How is warp knitted fabric manufactured?

warp and woof - Wiktionary, the free dictionary

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Warp Knitting Process

Warp knitting is a loop-forming method in which yarns are fed into the knitting zone in a parallel manner to the fabric selvage, forming vertical loops along a course before moving diagonally to create the next. This zigzag movement across the fabric length results in each stitch being created by multiple yarns. The manufacturing process is highly efficient and flexible, making it suitable for various applications and products.

History of Warp Knitting

The invention of warp knitting is often attributed to Josiah Crane in 1775, who likely sold the concept to Richard March. March patented the warp frame in 1778, which was further developed over the years. Significant advancements include Flint's point bar in 1786, Dawson's cam system for twist regulation in 1796, and the introduction of the bobbin by Lindley in 1799. By 1809, John Heathcote's improvements culminated in the creation of bobbinet, capable of producing wide fabrics.

Machine Classification

Tricot Machines

Tricot machines, equipped with sinkers that control the fabric throughout the knitting cycle, are mainly utilized for producing lingerie and underwear. The fabrics display fine lengthwise ribs on the front and crosswise ribs on the back. Tricot machines are versatile, producing materials with soft textures that exhibit some lengthwise stretch.

Towel Tricot Machine

The Terry Warp Knitting Machine, including Changzhou A-ZEN's TS4C and TS4C-EL models, plays a vital role in the production of microfiber terry towels, enhancing productivity and sustainability. The Superpol Towel Machine is another example of a tricot machine used for this purpose.

Milanese Knit

Milanese knit is known for its strength, stability, and smoothness. Often used in high-quality lingerie, Milanese fabrics are crafted from two sets of yarns knitted diagonally. However, this type of knitting is now almost obsolete due to its higher cost.

Raschel Machines

Raschel machines, developed in 1859 by Wilhelm Barfuss, are ideal for creating lace and trims. These fabrics, known for their minimal stretch and bulkiness, are often used in articles like coats and jackets. The adaptability of Raschel machines to synthetic fibers has solidified their place in modern textile manufacturing.

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Stitch-bonding Technique

Stitch-bonding is a specialized warp knitting process used for composite materials and technical textiles. It involves joining threads and fabrics with a knitting thread to create a layered structure called a multi-ply. This method, recognized for its high productivity and design flexibility, is prominent in industries like wind energy and aviation.

Needle Shift

The needle shift technique involves shifting the needle bar during stitching, allowing for innovative arrangements and patterns in stitch-bonded fabrics.

Patterning in Warp Knitting

Creating patterns in warp knitted structures is intricate due to the numerous possible configurations of yarn ends and guide bars. Modern machines have multiple guide bars, which contribute to a vast array of patterning possibilities. Advanced CAD software aids in designing 3D warp knitted fabrics, offering extensive patterning capabilities.

Advantages of Warp Knitting

Warp knitting offers several benefits, including higher productivity rates compared to weaving, diverse fabric constructions, large working widths, and low stress on the yarn. Additionally, it allows for the creation of three-dimensional structures using double needle bar raschels.

Applications of Warp Knitting

Warp knitted fabrics are widely used across various industries for products like mosquito nets, tulle fabrics, sportswear, shoe fabrics, and materials for printing and advertising. Research is also underway to explore their use in reinforcing concrete and producing biotextiles.

Warp Knitting and Biotextiles

The warp knitting process has extended into biotextiles, such as creating polyester cardiac support devices to limit the growth of diseased hearts. Animal studies suggest that the implantation of these devices may reverse disease states, offering a promising alternative to traditional treatments.

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