Technical Application of TPU in Rolling Process——Guangyuan Ruifeng New Materials

Category: TPU (popular science, no product)

Release Time: 2020-06-05

Summary: PVC has always been the primary material used in calendering processes. Its softness and hardness can be easily adjusted using plasticizers, and a large number of fillers, additives, and lubricants can be added to improve certain properties and control costs. However, the addition of large amounts of plasticizers not only poses health risks to production line workers, but the emitted VOCs (volatile organic compounds) also affect air quality.

PVC has always been the primary material used in calendering processes. Its hardness can be easily adjusted using plasticizers, and a large number of fillers, additives, and lubricants can be added to improve certain properties and control costs. However, the addition of large amounts of plasticizers not only poses health risks to production line workers, but the emitted VOCs (volatile organic compounds) also affect air quality. (TPU Leather)

I. TPU Calendering

Thermoplastic polyurethane elastomer (TPU) is a polymer material formed by the polymerization reaction of diphenylmethane diisocyanate (MDI) containing NCO functional groups, macromolecular polyols, and chain extenders. Its molecular structure is composed of alternating rigid segments obtained from the reaction of diphenylmethane diisocyanate (MDI) and chain extenders, and flexible segments obtained from the reaction of diphenylmethane diisocyanate (MDI) and macromolecular polyols. By using different raw materials and adjusting the proportions, engineers can make TPU elastomers have excellent resilience and physical properties. Coupled with its excellent mechanical strength, TPU elastomers have gradually replaced PVC in applications in the pipe, cable, and conveyor belt industries in recent years. (TPU Leather)

In the past, TPU elastomers could not be produced through calendering and were considered unsuitable for calendering production. The main reasons are: high torque during TPU processing, which easily damages drive shafts and causes equipment overload; the sticky nature of the TPU plasticization process, leading to adhesion to processing equipment and conveyor belts; and the narrow processing range of TPU, which does not meet the open nature of calendering processing. Therefore, TPU elastomers have been widely used in extrusion, blow molding, film casting, and injection molding processes, while the application of TPU in calendering processes is rarely heard of, limiting the product applications of TPU in the calendering field. (TPU Leather)

II. TPU Calendering Forming Process

Calendering is a multi-task, continuous production process with high production efficiency, large output, and online composite advantages. Although it is slightly more complex than other processes, once the production conditions are mastered, its productivity is the highest of all processes, reaching 800-1000 kg per hour, which is unmatched by other processes. (TPU Leather)

In terms of plasticization, the strong shearing action of the kneader (or high-power machine) ensures that the components of TPU are fully sheared, mixed, and melted, achieving uniform mixing and temperature distribution of the raw materials. In terms of feeding, an open mill and extruder are used, and the plasticized material is fed to the calendering machine through a transfer device, achieving replasticization. In terms of calendering, a calendering machine adjusts the roller gap within the set temperature gradient to press and extrude TPU into a film or sheet of the predetermined size, or it can be combined with a base fabric for online composite to obtain a composite fabric product. In terms of embossing, an embossing roller and a rubber roller work together to give the product surface a certain texture, which is then cooled and shaped by a cooling roller, cut, and wound. (TPU Leather)

III. Applications of TPU Calendered Products

Through improvements in TPU elastomer properties, the limitations of past calendering processes have been overcome. The biggest advantage of using TPU elastomers in calendering processes is the ability to produce online TPU composite materials. TPU composite materials are made by combining TPU film with various fabrics to form a composite material, combining the characteristics of both to create a new type of fabric. (TPU Leather)

In the past, TPU composite materials were made using a post-lamination method, where TPU film was first made and then laminated to the fabric with adhesive. This involved purchasing TPU film externally and then laminating it. Online composite, on the other hand, means that the fabric is pre-coated with adhesive or not, and the TPU film is directly laminated to the fabric using a calendering process to create TPU composite materials or products such as mesh fabrics and leather. (TPU Leather)

TPU calendered products are mainly used in synthetic leather (artificial leather). The rubber (film) is mainly used in life jackets, diving jackets, inflatable boats, tents, inflatable mattresses, airbags, and waterproof backpacks; synthetic leather/artificial leather is mainly used in sofa seats, wall decoration, sports mats, luggage, car interiors, and boat seats. (TPU Leather)

Guangan Ruifeng New Materials Co., Ltd. specializes in the production of TPU leather. We have mature production processes and can definitely meet your needs.

Keywords: Technical Application of TPU in Rolling Process——Guangyuan Ruifeng New Materials

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