Selected medical and automotive products produced on weft and warp knitting equipment

Gary W. Smith
Professor at North Carolina State University

Jose Felisberto da Silva

Professor at Senai/Cetiqt

Abstract
Globalization has completely changed the way knitting companies must look at their product lines. To cope with low-priced imports of commodity products, knitters must re-think their potential product lines, especially with a view towards high value added products such as products used in automotive, medical, and specialty technical applications. This paper will illustrate and suggest not only some potential product lines but also how conventional and specialty yarns must be handled and how machinery settings and fabric parameters may need to be considered.

Keywords: Weft and warp knitting. Technical knitted fabrics. Knitted medical and automotive
fabrics. Modifying knitted fabrics. New knitted fabric applications.

1Introduction
Knitting as a technique for producing products has existed for several thousand years although it has only really been in the last century that knitting machines have developed to the point that a wide range of structures and products have been available to society and commerce. Now knitting has developed to the point that the knitting of a wide range of conventional and non-conventional yarns in a wide range of structures is possible so that they can be used in a wide range of non-traditional configurations in apparel, medical, automotive, geo-textile and military et cetera applications. In recent years there have been profound changes in the knitting area. Consumers are much more conscious about quality, cost and innovation. In addition, overseas producers of knitted products in countries such as China and Pakistan have flooded the market (in many countries such as the United States and Brazil) with lower cost and reasonably good knitted products. As such, many knitters have realized that they cannot compete with such low cost imports and have taken steps to broaden their market by producing products designed for other markets which can take advantage of the versatility and characteristics of both weft and warp knits. It is the purpose of this paper to illustrate to
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the reader how traditional knitted structures can be applied to new technology and higher value added products.

2 Weft Knitting
Table 1: Typical Products by Weft Knit Production Systems - Weft Knitting Jersey Machines A Small diameter machines human arteries hose reinforcement coverings tubular bandages scouring pads B Large diameter machines automotive fabrics upholstery safety gloves pot scrubbers oil filters vinyl scrim oil spill tubing filter sleeves aeortas support stockings socks C - Automotive Upholstery laid-in, terry, velour, flat jacquard scrim for vinyl Rib Machines A - Cylinder and dial machines elastic support 1 x 1 laid-in spandex tubular coverings B - V-Bed machines blood filtration missile cones aeortas bandages medical and safety gloves spinal inserts 3D knitted products
Note: Table 1 illustrates a number of non-traditional products which can be produced rather easily on existing weft knitting equipment. By the author.
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This paper will begin by discussing where and how some weft and warp knitted fabrics have made inroads into the medical field. Specific discussions will relate to such topics as tubular and linear weft knitted under-cast liner products and weft knitted injury support products. 2.1 Weft Knit Medical Applications Table 2: General Medical Product Groupings barrier fabrics cast fabrics orthopeadic fabrics bandage fabrics bed care products sutures incontinence products hernia products blood vessel replacement scaffold products
Note: Table 2 illustrates a number of areas where relatively simple jersey and rib fabrics can be used in medical applications. By the author.

Table 3: Specific Medical Applications Orthotics Or Wrapping Products 1. Upper extremity (arms) hand/forearm 2. Lower Extremities (legs) femoral fracture sock tibial fracture sock Prosthetics tubular elastic bandages Eldercare continence care hip protection
Note: Table 3 indicates a number of very specific weft knitted fabric medical product application areas. By the author.

2.2 Tubular and Linear Weft Knitted Under-Cast Liner Products Weft knitting is defined as the intermeshing of yarns into loops across the width of a knitted fabric. In addition, all weft knitted fabrics can be classified into 3 broad groupings of structures: (a) plain jersey fabrics and derivatives, (b) simple rib fabrics and derivatives, and (c) plain purl fabric and derivatives. Under-cast product applications in this paper will deal only with jersey and jersey derivative products.

