Knitted Spacer Fabric - Manufacturing Techniques and Application
Knitted Spacer Fabric - Manufacturing Techniques and Application
Knitted Spacer Fabric - Manufacturing Techniques and Application
com
Abstract
Spacer fabrics are 3D fabrics that comprise of two outer textile substrates that are joined
together and kept apart by an insert of spacer yarns, mostly monofilaments. This creates a
ventilated layer of air, allowing heat and moisture to escape. One reason for development
of spacer fabrics was an attempt to replace toxic, laminated-layer foam with a single,
synthetic fibre type fabric, thus facilitating future re-cycling. An important advantage is
the low weight in proportion to the large volume. The application areas of spacer fabric are
unlimited ranging from healthcare, safety, military, automotive, aviation and fashion.
Currently it is being largely used for functional clothing comprising sports shoes, bra cups,
shoulder pads, knee and elbow protectors etc.
This paper deals with the manufacturing and applications of spacer fabrics and the
developments in this field.
Introduction
As the textile complex is faced with increasing competition, innovation and specialization
have been employed by many machinery and product manufacturers to create a niche in
the marketplace. In an effort to compete and appeal to the end-use market, products that
go beyond the current range of performance and style have been developed [1].
Through continuous improvement of both the technology and the produced fabric quality,
both warp and weft machines are now capable of producing spacer fabrics to the very
highest standard of quality for a wide range of applications. Using new possibilities and
improved machine technology, spacer fabrics have already become an established feature
of many of the fabric collections presented by our international customer base.
construction can alter the amount of air incorporated in the assembly [3].
The yarn material used to join the plain ground fabric at the front side and the plain
ground fabric at the backside with a defined “space” is mostly a stable, pressure tolerant
material. Spacer fabrics are breathable, resilient, flexible, and soft. They come in a variety
of weights, colors, textures, and designs.
Spacer structures offer more extensive conditions for varied application, as their stable 3D
structure encompasses scope for distinctive design and possess special physical attributes
[4], which are:
Filament 20-45/
Polyamide 6 1.14 109-1011 215-220 3.5-4.5 10-15
s 105-125
Filament 20-30/
Polyester 1.38 1011 -1014 250-260 0.2-0.5 3-5
s 100-105
Filament 10-30/
Viscose 1.52 106-107 175-190 12-14 85-120
s 100-130
20-50/
Cotton Fibres 1.55 Low --- 7-18 42-53
100-120
Followings are the knitting techniques used to manufacture spacer fabrics [3]-
• Warp Knitting
• Weft Knitting
• Flat Bed knitting
Through its unique manufacturing process, many different properties can be incorporated
into the fabric to meet individual specifications [5]
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• Variable thickness
• Variable compression
• Rigid or Conformable construction
• Varying degrees of open or closed knit
• Waterproofing on one or both sides
Warp knitted spacer fabrics consist of two separate fabrics linked by more or less stiff
spacer yarns, generally monofilaments. The height of the space in the structure is
determined by the set distance between the knock-over combs. The force with which the
two fabric faces are kept apart is determined by the count of the spacer yarns, and also
whether one guide bar is used or whether two guide bars are used in counter notation [6].
Knitting Techniques
Three different yarns are required to produce each course. These yarns are yarn for dial
needles, yarn for cylinder needles and spacer yarn. Two different techniques for knitting
these three yarns are described below:
Fig3. Tucking on dial and cylinder needles Fig4. Knit/plating on dial and tuck on
cylinder
• Plain as well as color and design and surface texture effects can be produced on the
face of the fabric knitted by the cylinder needles
• Various Shaped and true three-dimensional structures can be produced on
electronically controlled flat machines.
Limitations
i. Weft knitted spacer fabric is somewhat heavier, thinner and denser than the warp
knitted fabric.
ii. Warp knitted spacer fabrics show a higher thermal insulation in both dry and wet
conditions.
iii. The thermal absorption properties of warp knitted fabric are lower than the other
fabric, which signifies that relatively the former is warmer to touch as compared to
the weft knitted fabric, particularly when the fabrics have been wetted with water.
iv. The water vapour permeability and resistance to evaporative heat loss properties of
weft knitted fabrics are superior to warp knitted spacer material; therefore the
former will be relatively more comfortable to wear next to the skin during a
strenuous activity.
v. Both spacer fabrics are more or less identical in their tenacity, breaking extension
and initial modulus properties.
vi. The absorption capacity and the wicking characteristics of the warp knitted spacer
fabric are substantially superior to the weft knitted fabric. These may be due to two
reasons:
a. Warp knitted spacer fabric is much more bulkier than the weft knitted spacer
b. Textured polyester yarn was used in the warp knitted spacer fabric for the
face and back fabrics whereas flat multifilament polyester yarn was
employed in the weft knitted fabric for the two faces of the fabric.
Monofilament was used in both cases as the spacer yarn.
The Flat Knitting technology has been able to step out of its original areas of application.
There is a growing interest in the technology, since the specific quantities of fabrics knitted
on such machines as well as the exceptional way of production have been recognized for
new technical particularly medical applications.
Out of various forms of knitted fabrics, the V-bed arrangement allows production of spacer
fabric, which is a tubular fabric construction with tuck stitch connections. The production
of spacer fabrics is supported by positively controlled sinkers on both needle beds, which
press down the last row of stitches during the formation of new stitches or other knitting
operations [2].
Characteristics
• The thickness which can specifically be designed, depending on the gauge of the
machine and the material selection (i.e. 4-4.5mm of thickness for a fabric coming
from a machine of gauge E 14)
• The different degrees of softness, which can be set in dependence of the angle of the
inlaid tuck stitch and the chosen material.
