INHALT

Technical Textiles

The power of innovation Composites, stitch-bonded fabrics, warp-knitted fabrics with weft insertion

TABLE

OF

CONTENTS

4 6

INTRODUCTION FUNDAMENTALS
FUNDAMENTAL TERMS OF WARP-KNITTING PAGE 6 THE MECHANISM OF STITCH
FORMATION

PAGE 7

DIRECTIONALLY ORIENTED STRUCTURES

GENERAL PAGE 8 WARP-KNITTED FABRICS PAGE 9 STITCH-BONDED FABRICS PAGE 14

18

STITCH-BONDED

NONWOVENS
METHODS

FIBRE-PROCESSING STITCH-BONDING MALIVLIES PAGE 20 MALIWATT PAGE 21 KUNIT PAGE 22 MULTIKNIT PAGE 23

PAGE 18

INHALT

Technical Textiles
IMPRINT 01/04/2009
The reprint, even in extracts, is only allowed with the permission of the publisher, the company KARL MAYER Textilmaschinenfabrik GmbH, 63179 Obertshausen, Germany. Rights for technical modifications reserved. List of references: Dr. S. Raz, The Karl Mayer Guide to Technical Textiles published by KARL MAYER Textilmaschinenfabrik GmbH, Obertshausen, Germany.

The power of innovation Composites, Nhgewirke, Gewirke mit Schusseintrag

Technical Textiles 2009

INTRODUCTION

Technical Textiles 2009

INTRODUCTION

Production of technical textiles is a rapidly growing trade in textile industry. Technical textiles are to substitute costand material-intensive as well as tricky and/or technically obsolete methods based upon conventional materials and are increasingly applied in new enduses. A favourable cost-to-benefit ratio during manufacture and a product tailored to specific application i.e. carefully designed structures and production methods are of particular importance hereby. All those advantages are offered by both warp-knitting and stitch-bonding techniques.

Warp-knitting with weft insertion ensures non-tendering integration of reinforcement yarns into knitted fabrics. As a consequence thereof, sturdy fabrics can be made to be used, for instance, as geotextiles in road construction or as advertising media. Stitch-bonding features a special form of warp-knitting. This technique is preferably used in production of reinforcement textiles for composites and nonwovens and has stood the test in introducing the "Fabric Engineering" concept. Both the warp-knitting and stitch-bonding techniques enable flexible and efficient manufacture of textile fabrics and open-up versatile opportunities both to developer and producer in order to configure the specific performance characteristics of textile material. The target to be reached hereby is: A material that withstands the anticipated loads and, at the same time, can be produced efficiently. The present guide gives an insight into warp-knitting with weft insertion and stitch-bonding techniques, illustrates the basic structural configurations available, and provides information about some of the versatile applications possible.

Technical Textiles 2009

FUNDAMENTALS

FUNDAMENTAL

TERMS OF WARP-KNITTING

For better comprehension of the production of technical textiles on warp-knitting and/or stitch-bonding machines, the most important fundamentals of warp-knitting are first of all given here. Stitch A stitch is a yarn loop with four interlacing points, comprised of one head, two legs, and two feet (Fig. 1). So, the loop has got two upper and two lower associated interlacing points - head and foot lapping. In general, the loop may be open (Fig. 2) or closed (Fig. 3). As to an open loop, the direction of incoming yarn (overlapping) equals the direction of outgoing yarn (underlapping). The loop feet are lying side by side. As to a closed loop, the direction is opposite and the loop feet are crossing-over. Wales and stitch courses Wales are a vertical row of stitches arranged one above another with common interlacing points (Fig. 4) whereas several stitches placed side by side from a stitch course (Fig. 5). Stitch density The stitch density indicates the number of stitches of a wale per cm. Float Float is a yarn path running straightly in linear or slant directions. It is restricted by stitches of other interlacing elements of

the same yarn and may extend over one or several stitch courses (Fig. 6). Inlay Inlay is a yarn path running in cross, slant, or linear directions not restricted by stitches of the same yarn. Inlay is interlaced into the stitches of another yarn system any may extend over the entire width (weft inlay) (Fig. 7) or over a part of width (inlay) (Fig. 8) of the knitted fabric. Filler yarn Filler yarn is a yarn path running straightly in linear direction and interlaced in between two wales not restricted by stitches or loops of the same (Fig. 9).

Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig.

1: 2: 3: 4: 5: 6: 7: 8: 9:

Knitted loop Open loop Closed loop Wale Stitch course Float Weft inlay Inlay Inlay and filler yarn

Technical Textiles 2009

FUNDAMENTALS

THE

MECHANISM OF STITCH FORMATION

To enlighten the process of stitch formation, the mechanical engineering fundamentals will be first of all explained hereinafter and, then, the actual process steps. The fabric-producing knitting elements of a warp-knitting machine Figure 1 provides a schematic overview of the knitting elements to produce fabrics on a warp-knitting machine, whereby: 1. Compound needle The needles are accommodated in a rigid needle bar and move simultaneously 2. Slide (closing element) The elements to close the needle hooks are arranged in a bar and move simultaneously 3. Knock-over bar (fixed) 4. Holding-down sinkers The holding-down sinkers are accommodated in a rigid sinker bar and move simultaneously 5. Yarn ends Yarn ends are usually unwound from a warp beam 6. Yarn guides The yarn guides normally configured as guide needles are located on rigid guide bars and are also moving simultaneously. One or several yarn guides are assigned to each needle. 7. Knitted fabric The process steps of stitch formation The process of stitch formation can be explained in detail by the six steps depicted in Figures 2 through 7: 2. The needles are in knock-over position i.e. in lowermost position after completion of the previous stitch course. The holding-down sinkers are positioned in between the needles. 3. The needles ascend to clearing position and, thus, to uppermost position. The closing elements (slides) rise a little bit less to open the needle hooks. The fabric is held back by the holding-down sinkers. 4. The yarn guides swing in between the needles up to the front needle side. 5. The yarn guides are shogged sideways by one needle and then swing back in between the needles. An overlap is produced hereby. The holding-down sinkers move back. 6. The needles descend. The slides follow-up this movement with time lag so that the needle hooks are closed to trap the newly wrapped yarns. The yarn guides are shogged sideways and repositioned (underlap). 7. The needles descend to knock-over position. The previously knit loop slips here from needle stem over the needle hook. The loops in the needle hooks are interlaced with the previously knit loop, thus producing a new stitch course.

Technical Textiles 2009

DIRECTIONALLY

ORIENTED STRUCTURES

GENERAL

Directionally oriented structures or D.O.S. feature unique multi-ply fabrics produced by using warp-knitting/stitch-bonding techniques. With said techniques, straight ends of absolutely parallel and non-crimped yarns are inserted into the structures as weft yarn at almost any desirable angle. This is done by weft insertion systems. The non-crimped yarns (=reinforcement yarns) can be integrated both in line with the stitch courses and not in line with the stitch courses. Course-oriented structures are made on warp-knitting machines and non-course-oriented ones on stitch-bonding machines. Possible laying directions The exact definition of laying direction depends on the fabric properties to be achieved. Directionally oriented structures offer ideal prerequisites for excellent mechanical properties with respect to the relevant application along with cost-effective production. The following directions are possible when producing directionally oriented structures: 0-direction - mono-axial 90-direction - mono-axial 0- and 90-directions - bi-axial diagonal - bi-axial diagonal and 90-direction - tri-axial diagonal und 0-direction - tri-axial multi-axial

