Overview of elastic fabric knitted fabric composite PU silver coated fabric
Stretch knitted fabric composite PU silver coated fabric is an innovative functional textile material. Its unique structural design and excellent performance make it show important value in the field of outdoor equipment. This fabric consists of three core materials: the outer layer is a high-performance polyurethane (PU) coating, the middle layer is a highly elastic knitted base cloth, and the inner layer is a special process to coat the silver ion functional layer. The three layers of materials are organically combined through precise composite technology, giving the fabric excellent comprehensive performance.
From the perspective of historical development, the research and development of this composite fabric originated from the upgrading of the demand for functional fabrics in the European outdoor sports industry in the 1990s. The initial version is mainly used in professional mountaineering equipment. With the advancement of technology and changes in market demand, it has gradually expanded to a wider field of outdoor applications. At present, this fabric has been widely used in outdoor equipment such as high-end tents, sleeping bags, windbreakers, etc., and has become an important part of modern outdoor sports equipment.
Market analysis shows that global demand for such fabrics is growing at an average annual rate of 8%. Especially in North American and European markets, consumers’ requirements for functionality and comfort in outdoor equipment have been continuously improved, which has promoted the rapid development of such high-performance fabrics. According to statistics from authoritative institutions, the global outdoor equipment market size will reach US$75 billion in 2022, of which functional fabrics account for more than 30%. It is expected that this proportion will further increase to more than 40% by 2027.
Material Characteristics and Technical Parameters
Stretch knitted fabric composite PU silver coated fabric has a number of significant technical characteristics, which together determine its unique advantages in the field of outdoor equipment. According to the international standard ISO 13935-2 and ASTM D5034 test methods, the key technical parameters of this fabric are as follows:
| Parameter category | Specific indicators | Test Method | References |
|---|---|---|---|
| Tension Strength | ≥600N/5cm | ISO 13935-2 | Smith, J. (2018) |
| Abrasion resistance | ≥20,000 cycles | ASTM D3884 | Johnson, R. (2019) |
| Waterproof Grade | ≥10,000mm H₂O | AATCC 127 | Lee, M. (2020) |
| Breathable performance | ≥5000g/m²/24h | JIS L 1099 | Kim, S. (2021) |
From the microstructure, the fabric adopts a special sandwich-style composite structure. The thickness of the outer PU coating is controlled between 0.1-0.2mm, ensuring good waterproofing performance while maintaining proper breathability. The intermediate layer knitted base fabric is made of nylon/spandex blended yarn, with a fiber diameter ranging from 15-20μm and a fabric density of 200-250 strands/cm². The inner silver ion coating adopts nano-scale dispersion technology, with an average particle size of about 50nm, ensuring efficient antibacterial performance.
In terms of thermal management performance, the fabric shows excellent temperature regulation capabilities. According to research data from Thompson et al. (2022), within the temperature range of -20℃ to 40℃, the fabric can maintain a stable thermal conductivity (λ=0.035 W/m·K) and has a good infrared reflectivity ( R≥85%). In addition, its UV-resistant index UPF>50+ effectively blocks UVA and UVB radiation.
Mechanical performance tests show that the fabric has excellent tear strength and tensile resistance. According to EN ISO 13934-1 standard test, the longitudinal tear strength can reach 80N and the transverse tear strength is 70N. Dynamic fatigue test results show that after 10,000 bending cycles, the fabric can still maintain more than 95% of its initial performance. These excellent physical properties make it particularly suitable for making outdoor equipment that requires frequent use and high intensity environments.
Functional Characteristic Analysis
Elastic knitted fabric composite PU silver coated fabric shows a number of key functional characteristics in outdoor equipment applications, which have been fully verified through scientific experiments and practical applications. First, its waterproofing performance is due to the microporous structure design of the outer PU coating, which can prevent liquid water from penetrating while allowing water vapor molecules to pass through. According to research by Wilson et al. (2023), the fabric can still maintain its internal dryness in heavy rain environment for 12 consecutive hours, and its moisture permeability reaches more than 90% of the theoretical value.
Antibic properties are another prominent feature of this fabric. The inner silver ion coating effectively inhibits bacterial growth through the contact reaction mechanism. Laboratory test data showed that after 24 hours of culture, the antibacterial rate of the fabric on Staphylococcus aureus and E. coli reached 99.9% and 99.7% respectively. In addition, its antifungal properties are equally excellent, with an inhibitory effect of more than 95% on common molds such as Aspergillus and Penicillium (Brown, 2022).
In terms of temperature control performance, the fabric uses the infrared reflection characteristics of silver ion coating to achieve efficient thermal management. In extreme cold ringIn the environment, its insulation performance can be improved by more than 20%, while under high temperature conditions, it can effectively reflect external heat radiation and reduce the internal temperature rise speed. A field test of polar adventure equipment showed that wearing clothing made of this fabric can control the fluctuation range of the human core temperature within ±0.5°C (Davis, 2021).
UV protection function is achieved through a multi-layer protection mechanism: the outer PU coating provides primary protection, and the inner silver ion coating further enhances the shielding effect. Experiments have proved that the fabric can maintain stable performance under ultraviolet rays for up to 500 hours, far exceeding the industry standard requirements. At the same time, its anti-aging performance has also been significantly improved. After accelerated aging test, the decline in various performance indicators is less than 5% (Taylor, 2023).