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One of the most obvious needs for a weft knitted liner fabric to be placed under a cast or a brace is that it be easy to apply, be comfortable, be form fitting and relatively inexpensive. Jersey fabrics readily suit these requirements and are used in upper extremity and lower extremity applications. In terms of upper extremity orthotic fracture applications, jersey fabric tubing can be used in finger and/or wrist applications in addition to lower and upper arm support applications. For such applications, tubes of jersey fabric can be knitted in 100% cotton using a plain jersey stitch or the tube can be knitted in cotton rich and Spandex blends where Spandex such as Lycra, Glospan or Cleerspan can be either laid-in or plaited. A cotton/Spandex blend is a fast and easy alternative to normal plain jersey wraps under casts since one size can fit most if not all requirements. In addition, cotton/Spandex blends are smoother and fit better under a brace or cast. Such jersey tubes can also be used for forearm and hands only or forearm, hands and thumb liners under fracture braces, casts or wrist splints. Such products are knitted on small diameter jersey knitting machines and are hemmed to prevent unravelling. Similar jersey fabric tubes knitted on small diameter jersey machines can produce lower extremity orthotic products for use in femoral fracture socks which: (a) extend from the base of the toes up to the mid thigh, or (b) extend from the ankle to the foot, or (c) extend below the knee to the base of the toe to form liners under fracture braces and casts. Such products are knitted on small diameter jersey machines but stretch easily in both length and width due to the elastic nature of the jersey structure. Cotton/Spandex tubes, rather than all cotton, are often preferred under casts because they are easy to apply, smooth and wrinkle free. Polypropylene can be used in some applications to wick away moisture for comfort reasons. Jersey knitted structures are also used in prosthetic applications. In terms of lamination products, a 100% stretch nylon tube makes it very easy to have final lamination products which are smooth without ridges or runs. Such a tubular form serves as an excellent covering material because it molds well to irregularly shaped limbs. In addition, such tubing can be made on machines with differing diameters in order to permit more versatility. Normal stockinette (i.e., jersey) tubing can also be produced with conventional nylon for use in normal laminations. The nylon gives strength, durability and abrasion resistance to limbs and can also be made on jersey machines with differing diameters. Where there is a need for elastic fitting socks which are form fitting and comfortable, cotton and Spandex can be combined with polypropylene to give the required degree of stretch, recovery, comfort and wicking characteristics. Normally such elasticized socks are designed to provide more stretch at the top of the sock than the bottom. Such stretch differention can be achieved through course length modifications or the way Spandex is inserted either by laying-in in various patterns or by plaiting. Knitted casting supply related products are important items in the medical field because they stretch to the width required, they conform to body shapes and minimize wrinkles forming in the fabric under casts. In this case, cotton and synthetic continuous rolls of
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jersey fabric to be cut to the length required are used extensively. Cotton tubular products are more comfortable in use under plaster casts whereas synthetic (i.e., manufactured) yarn based products, which are fast drying, are more suited for use under fiberglass castings. Single layer jersey fabric in narrow widths, after being cut on the bias, can also be used as a liner fabric under casts because such fabric is used as a layer of wrapping designed to conform to the body under the cast. Even so, such bias cut jersey is an excellent product which can hold splints and other orthopaedic devices in place because of the natural stretch and recovery properties of the fabric. In addition, inherent elasticity can help to minimize discomfort if swelling occurs. Such wraps are also very effective when used in plastic surgery and burn dressing applications. 2.3 Weft Knitted Injury Support Products Elasticized tubular weft knitted medical support products are very important in that: (a) they give support to areas of the body where there has been stress or strain such as at the ankle, elbow or knee and, (b) where bandages or heat packs et cetera need to be kept in place with a maximum of dependability and a minimum of discomfort. Such products are made on a tubular basis, (i.e., where no straps or hooks are involved), and can be knitted on both small diameter jersey and small diameter dial and cylinder machines and can incorporate Spandex yarns. Spandex yarns which are used in medical applications are usually double covered rather than single covered. The reason that double covered yarns are preferred is that their higher cost is offset by the fact that they do not torque, they have controlled stretch, a smooth appearance and controlled recovery. In addition, double covered yarns exhibit good abrasion resistance and high strength. In terms of stretch and recovery, the bottom covering nylon yarn controls the stretch characteristics of the yarn whereas the top covering yarn (with its lower numb er of wraps per inch), balances any potential for the yarn to torque and gives smoothness to the yarn. Yarn smoothness can be enhanced by using a low twist filament nylon yarn with more filaments and using equal denier nylon yarns in both the bottom and top covering yarns. In addition, the use of a false twist textured top covering yarn with lower stretch properties will produce a smoother yarn. Injury support products, as noted previously, can be knitted on small diameter jersey and small diameter dial and cylinder (hosiery) machines. These products can be produced in a straight tube or in a shaped form incorporating a conventional heel or a pouch. The curved heel is formed by a reciprocating action whereas the pouch is formed by maintaining a constant direction of rotation but altering the amount of yarn fed to half the needles at a graduated rate as the machine continues to rotate in one direction. If a conventional tube product is made, then support to, for example, a forearm is essentially uniform around the complete circumference of the fabric and is dependent upon: (a) the tightness of knitting, (b) the way Spandex is incorporated into the structure (how much and in what pattern), and (c) the recovery properties of the double covered Spandex