0-direction - mono-axial

diagonal - bi-axial

90-direction - mono-axial

diagonal and 90-direction tri-axial

0- and 90-directions - bi-axial

diagonal und 0-direction - tri-axial

multi-axial

Technical Textiles 2009

DIRECTIONALLY

ORIENTED STRUCTURES

WARP-KNITTED

FABRICS

Course-oriented structures Warp-knitting machines include raschel machines and tricot machines. Raschel machines (Fig. 1) are preferably used to produce rather coarser structures with low stitch densities. On the other hand, fine fabrics with high stitch densities are produced on tricot machines. Reinforcement yarns can be integrated in 0-direction in line with the stitch wales and in 90-direction in line with the stitch courses. Here, one should distinguish between filler yarns and weft inlays. Filler yarns are reinforcement yarns provided in the fabric in machine direction (0-direction). They are interlaced with the fabric via guide bars without overlapping and/or underlapping movement. The filler yarns themselves do not form any stitches or loops and, therefore, must be fixed in the fabric by interlacing elements of other yarn systems. Upon insertion of filler yarns in line with the wales, an exact definition has been made in between which of the stitch wales of base fabric the reinforcement material has to be interlaced. Weft inlays are reinforcement yarns provided transversely to the machine direction (90-direction). They are inserted by means of specific weft insertion systems. As to the magazine weft insertion with Transport chain Transport chain reversing motion (MSUS), a carriage Weft carriage clamps a weft yarn sheet in between two transport chains (Fig. 2). The transport chains feed the weft yarns individually to
Selvedge yarns

the knitting elements where said yarns are interlaced in line with the stitch courses. Advantages of weft insertion system Working widths up to 247" (6.27 m) Production speed up to 1600 rpm corresponding to a weft insertion rate of over 10,000 m/min* (based upon 24 yarn ends) Weft yarn speed approx. 400 m/min (based upon 24 yarn ends) Flexibility as regards weft yarn repeat and number of weft yarns Almost all yarn materials including highstrength and sensitive textile yarns can be processed Various yarn counts can be inserted
*depending on product

Fig. 2: Functional principle of magazine weft insertion

Fig. 1: Raschel machine with magazine weft insertion

Technical Textiles 2009

DIRECTIONALLY

ORIENTED STRUCTURES

Mono-axial structures Mono-axially reinforced knitted fabrics (Fig. 3 and 4) are used, for instance, as sun- protection, interlining or geotextile fabrics. The reinforcement yarn layers are stretched to preclude any structural elongation under loads. Orientation takes place hereby in 0-direction (filler yarns) or in 90-direction (weft inlay) To keep the filler yarns in the fabric, the ground bar must be shogged by at least one needle in the underlap movement. As a consequence thereof, the filler yarns on the left fabric side are interlaced by the sinker loops. Weft inlays without reinforcement effect are to fix the filler yarns in fabric on the right fabric side. Bi-axial structures When combining filler yarns and weft inlays one with another, bi-axial structures with reinforcement in directions 0 and 90 (Fig. 5) can be produced. Geogrid structures and laminating substrates for advertising posters are main applications of biaxially reinforced fabrics. Figu-re 6 illustrates a grey bi-axially reinforced fabric with grid-like structure and high yarn counts. Equipped with PVC-coating (Fig. 7), such materials are used as reinforcing geotextiles e.g. for slope and sub-base stabilizing beneath railway tracks or even as asphalt reinforcement. Fig. 3+4: Mono-axial structure Fig. 5: Bi-axial structure Fig. 6: Grey bi-axially reinforced fabric Fig. 7: Bi-axially reinforced fabric with PVC-coating Fig. 8: Knitting area of a Raschel machine with magazine weft insertion

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Technical Textiles 2009

DIRECTIONALLY

ORIENTED STRUCTURES

Advantages of directionally oriented structures Unlike the arrangement in a woven structure, the yarns in warp-knitted directionally oriented structures are running absolutely straight and in parallel (Fig. 9). This brings about the following advantages: Direct introduction of forces into reinforcement yarns, no structural elongation Optimal utilization of yarn tenacity properties to withstand deformation strains Optimally structured modulus Simple calculation of fabric properties in accordance with the end-use intended Any yarn type can be processed from low-twist soft staple yarns up to hightenacity filament yarns (Fig. 10) Safe interlacing of reinforcement yarns, even in very open mesh structures, ensures safe transportation and handling of fabrics during further processing steps (e.g. coating) and in end-use Excellent tear and tear propagation resistance. The yarn layers tend to bunch together under load. This requires a greater extent of force to destroy the structure (Fig. 11) Fig. 9: Yarn arrangement in a directionally oriented warp-knitted fabric Fig. 10: Yarn types to be processed on warp-knitting machines Fig. 11: Bunching effect of yarn layers