• The special fabric construction, which allows an excellent drapability; the fabric
tends to keep the form, it is brought in.
• The shaping ability similar to the regular fully-fashioned knitwear pieces. The
spacer fabrics can also be knitted to shape.
Applications
• Support fabrics in casting elements, which are used to support and fix broken limbs
in defined positions.
• Incontinence pads made out of superabsorbent fibres.
• Special, ready to wear bandages with impregnated areas of curing emulsions.
3-D textiles provide a perfect structure for car interiors because of softness, comfort,
breathability, upholstery properties and aesthetic functions. They can be produced by two
needled warp knitting, weft knitting, and flat knitting. Processing methods such as back
spraying, back lining and laminating play an important role to impart required properties.
For the seat comfort researchers investigated the possibilities of spacer fabrics for seat
covering applications. The electronic jacquard machine was used for the development of
the fabric. Initially, the research engineers developed fabric surfaces and designs similar to
the appearance of fabrics used today for the manufacture of car seat covers. These fabrics
have capability to completely replacing polyurethane foam lamination in the vehicle seat
through the integration of PES monofilaments. The foam has drawbacks like flammability,
lack of compression and resilience and delamination. The polyester materials performed.
Sports and athletics have been increasing worldwide, as has for athletic apparel. In order
to maximize the comfort and performance both moisture and temperature must be
managed. This is possible with spacer fabrics. Spacers can offer different attributes like the
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layer closest to the skin can be hydrophobic, the middle can be used for diffusion, and the
outer layer can be hydrophilic thereby absorbing and evaporating heat energy. Spacer
fabrics are also used in sports shoes because they are lightweight, high bulk, springy,
washable, and a superior substitute for laminated foam. Gehring Textiles in St. Johnsville,
NY makes a spacer fabric used in sliding shorts for baseball players.
Lingerie [16]
In the lingerie area too, spacer fabric has created a revolution of sorts and due to its
comfort and moisture management/ wicking properties a number of companies are using
it to create various lingerie collections, particularly brassieres. These brassieres are
modified double knit structures in which both faces are joined during knitting process and
require no further addition of foam or laminating aids.
Properties such as heat and moisture regulation associated with both warp and weft
knitted fabrics are ideal for use in medical textiles. An important field of application is
wound care and prevention of chronic wounds, in particular pressure sores. There is a
huge market for bandages and wound dressings. Spacer fabrics offer far superior
characteristics to those of textile composites such as woven or nonwovens for medical
applications such as orthopaedics, prevention of decubitus for the long -term bedridden,
for surgical applications and convalescence, as well as for incontinence products. Other
medical uses are Warp-knitted spacer fabrics for pressure relief, Multilayer compression
stocking or bandage system, Bandage for the ankle joint, Absorbent diaper with
therapeutic orthopaedic pad
Other promising applications in prospect for spacer fabrics are opening up in the field of
protective and sports clothing e.g. linings for firefighters' protective suits. The 3-D
construction of the textile means that an insulating layer of air is formed between the two
outer surfaces of the textile, which protects the wearer from the effects of heat, while at the
same time guarantees that the garment is both breathless and comfortable. The
flammability tests showed that the flame-resistant fabrics can be used both in protective
clothing for firefighters as well as for mattress covers in the medical care sector, whereby
their functional characteristics are not only determined by the use of flame-resistant
materials alone. Their good compression behavior, moisture conductivity and
thermoregulatory properties are also important criteria for guaranteeing physiological
comfort.
Some analysts predict that these fabrics will replace neoprene in sports medicine
applications such as shoulder pads, and knee/elbow protectors.
References
1. www.tx.ncsu.edu/jtatm/volume4issue4/vo4_issue4_abstracts.htm
2. M.Heide, “Spacer fabrics with specific protective characteristics”, Melliand
International, Vol. 6, June 2000, Pg 132-134.
3. “Spacers-At the Technical Frontier”, Knitting International, July 2003, Pg 38-41.
www.fibre2fashion.com
4. www.baltex.co.uk
5. www.heathcoat.co.uk
6. “RD 6N Raschel machine for spacer structures- product-oriented and highly
productive”, Kettenwirk-praxis, 4/94, Pg E3-E4.
7. www.karlmayer.de
8. Walter Schmidt, Krems, “The newly developed APL plush circular knitting machine”,
Knitting Technique, 14(1992) 3, Pg 163-169
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4/2001, Pg 14-16
10. “Spacers-At the Technical Frontier”, Knitting International, July 2003, Pg 38-41.
11. http://automotivetextiledesign.blogspot.com/2009/03/3d-spacer-fabrics.html
12. Dr Rangaswamy Venkatraj, “Double needle bar warp knitted patterns”, The Indian
Textile Journal, March 1997, Pg 66-74
13. www.terrot.de/aktuelles/en/berichte
14. http://ara-texworld.com/index.php?view=article&catid=163%3Aindustrial-
fabric&id=307%3Aknitting-fabrics-for-industrial-application-
&tmpl=component&print=1&page=&option=com_content
15. http://www.inteletex.com/FeatureDetail.asp?PubId=&NewsId=191
16. www.faqs.org/patents/app/20080261490
17. Davies A et al, “The Use of Spacer Fabrics for Absorbent Medical Applications”,
Journal of Fiber Bioengineering and Informatics, Vol.1 No. 4 2009, pp321-330.
18. http://www.tx.ncsu.edu/ci/homeland/article_details.cfm?
19. http://www.human.cornell.edu/che/TXA/Outreach