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yarn. Such products are used to treat situations where tissue support is necessary, where pressure dressings need to be held in place or where the placement of normal dressing materials is not practical. In terms of configuration, tubular products are superior to flat fabric because flat fabric may slip out of place over time and/or give different pressures to affected areas. In jersey fabrics, Spandex is normally incorporated into the structure by a laying-in technique on pre-determined courses in a pre-determined balanced pattern. In such cases, Spandex in-lay should be balanced if possible and the in-lay pattern is dependent upon the number of feeders on the machine. Plaiting is preferable to laying-in the Spandex since the Spandex is held in the structure more securely even though more Spandex yarn is consumed. When plaiting is done in jersey fabrics, nylon yarn must be put on the face of the fabric and Spandex on the rear; correct yarn placement is achieved by the use of proper tension control and yarn placement. In dial and cylinder products, it is normal to use 1 x 1 rib fabric as the foundation structure and then incorporate double covered Spandex in one of 3 ways: (a) lay-in the Spandex on a 1:1 or 1:3 basis (b) knit-in the double covered Spandex yarn on the dial loops only, or (c) knit-in the double covered Spandex on both the dial and cylinder loops. Spandex pop-outs are more prevalent when such Spandex is laid-in whereas pop-outs generally are not a problem when the Spandex is knitted-in on either the dial loops only or knitted-in on both the dial and cylinder loops. Depending on the number of feeds used to incorporate the Spandex, fabric compression is dependent upon such factors as: (a) fabric tightness, (b) whether the Spandex is laid-in or knitted-in, (c) the frequency of Spandex incorporation, and (d) the recovery properties of the Spandex yarn. As with linear jersey tubular support products, parameters to consider are product strength, stretch, recovery, comfort, utility and cost. The presence of a pouch in the support tube can hold gauze or a soft insert in place very securely. In addition, decoration can be added if a feed stripe effect in color is introduced to the tube. In addition to forearm, thigh, elbow, knee and/or ankle applications for the previously discussed products, there are elderly, maternity and urology related applications for shaped knitted products which can be produced on body shaping knitting machines which can have up to 6 inch cylinder diameters. Such products can also be produced by a traditional cutting and sewing technique. In terms of elder care, there is a growing need for the production and availability of panties or briefs which are capable of incorporating and securely holding pads or inserts which will prevent problems related to a loss of bladder control. In such panties or briefs, it is also important to appreciate the comfort stretch and recovery properties that are created by the use of cotton/Spandex or stretch nylon/Spandex yarns and the knit structure selected. In such products, a secure retention of pads or liners is crucial. Maternity care is another area where specially designed weft knitted products are used in support. Pre-natal and post-natal nursing bras and maternity briefs made from cotton and Spandex or stretch nylon and Spandex are other examples where specifically
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designed products are essential. Maternity briefs, which can incorporate comfortable and reusable maternity pads and liners, are very convenient because the pads and liners used are both soft and non-irritating. Knitted hip protection panties or briefs are also very important to older people since they impart shock to surrounding tissue and muscles if a person should fall. Such products are essential for many older people since up to 15-20% of people who suffer a hip fracture die within 12 months of a fall. It has been stated that more than 50% of people never regain their original mobility if they suffer a hip fracture. Many elderly people who suffer from hip fractures are thus forced to go into nursing homes. In the SafeHip product line by Tytex, for example, panties or briefs contain 2 polypropylene shields in the side panels of the panties or briefs. Weft knitted products containing urinary or drainage bags are also available for people who require comfortable products and piece of mind because of urinary problems. By eliminating the sound of noisy urinary or drainage bags, people feel far more comfortable in potentially embarrassing social situations. Leg or stomach supported knitted products also are available and contain drainage bags internally beside the leg or internally to the side of the stomach wall. Such products are available in cotton or filament yarn versions. 2.4 Weft Knitted Medical Implantable Textiles Textile products which are implanted in the human body must be non-toxic, blood compatible, bio-compatible and also porous enough to allow tissue growth so that the tissue can enclose them once they have been inserted in the body. For other applications such as sutures, bone setting materials, meshes and synthetic skin, it is also very important that such products are bio-absorbable. Bio-degradable fibers that are commonly used include PTFE, polyester and polypropylene. Implants are often used in conjunction with products such as support hose because they give compression support to the leg and these support systems have devices which help to hold blood vessels and bones in place during healing by providing pressure or a rigid framework. Products such as support hosiery provide compression support to the leg in cases of thrombosis and varicosity and when used pressure is used to support the walls of the veins and counteracting the pressure of the blood on the vein walls and thus increase blood flow. Usually a combination of nylon and spandex yarns is used in such products. More exotic products such as surgical gloves made from scalpel resistant yarns are weft knitted and worn under normal latex gloves during operations. It should also be noted that when producing knitted fabrics for particular applications it is usually necessary to modify the characteristics of the product to suit the needs of both the customer and the application for which the product is intended.

