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he first commercial developers of spacer fabrie were Matthew and Townsend in 1868. The patent was for knitting mattresses on a two needle-bed hand frame with interlocking thread. Spacer fabries are much like sandwich structure. Two complementary slabs of fabric are tucked in between by a third layer. The yarns in the inner layer are much different than that of the top and bottom slab of fabri are called spacer yarn. Spacer fabrics can be made of variety of shapes. sueh as: tubes, pleat or other engineered forms, which provide the entire three- layer fabric a wide range of applications, Spacer fabric isa theee-dimenstonsl knitted fabric consisting of two separate knitted substrates which are joined together or kept apart by spacer yarns. The fabric with same or diflerent surface structure between the top layer and bottom layer can meet different needs, hile their structure is very flexible and can form various products, The unique structure and performance of 3D spacer knitted fabrie make it widely used in our ally Iie. Spacer fabrics are widely used in different products such as mobile textiles (car seat covers, dashboard cover), Industrial textiles (composites medical textiles (anti-deceits blankets, sports texilles and foundation garments (bra cups. pads or swimwear), Spac These yarns Spacer fabric is a three- dimensional knitted structure consisting of two outer textile substrates which are joined together and kept apart by spacer yarns. {abies in medic fnew spacer fabric. Spacer fabric as a component material is highly breathable, thus ereating a moisture free environ ‘which in turn reduces the chances of skin maceration, These lead to an increased level of comfort when con Bras cups made from pared to materials such as foam, neo- SPACER FABRICS Spacer fabrics Features - Applications Subhankar Maity Department of Teste Technology, Dr B F Ambedkar National Institute of Technology Jalandhar 144 011 Inia mally texte @ gmail com prene and laminate fabrics. Spacer fabrics are regarded as environmentally weft-knitied spacer fabrie, The welt- knitted spacer fabrics are produced on dial and cylinder. v-bed and purl type of knitting machines whereas warp knitted spacer fables on tricot and Raschel machines. The rest type is knitted on a rib Rachel machine having two needle bars, while the second is Knitted on a circular double Jersey machine Dial and cylinder spacer fabrics Producing knitted spacer fabrics on dla and cylinder machines can be done using a variety of comb SMches that connect two independent layers of fabric together, All techai- ques require the use of at least thre different yarns for each course of visual fabric, i Variety in spacer fabrics + yun forthe cinder needles yarn forthe dial needles; and There are two varieties of spacer a spacer yarn, normally monofila- fabries: warp-knited spacer fabric and ment yarn connecting the two layers. ig 1: Schematic representation ‘of spacer fabric ation of friendly textile materials (unlike polyu- rethane foam), since they can be reeyeled Asian Textile Journal ¢ February 2017 « 29, ‘SPACER FABRICS The distance between the two fabrics can be manipulated by the dial height adjustment. ultimately determining the ‘amount of pile yarn being put between the two ground fabrics Another example of a spacer fabric produced on a dial and eylinder machine hhttititilits TOPE TTT: mre ciblitilililitile Fig 2: Circular knitted spacer fabric formed by tucking on dal and cylinder HEEL t | Perey titiy (a) (b) HLELL Litt IIT rita Cc) Cd) Fig 3: Kaitting structure diagram for fat pattern spacer fabric is created by using jacquard pattering. In this case a jacquard pattern layer Is welt knitted om the eylinder needles, @ plain layer is welt knitted on the dial needles, ‘and the two layers are coupled together with spacer yarn connected in cach layer on alternate needles of the eylinder for dial as shown in Fig 3. Both of the ‘example given show fabrics having the same structure on the front and back ‘and do not indicate what type of yarns are being used, however. i is possible to produce the two outer layers from different materials and with completely different structure \V-Bed spacer fabrics ‘When Mlat-bed knitting machines is, used in the production of three~ Fig 4 Top & cross-sectional view of facquard ‘Spacer fabric dimensional spacer fabrics, two types of product can be created: ‘© two independent structure connected by cross threads, and © two Independent fabric structures connected by fabric layers. A specific example of the production and application of a spacer fabric Knitted on a v-bed machine are shown in Mg 4. The product depicted is a decorative faced multi-layered Fabric used in the production of brassieres (Fig 5). The knitting sequences. show layers being created through the use of varying stitches that are connected by tucks, Feed 1 hhas yarns being tucked on alternate rncedle of the back and the front needle beds while Feeds 2 and 3 are knitting fon the alternate