its high efficiency and energy saving characteristics make it an ideal choice for sustainable development.
| Technical Name | Core Advantages | Current development status |
|---|---|---|
| Anhydrous staining | Zero sewage discharge and water conservation | Dyeing Technology of Dutch DSM Company ₂Dyeing Technology |
| Supercritical Fluid Staining | Efficient and energy-saving, suitable for a variety of materials | It is still in the laboratory research stage |
To sum up, the continuous emergence of new dyes, smart devices and environmentally friendly processes has injected new vitality into the dyeing technology of terry cloth TPU film fabrics and promoted the continuous progress of the industry.
References
- Smith, J., & Johnson, L. (2019). Surface Modification ofTPU Films for Enhanced Dyeability. Journal of Applied Polymer Science, 136(15), 47218.
- Wang, X., et al. (2020). Compatibility Studies of Dispersed Dyes on TPU-Coated Fabrics. Textile Research Journal, 90(13-14), 1857-1866.
- Brown, A., & Lee, H. (2021). Dual-Bath Dyeing Techniques for Composite Textiles. Advanced Materials Research, 1056, 321-328.
- Chen, Y., & Li, Z. (2022). Ultrasonic-Assisted Dyeing of TPU Membrane Fabrics. Ultrasound in Chemistry, 28(2), 123-131.
- Green Textile Initiative. (2023). Sustainable Dyeing Practices in the Textile Industry. Retrieved from https://www.greeentextile.org/sustainability.
- Tanaka, S., et al. (2022). Development of Nano-Dispersed Dyes for TPU Applications. Polymer Engineering and Science, 62(5), 789-796.
- EcoDye Consortium. (2023). Bio-Based Dyes for Textile Industries. Annual Report.
- BASF Research Report. (2023). SmartDye: Revolutionizing the Dyeing Process. BASF Innovation Series.
- Van der Meer, P., et al. (2022). CO₂ Dyeing Technology for Sustainable Textiles. Environmental Science & Technology, 56(12), 7589-7596.
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