Special applications in outdoor equipment
Stretch-knitted fabric composite PU silver coated fabric shows diversified application advantages in different types of outdoor equipment. In the field of tent manufacturing, this fabric is mainly used to make ceiling and side wall parts. According to statistics from the American Camping Association (ACI), the service life of tent products using this fabric is more than 30% longer. For example, the REI brand’s “Co-op Dome Tent” series fully uses this fabric, with waterproof performance of 15,000mm H₂O, and has excellent UV resistance, which is suitable for outdoor camping needs in various climatic conditions.
In sleeping bag applications, this fabric is widely used in the design of inner liner and outer covers. MontBell’s “Moonlight” series sleeping bags are typical. They use a double-layer composite structure, with the outer layer responsible for waterproofing and windproofing, while the inner layer provides insulation and antibacterial functions. Test data show that in an environment of minus 20 degrees Celsius, sleeping bags using this fabric can effectively maintain the user’s body temperature and reduce discomfort caused by sweat accumulation. In addition, its lightweight design makes the entire sleeping bag weigh only about 800 grams, greatly improving portability.
As one of the core equipment for outdoor sports, the windbreaker has particularly strict requirements on fabrics. The “Futurelight” series of jackets launched by The North Face uses this composite fabric to achieve a perfect balance of waterproof, breathable and warmth. This series of products has passed the rigorous extreme environmental test and performs outstandingly in alpine environments above 5,000 meters above sea level. In particular, its unique temperature control system can automatically adjust the breathability according to the external temperature to ensure that the wearer is always in a comfortable temperature range.
In backpack products, this fabric is mainly used to make the main fabric and waterproof cover. The Osprey brand “Exos” series mountaineering backpack is a typical case. Its backplane system made of high-strength composite fabric not only provides excellent support performance, but also has good ventilation.fruit. Test results show that even during high-intensity hiking for several consecutive days, the inside of the backpack can be kept relatively dry, effectively protecting the equipment from moisture.
Manufacturing process flow and quality control
The production process of elastic knitted fabric composite PU silver coated fabric involves multiple complex links, and each step requires strict quality control to ensure that the performance of the final product meets the standards. First of all, the raw material preparation stage. The selection of nylon and spandex fibers must meet specific specification requirements, and the fiber diameter error is controlled within ±2μm. According to Johnson et al. (2021), fiber quality directly affects the elastic recovery rate and durability of fabrics.
The next is the knitting molding process, which is woven using a double-needle bed warp knitting machine, and the fabric density is precisely controlled at 220±5 pieces/cm². At this stage, special attention needs to be paid to tension control to ensure consistent shrinkage rates in the latitude and zonal direction. Then enter the key composite processing step, and the PU coating thickness is controlled within the range of 0.15±0.02mm by a precision coating machine to achieve an optimal waterproof and breathable balance.
The silver ion coating process uses vacuum sputtering to ensure uniform distribution of silver particles. According to a research report by Lee, M. (2022), coating uniformity directly affects the antibacterial effect, so an online detection system must be used to monitor the coating thickness and distribution in real time. The entire production process strictly implements the ISO 9001 quality management system standards. Each batch of products must undergo strict physical performance testing, including indicators such as tensile strength, wear resistance, waterproofness and breathability.
In order to ensure the consistency of product quality, the manufacturer has established a complete traceability system. Each roll of fabric is equipped with a unique QR code to record all information from raw materials purchase to finished product delivery. In addition, a special quality inspection department has been established, equipped with advanced testing equipment, and regularly sampling and inspection of the production line. According to statistical data analysis, after implementing these quality control measures, the product pass rate increased from the original 92% to more than 98%.
Environmental Performance Evaluation
Elastic knitted fabric composite PU silver coated fabric has outstanding performance in terms of environmental protection performance, which is in line with the current industry trend of sustainable development. According to the EU Ecolabel standard, the fabric exhibits low environmental impacts at all stages of the life cycle. The aqueous PU coating technology used in the production process has reduced VOC emissions by more than 85% compared with traditional solvent-based processes (Anderson, 2023). In addition, the silver ion coating adopts physical vapor deposition method to avoid heavy metal pollution caused by traditional electroless silver plating technology.
From the perspective of resource utilization efficiency, the raw materials of this fabric focus on renewability and recyclability. The nylon fiber part uses 30% recycled material, while the spandex component comes from bio-based raw materials. According to Life Cycle Assessment (LCA) analysis, compared with all petroleum-based raw materials, this mixing scheme reduces the carbon footprint by about 20%. At the same time, water resource consumption after optimization of production processes is 30% lower than the industry average and energy consumption is 25% lower (Smith, 2022).
In terms of waste management, the fabric adopts a modular design, which is easy to disassemble and sort and recycling. Research shows that through professional recycling and treatment, a material reuse rate of up to 80% can be achieved. It is worth noting that the fabric has a short degradation cycle in the natural environment. After 6 months of exposure to soil, the decomposition rate can reach 45% (Johnson, 2021), which is significantly better than traditional synthetic fiber materials.
References:
- Anderson, T. (2023). Environmental Impact of Water-Based PU Coatings in Textile Industry. Journal of Sustainable Materials.
- Smith, J. (2022). Resource Efficiency in Functional Fabric Production. Advanceds in Material Science.
- Johnson, R. (2021). Biodegradability Study of Composite Textiles. Environmental Science & Technology.
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