Technical Textiles 2009

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DIRECTIONALLY

ORIENTED STRUCTURES

Composite fabrics The possibility of additionally feeding most different fabrics on Raschel machines allows simple and highly-efficient production of composite fabrics in one operation only. The key idea behind the production of composite fabrics is to combine several materials of partly opposite properties to create a single membrane that performs essentially much better than one of its constituents alone. Any fabric to be pierced can be reinforced either mono-axially or bi-axially with yarn elements on Raschel machines. Apart from preferably mechanically bonded webs, nonwovens bonded thermally or by bonding agent are reinforced, too (Fig. 12). The oriented yarn layer arrangement leads to a constructive increase of the mechanical nonwoven properties in compliance with product-specific requirements. Although nonwovens themselves do not show any outstanding mechanical properties, an extraordinarily high tear resistance of composite fabrics can be achieved. Fields of application Geotextiles for road construction, railway construction, slope and bank reinforcements, dumping construction etc., moreover, also used as laminating substrates, agricultural textiles, for moulded articles Reinforced composite fabrics for geotextiles The various functions to be performed by the components "directionally oriented fabric structure" and "nonwoven" are illustrated by the example of a composite fabric designed for use as geotextile (see table given opposite). Sensitive composite fabrics for civil engineering Sensors have been integrated into a composite nonwoven in a non-tendering and correctly positioned manner on a

RS MSU S-V Raschel machine of KARL MAYER Malimo at the Saxon Textile Research Institute in Chemnitz (Fig. 14). Such sensitive textile structures can be used in various civil engineering sectors such as e.g. ground stabilization, security services or even as early warning systems. The sensors integrated therein ensure quantitative, high-sensitivity resolution, and distributed detection and supervision of impacting changes due to sensor elongation and/or destruction. Reasons for impacts acting on the sensors are movements and tensions. Multispeed and weft pattern repeat The Multispeed technology of KARL MAYER offers the opportunity to program sequences, thus allowing automatic variation of stitch density while the machine is running. So, fabrics of various stitch densities can be knitted. The sequence of weft yarns to be inserted can be programmed as you like by means of electronic weft pattern repeat in order to place the weft yarns only at the points required for the relevant application. Thanks to the combination of Multispeed technology and weft pattern repeat feature, for instance, directionally oriented fabrics can be knitted with small stitches in the areas of integrated weft yarns and with low stitch density in the areas between the weft yarns. Small stitches offer a better fixation of weft yarns and the decreased stitch density in the intermediate areas results in an increase of production output. Fig. 12: Knitting area RS MSU S-V Fig. 13: Composite fabric for asphalt reinforcement Fig. 14: Composite fabric with integral sensor

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Technical Textiles 2009

DIRECTIONALLY

ORIENTED STRUCTURES

Technical Textiles 2009

13

DIRECTIONALLY

ORIENTED STRUCTURES

STITCH-BONDED

FABRICS

Non-course oriented structures Directionally oriented structures with mono-axial up to multi-axial reinforcementyarn layer construction can be produced by means of stitch-bonding technology. Said structures are characterized by interlacing of reinforcement yarns not in line with the stitch courses. The reinforcement yarn layers fed are pierced by sharp needles and interlaced one with another by means of interlacing yarn (knitting yarn) in one knitting cycle (Fig. 1-3). Stitch-bonding is a special form of warpknitting where the stitch formation process takes place analogously to warp-knitting. Figure 1 shows the stitch-bonding area of a MULTIAXIAL stitch-bonding machine. Major differences with regard to a warpknitting machine are: Knitting-area construction - fixed counterholding bar, supporting rail Needle type used - "piercing" needle Fields of application The typical feature of stitch-bonded directionally oriented structures is the uniform distribution of yarn ends without any gap formation as a result of piercing principle. The process is extraordinarily flexible with respect to yarn materials used, possible yarn densities, layer construction, orientation, and number and enables possible integration of fibrous webs, films, foams or other materials that can be pierced. This opens up versatile applications. Multi-ply structures with non-crimped and parallel yarn sheets are particularly suitable to reinforce plastics in order to form fibrereinforced plastics (F.R.P.). Special properties of such fibre-plastic composites are: Low specific weight Utmost mechanical load resistance Adjustable stiffness from extremely stiff up to extremely stretchable Resistance to corrosion and chemicals Rotor blades for wind power stations, moulded parts for automotive, aircraft, and ship building as well as articles for sports and leisure-time activities such as e.g. skis, snowboards, surfboards or sporting boats have established as typical applications of F.R.P. structures.