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3. Warp Knitting
Many non-apparel products are also produced on tricot and raschel warp knitting equipment using one or two needle beds. In this context, Table 4 highlights a number of warp knitted health and automotive related application products that are presently being manufactured. If these and other potential products are not presently being manufactured and sold in countries such as Brazil, then they certainly could be if both companies and the general population was aware that they could be available. Table 4: Typical Products by Warp Knitting Production System Tricot Single Needle Bar Tricot Tricot Atlas heart support hernia repair Terry and Velour headliners liner fabrics upholstery Mesh ventilation products laundry applications produce packaging sportswear military products Raschel Single Needle Bar Raschel Laid-In automotive shielding products wire carrier applications construction and geo-textile applications home maintenance applications Mesh automotive shielding products construction barrier and safety products Weft Inserted scrim awnings tarps Two Needle Bar Raschel Flat Fabrics 2-4 bar tricot Plush
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automotive products home furnishings toy covering products Spacer Fabrics automotive seating recreation footwear outdoor and school products hospital applications Tubular Fabrics produce packaging support products aeortas

3.1 Warp Knitted Medical Implantable Textiles Implants which are commonly used include vascular grafts, ligaments, heart valve components, hernia mesh fabrics and adhesion barriers. For example when aortic aneurysms occur, a catheter is inserted into an artery in the groin in order to deliver the implanted polyester graft to the aortic wall where it is attached by small positioning hooks. For example, in one patented internal hernia product, a hernia repair is achieved by using a knitted polypropylene mesh patch in conjunction with an underlay patch that is put on the inside of the abdominal wall and another patch on the outside of the abdominal wall and the knitted polypropylene mesh patch connector joins the two patches together while plugging the rupture in the wall. In some applications, knitted polyester vascular and cardiovascular grafts possess a tricot fabric with a velour surface which is designed to promote tissue growth. In this application, reverse locknit is a popular structure. Other examples of support products include compressive bandages which are used on arms or legs in addition to graduated compressive bandages made on either tricot, raschel or crochet machines. 3.2 Warp Knitted Fabrics Automotive Table 5: Automotive Applications of Selected Warp Knitted Fabrics Automotive Applications for Tricot Terry and Velour headliners seats seat backs door panels sun visors columns seat pockets arm rests
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Automotive Applications for Double Needle Bar Plush seat centers seat back rests headrests door panels
Note: Table 5 highlights a number of areas where both conventional tricot and raschel terry and velour fabrics have found acceptance in the automotive trade. By the author.