needles on the back needle bed, Feed 4 Is sporadically knitting and tucking to create the two fabric decorative jacquard pattern seen on the front of the fabric. Warp knitting spacer fabrics ‘The warp knitting mach mainly classified in two ‘© ‘Tricot warp knitting machine © Raschel warp knitting machine Teicot warp knitting machine (having one set of needle) are similar to plain jersey fabries in ‘that they are different on the front and back. Fabrics made on Simplex machines having two set ‘of needles) make fabries similar to Interlock. Nether fabrics have two distinet layers, as spacer fabric have two layers and one ‘connecting layer and therefore iti not possible to make a spacer fabric on a Tricot machine. But production of spacer fabrics on a Raschel machine with two needle bars is possible. Raschel warp knitting machine Raschel machine with two needle bars produces spacer fabric and has Raschel machine with two needle bars produces spacer fabric and has similarity to flat knitting. fareat similarity to flat knitting in that there is a front and back bed of needles being used to created distinet layers that are connected by spacer fabrics. Raschel machines are producing both outer layers simultaneously on different bars using their own sets of needle. Because the Fig 5: Cross-sectional view of brassiere cups Asian Textile Journal e February 2017 « 30 Fig 6: A schematic drawing of Raschel kniting machine used to produce spacer Tabric having two pile bars layers are knit on their own needle beds and for the front and back the use of different yarns can produce completely different structures. Two layers are connected by pile varns which switch regularly from one knit spacer fabrics. needle-bar to the other in a systematic method of joining the two independent sides of the spacer structure as sho- wn in Fig 6. Raschel knitting have the gr production capabilities due to greater range In yarn tex, higher production speeds (relative to the dial and cylinder. v-bed and purl machines), and ability to adjust the distance between the two needle bars providing greater ‘opportunity for spacer thickness Various means of forming Raschel knit spacer fabric exist, The fabric shown in Fig 7 is knitted on a double needle bar machine with at guide bars. composed of The front and back are stretchable sets of ground and clastic yarns interknitted with one another while simultaneously Rote Fig 7: Various Raschel spacer fabrics ‘SPACER FABRICS round fabric used for athletic shoes and support bandages. Guide bars one and two are feeding yarns to the needle bar, guide bar six and seven feed yarns being fed on bars 3-5 alternate knitting on the front and back beds to join the two independent fabric structure Comparison of advantages and disadvantages of different spacer fabrics Is shown in Table 1, front End-use application of spacer fabrics Fig 8 : Knit pattern and cross-section of spacer fabrics today the market for tech. neal textiles has found that there is & rising demand for knit spacer fabrics knitting at least monofilament pile yarns between the Raschel —_¢ No ripping or raveling ‘© Expensive equipment '* Does not require bonding or © Large floor space requirement lamination ‘© Low machinery productivity ‘© Pliable, flexible, retains shepe © Large labour requiremant per ‘© Can build in dimensional machine stability andfor stretch ‘+ Limited pattern scope '* Customise permeability to alt © Spacer has tendency to ‘and vapour collapse and flatten ‘© Efficient moisture transport ‘© Conformation to body parte «Insulating ‘© Available in wide widths Flot ‘© Fabric may be fashioned to'a ¢ Slow production speeds specific shape and size ‘© Small number of feeds and ‘+ No cutting results in no waste knitting systems of yarn of fabric ‘© Complex and expensive ‘© Cen accommodate almost any equipment ‘ype of yarn ‘© Not economics! to make piece ‘© Possibility of weft insertion goods between fabric fac © Can unravel and ladder ‘© Easy jacquard patterning ‘+ Lower yarn costs since the ¢ Availabe in ust one width syste can use heavier count Low dimensional stability yarn ‘© Rigidity when using ‘© Less floor space required monofilaments Low operating skils levels ¢ Limited choi of stitch ‘+ Can accommodate spun yarns ® Limited variation of thickness —-*-Quick maching sej-up time (2-10 mm) ‘© Extensive patterning scope «Can unravel and ladder ‘© Soft fabric that comfort 10 shape Asian Textile Journal » February 2017 « 31 ‘SPACER FABRICS ar root lining Knittod fabrice for reclining (collapsibie) surfaces Car window shell A-B-€ pillar lining ‘Automotive Home Textiles Sports/Leisure/Clothing Medicine Technical Fabrics Seat cover Chair Underwear Bandages (elimination of upholstery Brassiere cups Compresses polyurethane foam) oor panelling Mattress Functional underwear for Oecubitus ma Shoulder pads covers extreme sports ‘hospital beds, str ich T-shirts Diving underwear Lingerie High-low embossing ffects support cushions) Incontinence pods Laminates (fibreglass) absorbent fleace/wett | Sensor fabrics for Patient monitoring Operating table mats Thermal mats Protective clothing Ballistics Insulating mats in the areas of automotive and oth medical, hygiene ‘engineering, building and construction: sports and leisure, environmental protection, filtration and cleaning and safety and protection as shown, In Table 2. Automotive application Today's car seat offered in the global marketplace consists of three layers: the Knitted spacer fabrics allow for elimination or reduction of polyurethane foam, top layer which is often plush and of polyester; the middle layer made of a made polyurethane foam: and the bottom layer. 