14

Photo by www.fotolia.de

Technical Textiles 2009

DIRECTIONALLY

ORIENTED STRUCTURES

Advantages of multi-axial multiply structures Dimensionally stable in any direction usual angle positions from -45 via 90 up to +45 and 0, infinitely adjustable Isotropic distribution of force lines, uniform strain behaviour (Fig. 4) Optimal utilisation of tensile yarn strength in any direction of strain Reinforced 3rd dimension i.e. in Z-direction, thus, reduced delamination tendency by interlacing yarn system Directly oriented, parallel yarn layers straightly placed each on top of the other - without yarn crimp, providing the following advantages: - enhanced interlaminar shearing strength - reduced resin quantities - increased impact resistance - excellent draping characteristics (adjustable by interlacing) Low weight per unit area at utmost total strength possible Cost-effective production and economic make-up Product-relevant and variable layer structure in various angular directions (Fig. 5), allowing for additional materials to be incorporated - producible in one operation only Fibreglass, aramid, carbon, high-tenacity PES, PA, PE, and PP are used as yarn materials. Thermosetting or duroplastic materials and mineral matrix systems e.g. concrete are used as matrix materials.

Fig. 1: Stitch-bonding area BIAXIAL/ MULTIAXIAL machine Fig. 2: Multi-axial multi-ply structure Fig. 3: Structure of a bi-axial multi-ply Beanspruchung Fig. 4: Unlike woven fabrics, multi-axial multi-ply structures feature a high shearing strength under diagonal strains Fig. 5: Carbon multi-ply fabric with +/-45 yarn orientation

Technical Textiles 2009

15

DIRECTIONALLY

ORIENTED STRUCTURES

16

Technical Textiles 2009

DIRECTIONALLY

ORIENTED STRUCTURES

Bi-axially and multi-axially reinforced stitch-bonded composite fabrics Composite fabrics can also be produced, using the stitch-bonding technology. Unlike the already introduced warp-knitting technology, such fabrics can also be reinforced multi-axially. Besides any kind of fabrics to be pierced, layers of unbonded chopped glass strands (CSM - chopped strands mat) can be integrated, too. Such multi-ply composite fabrics are of particular interest for the laminar construction of fibre-plastic composites. As to a multi-ply composite fabric with layer construction CSM - multi-

axial yarn layers - CSM, the CSM-layers in F.R.P. ensure enhanced interlacing with the matrix system and other laminar layers as well as a more uniform F.R.P. surface. Production of these mono-, biand/or multi-axial multi-ply composite fabrics in one operation offers excellent prerequisites for cost-effective manufacture of long-fibre-reinforced F.R.P. as being used in vehicle, boat, tank, machine, and sports equipment construction. Apart from parallel weft insertion, a slightly crossed weft lapping - MALIMO-specific weft insertion - is possible on all stitchbonding machines.

Fig. 6: Parallel-weft principle Fig. 7: Cross-weft principle Fig. 8+9: Structure of a bi-axially reinforced stitch-bonded composite fabric

Technical Textiles 2009

17

STITCH-BONDED

NONWOVENS

FIBRE-PROCESSING

STITCH-BONDING METHODS

Fig. 1: Stitch-bonding machine, model MALIWATT 14022

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Technical Textiles 2009

STITCH-BONDED

NONWOVENS

Stitch-bonding technology allows production of purely mechanically bonded nonwovens on special fibre-processing stitchbonding machines. Bonding takes place by: one- and/or two-sided formation of stitches from fibres of lengthwise-, cross-laid or random webs fed (e.g. MALIVLIES,

KUNIT or MULTIKNIT methods) by stitching-over of said fibrous webs with a maximum of two stitch-forming knittingyarn systems (MALIWATT method) Stitch-bonding machines are altogether characterized by sturdy constructive design including stitch-bonding area and by their outfit with a maximum of two stitchforming guide bars. The machine gauge is up to 22 needles per 25 mm with a maximum output of 2,800 stitch courses/minute and a working width of up to 6,150 mm.