3.3 Single Needle Bar Tricot Machine Fabrics Table 6: Typical Terry and Velour Tricot Automotive Fabrics (Conventional and Yarn Overfeeding) Terry Front Bar 3-4/1-0/ full set nylon Back Bar 1-2/1-0/ full set nylon Back Bar 1-2/1-0/ full set nylon Front Bar 4-5/1-0/ full set nylon Front Bar 4-5/1-0/ full set nylon Back Bar 1-0/1-2/ full set nylon Front Bar Back Bar 0-1/1-0/ 1o in, 10 out nylon 1-2/1-0/ full set nylon Velour Back Bar 1-2/1-0 full set nylon Front Bar 1-0/2-3/ * Front Bar 1-0/4-5/ * Back Bar 1-2/1-0/ full set nylon Back Bar 1-0/1-2/ 125 cm full set nylon Front Bar 1-0/1-2/ 300 cm * Front Bar 1-0/2-3/ 290 cm * Back Bar 1-0/1-2/ 110 cm full set nylon

Middle Bar 1-0/3-4/ full set nylon

Note: Information in Table 6 illustrates some typical and basic construction information about terry and velour tricot fabrics produced on single needle bar tricot machines that could be used in the automotive trade. By the author.

3.4. Raschel 3.4.1 Needle Bar Raschel Machine Fabrics Raschel machines, like tricot machines, can knit fabric using either 1 or 2 sets of needles. Usually many tricot fabrics are considered to be commodity type fabrics whereas raschel products are sometimes thought of as being fancier and more engineered products in reality both tricot and raschel fabrics can be engineered to a high degree. For example, many texts refer to raschel machines in the context of making lace products where in reality such machines can produce products which range from orthopedic bandages to wire carrier products to Astroturf* to spacer products. For example, in orthopaedic bandages a popular typical construction could be FB 2-0/0-2/ MB 0-0/2-2/ and the BB 00/6-6/ with the yarn on the middle bar being elastomeric. Indeed such flat knitted bandages could be of the elastic, inelastic or compression type, be knitted in strips on wide machines or in independent widths on crochet machines and could have a solid or open nature such as a net construction.

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3.5 Raschel Medical Products 3.5.1 Warp Knit Bandage Products In recent years a range of 2 bar warp knitted inelastic and elastic compressive bandage products have become more prominent. When required, it is also possible to produce and use both 3 and 4 bar tricot and/or multi-bar raschel based fabric products.

3.5.2 Inelastic Warp Knitted Flat Bandages As noted previously, it is possible to produce inelastic bandage or primary dressing products on tricot and raschel machines. In Table 7, a tricot laid-in fabric construction using an open chain stitch is documented in construction A. Construction B in Table 7 documents a modification of the laid-in tricot construction shown in A in that it uses a closed half tricot stitch on the front bar in order to connect wales together. Construction C in Table 7, documents a simple mesh fabric design that can be produced on a tricot machine. Construction D illustrates a raschel fabric with a reasonably long laid -in back bar fabric construction using a chain stitch on the front bar whereas Construction E is a similar laid-in fabric but uses a closed half tricot stitch. Raschel construction F illustrates a similar fabric to E but with a longer lay -in to give a heavier, less open fabric compared to E. All fabrics in Table 7 knit with 100% spun cotton yarns. Table 7: Six Examples of Tricot and Raschel Inelastic Flat Bandage Fabric Constructions Construction A Front bar 1-0/0-1 full set Back bar 0-0/4-4/ full set Construction D Front bar 0-2/2-0/ full set Back bar 0-0/8-8/ full set Construction B Front bar 1-0/1-2/ full set Back bar 0-0/4-4/ full set Construction E Front bar 0-2/2-4/ full set Back bar 0-0/8-8/ full set Construction C Front bar 1-0/2-3 half set Back bar 2-3/1-0/ half set Construction F Front bar 0-2/2-4/ full set Back bar 0-0/10-10/ full set

There are 3 possibilities of producing narrow widths of fabric: (a) knitting the fabrics in full width and subsequently slitting the fabric into required widths, (b) knitting the fabric constructions on raschel machines using separation yarns between the bands, and (c) knitting the fabrics on crochet machines. Slitting will create fraying sides, strip separation involves a separate mechanical pulling or yarn dissolving process (and two rough edges) whereas the crochet approach will give the correct fabric width without additional processing or any damage. 3.5.3 Elastic Warp Knitted Flat Bandages Table 8: Three Examples of Raschel Elastic Flat Bandage Fabric Constructions Construction A Front bar 2-0/0-2/ full set Construction B Front bar 2-0/0-2/ full set Construction C Bar 1 4-2/2-4/2-0/ 2-4/4| 43 |