4 polyamide warp knit. The demand for abric is met throug! four alternatives : wovens, nonwovens, knit and leather. Alternatives of the current automobile ollering are presently but_ must being sous meet five requirements, © Be luxurious in a pearance through Because stuributes associated with warp-knitted spacer fabric make interest head liners of the In addition cushion as the prerequisite implied. spacer fabrics also offer alternati covers, seat packets and dash boards. With over 20 kj of the approxin lechnology and patterns and the ability to knit @ range of yarn type) it is possible to achieve all of these require- i compartment used in each 45 million cars Car seat made of spacer fabric such as flammability, lack of com pression and resilience and delimitation bars to By creating car seats with this new structure. the reeyeling procedures are simplified atthe end of the vehicle’ usefu \n 8" Medical applications 8 a8 The properties, such as heat and moisture regulation associated with both warp and welt- knitted spacer fabrles are medical textile. ‘The knitted fabrics or ideal for use in structure and colour © Have a soft textile feel of spun yarn, © Be comfortable Have the potential for small patterned and multi-coloured designs ‘¢- Have a look that is similar to that of woven fabrics Asian Textil made every year worklwide, having great future for warp-knitted spacer fabries in automobiles Perhaps most importantly, knitted spacer fabries allow for the elimination or reduction of polyurethane foam Foams have many serious drawbacks Journal « February 2017 « 32 products in which loops are coformed across the width of the fabric ereates a functional handage that is inelasti ng high level of compre ssion and support hereby offer Warp-knitted fabrics offer greater flexibility and elasticity due to the SPACER FABRICS Fig 10 + Moisture regulation phenomena formation of loops along the length of the fabric. Spacer fabries are the key the development for medical textiles as they are composed of textile Interconnected by distance — fibres, which may be polyamides sheets Fig 11: Wrist splint polyesters, viscose bandage -space or even natural fibre like cotton, With these fabries. a more ev bution of pressure becomes possible and. depending on the selection of capillary or surface fibres, fluid trans- port through the fabric is enhanced as distri= ‘The common and most important example of spacer fabric is bandages. shown in Fig 10. The common and most important example of spacer fabric is bandages. Bandages have been used to ‘reat such alignment as Iymphedema and found to be were as effective as Fig 12 Shoes sole spacer fabric traditional bandages. comfortable due to the micro- climatic qualities associated with spacer fabrics. Other examples fare shoes insole and surgical gowns. caps and gloves made of spacer fabric especially used in medical textile These types of shoes are used by those people who are suffered by foot ulcers, And with these sole fabrics, a more even distribution of pressure becomes possible and good thermal conductivity, early recovery Is possible. The surgical dresses are used to protect from infections and they are easy to wash and some are disposable ‘and can be recycled. Applications in geotextiles, civil engineering, building, construction, environmental protection and cleaning Geoteutles are defined as, ‘permeable textile materials which are designed for the use in civil engineering applications such as erosion control, soil reinforce bur ‘nd shaded fabric nets ment, scparation, filtration and drainage Knitted fabries are not commonly used In geotextles with 70% of materials used ‘coming from nonwovens and 2 wwovens. An increase in the use of knitted spacer fabrics is expected as geotextiles are forecast to be the fastest growing sector in technical textiles, Knitted spacer fabrics offer an opportunity for geotextiles as their construction is exceptionally funct- lonal. As iis known that with both weft and warp knit spacer fabrles, 1 1s possible to create the two outer layers ‘with different structure such as a grid shape or mesh which is more effective at ‘grabbing the soll than smooth fabrics. ‘A specific environmental application was made using polyethylene warp- [knitted spacer fabric. The labric offers a vertical filtration system for use in construction applications, The fabric can be placed against a building and water can