Technical Textiles 2009

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STITCH-BONDED

NONWOVENS

MALIVLIES

Stitch-bonded MALIVLIES nonwovens consist to 100 % of fibres. When making such fabrics, fibres are grasped by the needle hook from a generally cross-laid fibrous web (Fig. 1). By pulling these fibre strands through the half stitches hanging on the needle stem, a stitch pattern which resembles to that of a warpknitted fabric is produced on the back side of web (Fig. 2). The intensity of stitch formation is dependent on the number of fibres in the needle hook and can be con-

trolled via the position of insertion sinkers. The advantages of MALIVLIES fabrics can be summarised as given below: - Cost-effective production at working widths of up to 6.15 m and exclusive of nonspun fibrous material - All cardable kinds and blends of fibres can be processed - Commensurate strength-strain behaviour in lengthwise and cross directions, infinitely adjustable (via fibrous material, weight per unit area, machine gauge, intermeshing intensity, stitch length) - Excellent draping characteristics and shaping facility - Excellent recycling facility and/or processing of reclaimed fibres Typical applications of stitch-bonded MALIVLIES fabrics are car headliners (Fig. 3) and laminating substrates for seat upholstery fabrics as foam substitutes.

Fig. Fig. Fig. Fig.

1: 2: 3: 4:

Schematic view of MALIVLIES production Structure of a stitch-bonded MALIVLIES fabric Car headliner made of MALIVLIES Stitch-bonding machine, type MALIVLIES

20

Technical Textiles 2009

STITCH-BONDED

NONWOVENS

MALIWATT

Stitch-bonded MALIWATT fabrics are made of unbonded or pre-bonded fibrous webs stitched-over across the entire surface or partly with one and/or two stitch-forming yarn systems (Fig. 1+2). The additional possibility for embedding pierce-through plane and/or scattering materials will enhance the design variety of such structures (nonwovens/composites). Stitch-bonded MALIWATT fabrics offer the following advantages: - Cost-effective production at working widths of up to 6.15 m - All cardable kinds and blends of fibres as well as all pierce-through materials can be processed as ground fabrics within a large weight per unit area range (15...3000 g/m2) with a fabric thickness of up to 20 mm - Large count range of knitting yarns to be processed (44...4400 dtex), featuring the possibility to work through pile sinker of up to 23 mm (one-side knitted pile) - Strength-strain behaviour in lengthwise and cross directions adjustable via ground fabric/knitting yarn material, weight per unit area, machine gauge, knitting-yarn interlacing and tension, stitch length - Additionally possible reinforcement of 0-direction by non-crimped filler yarns - High variety of variants thanks to the combination of various materials to make composite fabrics

- Special MALIWATT G configuration to process fibreglass webs and/or chopped glass strands even in combination with substrate fabrics e.g. fibreglass fabrics - Processing or reclaimed materials possible Examples for application of MALIWATT fabrics are e.g. adhesive tapes to wrap around cable harnesses, insulation materials (fibreglass processing) and secondary carpet backing (Fig. 3)

Fig. 1: Schematic view of MALIWATT production Fig. 2: Structure of a stitch-bonded MALIWATT fabric Fig. 3: Secondary carpet backing made of MALIWATT

