Knitted Spacer Fabric - Manufacturing Techniques and Application

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Spacer fabrics are 3D fabrics that provide ventilation and insulation. They are lightweight, breathable, and flexible with a variety of potential applications.

Spacer fabrics are fabrics made of two outer layers joined by spacer yarns or fibers to create an insulated middle layer of air for ventilation.

The main knitting techniques used are warp knitting, weft knitting, and flat bed knitting. These techniques can be varied to control properties like thickness, compression, rigidity, and porosity.

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Knitted Spacer Fabric – Manufacturing Techniques and


Application

By: Palash Paul & D P Gon


Department of Textile Technology, Panipat Institute of Engineering &
Technology, Pattikalyana, Samalkha, Panipat.

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.

As far as technical textile is concerned, current tendency of the market to become


saturated, and in the light of fierce international competition in the clothing, home and
household textile markets, the textile industry is becoming increasingly interested in new
technologies. Knitted spacer fabric represents a special product group within this sector
because of their excellent crush resistance, breathability, and 3D appearance. [2]

What is Spacer Fabric?

Spacer structures are fabric constructions


comprising two separate fabric webs, which
are joined together by spacer threads or
fibres of varying rigidity. The intermediate
zone creates a layer of air, which has an
insulating and thermoregulatory effect.
Modifying the structure of the knitted
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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.

How Spacer Fabrics are different from Conventional Fabrics?

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:

• Lightweight, soft, pleasant on the skin


• Offer active breathing properties
• Pressure-elastic
• Transport and absorb moisture
• Definable elasticity properties
• Thermo-regulating properties
• Wash-resistant
• Ageing resistant and capable of sterilization

Properties of Fibres used in Spacer Fabrics

Sp. Electric Water Water


Fiber Density Extension % Melting
Fiber Resistance, Sorption Holding,
Type (g/cm3) Dry/wet Point,°C
Ω/cm (%) %

Filament 20-45/
Polyamide 6 1.14 109-1011 215-220 3.5-4.5 10-15
s 105-125

Polyamide Filament 20-40/


1.14 109-1011 225-260 3.5-4.5 10-15
6,6 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

Knitting Techniques of Spacer Fabric Manufacturing

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

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 Construction [7]

In warp knitting the needle bars are operating alternately


and the guide bars swing between the needles of each
needle bar in turn. Each guide bar shogged to make an
overlap on each needle bar and so form knitted loops on
the selected needle bar and a warp-knitted fabric is
produced. Guide bar 1 is fully threaded and overlaps
needle bar1. Guide bar 4 is also fully threaded and overlaps
needle bar 2. Guide bars 2 and 3, which are threaded with
spacer thread, overlap both needle bars. This way a warp
knitted spacer fabric is formed.
Features of Warp Knitted Spacer Fabric [8]

• Selectable spacing distance


• Permanent elasticity
• Durable elastic force
• Good sound insulating properties due to porous surface
• Saving in raw materials due to the entrapped air
• Reasonable price because material consumption is lower
• Easy to dispose of and environmentally friendly

Weft Knitted Spacer Fabrics [9, 10]

Spacer fabrics can be produced on circular double jersey


machines as well as electronically controlled flat machines.
The spacer threads are generally made of PES or PA
monofilament yarns. The threads of the dial and cylinder
stitches are made of textured PE filament yarns, depending
on their intended field of application. The degree of space or
height between the two fabric faces is determined in the
circular knitting machine by the setting of the dial and
height relative to the machine cylinder. Spacer fabrics preset
in this way can vary between 1.5 and 5.5mm. The majority of
spacer fabrics are currently produced using 8-lock circular
knitting machines as it still offers the greatest scope for design versatility.
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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:

1. Tucking on dial and cylinder needles at the same feeder (Fig 3)


a. Tucking on dial and cylinder needles on feeders 1 and 4 (monofilament spacer
yarn) on low and high butt needles alternately
b. Knitting dial needles with dial yarn at feeders 2 and 5 on low and high butt
needles alternately
c. Knitting cylinder needles with cylinder yarn at feeders 3 and 6 on low and high
butt needles alternately

2. Knitting/plating on the dial needles and knitting on cylinder needles (Fig 4)


a. A special yarn feeder is required with two holes to enable two yarns to be knitted
at the same feeder (feeders 1 and 3)
b. Dial yarn knitted on the dial needles on low and high butt needles alternately;
and spacer yarns knitted on dial needles and tucked on cylinder
c. Cylinder yarn knitted on cylinder needles at feeders 2 and 4 on low and high
butt needles alternately.

Fig3. Tucking on dial and cylinder needles Fig4. Knit/plating on dial and tuck on
cylinder

Advantages of Weft Knitted Spacer Fabric

• 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

• The thickness of the spacer is normally limited to between 2 and 10mm


• The basic structure of the spacer fabric is normally limited to either knitting the
spacer threads on the dial and tucking on the cylinder, or tucking the spacer threads
on the dial cylinder needles.
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Warp versus Weft knitted Spacers [10]

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.

Flat Knitted Spacer Fabrics

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

• Cushioning elements for orthopedic use


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• 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.

Applications of Spacer Fabrics

3-D Automotive Textiles [11]

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.

Car Seat Covers [12, 13]

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.

Climatic Seat Comfort [13]

The breathing activity and also the moisture buffering capacity of


the car seat can be markedly improved if a warp knitted spacer
fabric is used, particularly instead of the foam material. It’s more
open structure provides for the better conveyance of water vapour
between body and seat, consequently producing better moisture
management in the microclimate close to the body, which people
immediately experience subjectively. Through the use of seat lining
of a synthetic spacer fabric with an approximate thickness of
10mm, moisture management and heat conveyance are both
optimized without forced ventilation by means of a fan.

Spacer Fabric for Geotextile [14]

Knitted spacer fabrics offer an opportunity for Geotextile as their construction is


exceptionally functional. By warp and weft knit spacer fabrics, it is possible to create the
two outer layers with different structures such as a grid shape or mesh which is more
effective at grabbing the soil than smooth fabrics. The spacer fabric offers a vertical
filtration system for use in construction applications. The fabric can placed against a
building and water then can drain into a sub grade.

Sports and Leisure application [15]

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.

Medical Application [17]

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

Protective and Sports Clothing [18]

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.

Shoulder Pads [19]

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.
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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
9. “Warp knitted spacer fabrics- design and application fields”, Knitting Technology,
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

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