drain into a subgrade. Application in sports and leisure from Sports and athletics have been Increasing worldwide: and so has the demand for athletic apparel. To provide comfort and to get excellent performance bboth moisture and temperature must be managed and billions of dollars are spent on athletic apparels and footwear. To achieve the ultimate athletic apparels three criteria are to be considered: © Using the right combination of fibres © Using the right fabric © Using the right chemicals oF finishes on the fabric The spacer fabries used Fig 13 : Spacer labric in gootextiles as river embedment Fig 14 Spacer fabric used in Jacked tunnel section and sandwiched between two Semispermeable membranes for litation Asian Textile Journal e February 2017 « 33, SPACER FABRICS because of the various layers can offer different attributes - the layer closest to the skin can be hydrophobic, the layer in the middle can be used for diffusion, and the outer layer can be hydrophilic ig 13 Sports dress and sports footwear hhaving kotied spacer fabric lining = +a | Fig 16 : Moisture drawing action from sportswear thereby absorbing and evaporating heat ‘energy. Spacer fabric draws moisture from air chambers to keep body cool as shown in Fig 16. In addition to sportswear, spacer fabrics are being used in conventional intimate apparel. Some companies ike Champion is making use of the wicking capabilities offered through spacer fabrics in their Double Dry Everyday bras, with Space Aire. The initial line olfered an inner layer that wicks away moisture. while the outer layer evapora tes the moisture. The enhanced techno- logy offers two layers that wicks and evaporates with @ mile layer. or spacer fabric, that features tiny knit-in ale pockets giving a smooth silhouette and comfort Applications in safety and protection A variety of potentially harmful scenarios and condition exist in the environment and knitted spacer fabrics offer a solution through thelr properties and construction capabilities. Warp and weft knitting machines have the ability to produce fabries using many high perfor: fibres such as glass, Nomex, Kevlar; PEEK, Basofil, carbon, metals and UHMWPE, The use of such fibres enables knitted fabri to protect against extreme heat and fire, harmful chemicals and gases, mechanical and electrical hazard, contamination, radiation, vacuum and pressure fluctuations, extreme cold. virus and bacteria and cut and ballistic havards. Conclusion In terms of end-use products and machine progress, spacer fabries are still seeing rapid development and improvements. Special abilities and versatility offered by spacer fabrics include the ability to knit two entirely different fabrics having. different properties and connect them to form a single structure. ‘This offers end users a great deal of opportunity t modify the weight, aesthetics, properties and cost of the fabric to meet consumer demands, ‘As the production of technical textiles, medical textiles, automobile interiors and apparel products become more comfortable with the products, Fig 17: Ditlerent spacer fabrics in protective suits Asian Textile Journal « February 2017 « 34 advancement will continue to be made in machine and yarn technology and the prevalence of spacer fabries in the marketplace will Increase The use of spacer fabric techno- logy. however, offers a niche market for machine, fibre and end-product manufactures. By pursing specialization In this area, manufacturers are likely to see less competition based on price ‘compared to alternative materials such as foam and corresponding increased margins, References 1 LiXingin, Jiang Gaoming, Ma Pibo, ‘Autex Research Journal, an 2016, Vol 16 Issue 2, 51-56, 6p, DO: 10.1515 aut-201 5.0027 2 ZhiChao, Long Maira, Autex Research Journal, un2016, Vol 16 sue 2 p 10p, DOK: 10.1515/aut-2015-0028 3. Xiaoying Li, Gaoming fiang, Xiaolin Nie, Pibo Ma, Zhe Gao, Autex Research Journal, Sep 2015, Vol 15 Issue 8, p191-197, Zp, DOL 10.1515) aut-2015.0006 4 SiChen, Hai-Ru Long, Industria Testa, 2015, Vol 66 ssue 5, p259-268, 6p Acumugam Veerakumar, Mishra Rajesh, salitky i, Tunak, Maros, In plane shear behavior of 3D spacer knitted fabries, Journal of Industrial Teatiles Sep2016, Vol 46 Issue 3 868-686, 19 DO! 10.1177 1528083715601509 © Rajan T Palani, Souza Louis D, Ramakrishnan G, Zakriya G, Moha- med, Comfoat properties of functional warp-knitted polyester spacer fabrics for shoe insole applications, Journal of Industrial Textiles, May 2016, Vol 45 Issue 6, p1239-1251, 13p, DOK: 10.1 17711528063714557056 Chen Si, Long Hai, Liv Ying-hao, Hu, Feng-chao, Mechanical Properties (Of 3D-Structure Composites Based On \Warp-Knitted Spacer Fabrics, Aulex Research Journal, June 2015, Vol 15, Issue 2, p127-137, Ip, DOk 10.2478 out-2014-0045, 8 Gokarneshan, Narayanan, Design of Warp Knit Spacer Fabrics: Recent res. earch insights on technical application, sJournal of Testile & Apparel Techno: logy & Management JTATM), 2015, Vol 9 sue 3, p25, 25 oo

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