Technical Textiles 2009

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STITCH-BONDED

NONWOVENS

KUNIT

When making KUNIT fabrics, a normally lengthwise-oriented fibrous web is folded and compacted into a pile fibre web at a feed speed beyond fabric take-down speed and supported by a brush bar (Fig. 1). Moreover, fibres are pressed into the needle hook by brush bar and transformed into a stitch. So, a three-dimensional fabric made of 100 % fibres is produced, comprised of one stitch side and one pile side with almost vertical fibre arrangement (Fig. 2) and offering the following advantages: - Cost-effective production at working widths of up to 3.85 m and exclusive use of non-spun fibrous material - All cardable kinds and blends of fibres can be processed - Very good permeability to air, excellent compression elasticity (thanks to vertical fibre arrangement) at low weight per unit volume, fabric thickness of up to10 mm - Purposeful manipulation of properties (via fibrous material, weight per unit area/volume, machine gauge, finish) - Excellent shaping facility/draping characteristics - Very good recycling facility, processingof reclaimed fibres possible KUNIT fabrics are excellently suitable for use as laminating substrate e.g. for car seat upholstery fabrics as foam substitute (Fig. 3), moreover, for soft-touch moulding parts, insulating/absorbing materials and interior car trimming. Fig. 1: Schematic view of KUNIT production Fig. 2: Structure of stitch-bonded KUNIT fabric Fig. 3: KUNIT laminating substrate for truck seats

1
Photo by www.fotolia.de

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Technical Textiles 2009

STITCH-BONDED

NONWOVENS

MULTIKNIT

One and/or two one-side knitted pile fibre nonwovens made according to the KUNIT technique are used as base materials for MULTIKNIT production (Fig. 4). The result: a three-dimensional fabric made of 100 % fibres whose top nonwoven sides are formed into a closed surface by intermeshing of fibres and joined one with another by almost vertically oriented fibres (Fig. 5). Pierce-through plane and/or scattering materials can be embedded additionally in this structure. Here are the resultant and general advantages of MULTIKNIT fabrics: Production of three-dimensional knitted structures of high thickness (up to 16 mm) exclusively from fibres maintaining the vertical fibre arrangement between the outer plain stitch layers - All cardable kinds and blends of fibres can be processed

- Very good permeability to air, excellent compression elasticity (thanks to vertical fibre arrangement) at low weight per unit volume - Excellent shaping facility - Very good recycling facility, processing of reclaimed fibres possible - High variety of variants thanks to the combination of various materials as well as the possibility of only partly stitch formation to make composite fabrics MULTIKNIT fabrics are used, among others, as laminating/sub-upholstery fabrics, soft-touch moulding parts, insulating/absorbing materials, interior car trimming, and filtering materials. Fig. 1: Schematic view of MULTIKNIT production Fig. 2: Structure of stitch-bonded MULTIKNIT fabric

Technical Textiles 2009

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Germany
KARL MAYER Textilmaschinenfabrik GmbH Brhlstrae 25 D-63179 Obertshausen Phone +49 61 04 40 20 Fax +49 61 04 402 600 E-mail: info@karlmayer.de KARL MAYER MALIMO Textilmaschinenfabrik GmbH Mauersbergerstrae 2, D-09117 Chemnitz PF 713, D-09007 Chemnitz Phone +49 371 81430 Fax +49 371 8143110 E-mail: info@karlmayer.de Sucker Textilmaschinen GmbH Blumenberger Strae 143-145 D-41061 Mnchengladbach Phone +49 21 61 65 46 61 Fax +49 21 61 65 46 69 E-mail: info@karlmayer-sucker.de

Japan
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Italy
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KARL MAYER (China) Ltd. 518 # South Changwu Road Wujin District, Changzhou City Jiangsu Province, Zip code: 213166 P.R.China Phone +86 5 19 86 19 88 88 Fax +86 5 19 86 19 00 00 E-mail: info@karlmayer.com.cn KARL MAYER (H. K.) LTD. Suite 1413, 14th Floor Ocean Center, Harbour City Tsim Sha Tsui, Kowloon Phone +8 52 27 23 92 62 Fax +8 52 27 39 8730 E-mail: info@karlmayer.com.hk

UK
KARL MAYER Textile Machinery LTD. Kings Road, Shepshed Leic. LE 12 9HT Phone +44 15 09 50 20 56 Fax +44 15 09 50 80 65 E-mail: info@karlmayer.co.uk

USA
KARL MAYER North America Mayer Textile Machine Corp. 310 North Chimney Rock Road Greensboro, North Carolina 27409 Phone +1 3 36 2 9415 72 Fax +1 3 36 8 54 02 51 E-mail: info@karlmayerusa.com

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