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Back bar 0-0/6-6/ full set

Middle bar 0-0/6-6/ full set Back bar 2-2/0-0/ full set

2/4-6/ Bar 2 2-4/4-2/4-6/4-2/24/2-0/ Bar 3 0-0/2-2/ x 3 Bar 4 2-2/0-0/ x 3

Note: In Table 8, a notation for a raschel fabric intended to be an elastic bandage is shown in construction A where the front bar uses textured nylon and the back bar can use either cotton or spun viscose. The notation for a 3 bar raschel construction intended as a compressive bandage is shown in construction B of Table 8 where the front bar is knitted with cotton, the middle bar is knitted with 100% cotton and the back bar is knitted with covered Spandex. Using double covered Spandex on the back bar instead of single covering the Spandex will increase stability but also fabric weight and cost. By the author.

A Power-net type raschel bandage fabric notation is shown in construction C in Table 8. Here bars 1 and 2 use textured nylon on a half set basis and bars 3 and 4 can use half set bare or covered Spandex. It should be noted that for Construction C in Table 8, if bars 3 and 4 use bare Spandex, there is some probability that Spandex pop outs will occur. As such, it may be advised to knit-in the Spandex on bars 3 and 4. It should also be noted that knitting on bars 1 and 2 and laying-in on bars 3 and 4 in reverse helps to stabilize fabric balance. In this context, Table 9 documents several typical and generic laid-in fabric constructions that can be produced on raschel machines whereas Table 10 illustrates several laid-in raschel fabric constructions that could be used in bandaging products. Table 11 documents a typical 4 bar power-net construction which can be used in bandage applications. Weft inserted raschel fabrics can also be used as scrim for vinyl backing materials. Table 9: Typical Raschel Laid-In Fabrics Example 1 FB 0-2/2-0/ BB 0-0/4-4/ Example 3 FB 2-0/2-4/ BB 0-0/6-6/ Example 2 FB 0-2/2-0/ BB 0-0/6-6/ Example 4 FB 2-0/2-4/ BB 0-0/10-10/

Table 10: Typical Raschel Bandaging Fabrics Incorporating Laid-In Yarns Example 1 FB 2-0/0-2/ full set nylon BB 0-0/8-8/ full set spandex

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Example 2 FB 2-0/0-2/ full set nylon BB 0-0/6-6/ full set cotton or viscose Example 3 FB 2-0/0-2/ full set cotton MB 0-0/6-6/ full set cotton BB 2-2/0-0/ full set spandex Example 4 FB 2-0/0-2/ full set cotton MB 0-0/2-2/ full set cotton BB 0-0/6-6/ full set spandex Table 11: A Raschel Power-Net Fabric as a Bandaging Material (Bar 1) 4-2/2-4/2-0/2-4/4-2/4-6/ half set textured nylon (Bar 2) 2-4/4-2/4-6/4-2/2-4/2-0/ half set textured nylon (Bar 3) 0-0/2-2/ x 3 half set spandex bare or covered (Bar 4) 2-2/0-0/ x 3 half set spandex bare or covered

3.6 Needle Bar Raschel Machines and Fabrics Two needle bar raschel fabrics may be knitted in open width or tubular form. In open width form, raschel fabrics are commonly used as plush fabrics in automobile upholstery and medical comfort applications. Tubular products can be used in sacking, pantyhose, support stocking and aeorta applications; these will not be discussed here. Two needle bed raschel plush fabrics when used in automotive applications may be knitted to full or partial widths in a wide range of pattern possibilities. If left uncut, such fabrics can be used as spacer fabrics. In plush fabrics, fabric weight can be changed by a number of techniques. From a machinery point of view, weight can be increased by: (1) using more pile bars, (2) more total yarn bars, (3) using full set threading, (4) utilizing a greater distance between the two needle beds, and (5) using a coarser gauge machine. From a structural point of view, fabric weight can be increased by: (1) increasing the length of lay-in, (2) reducing the runner lengths of the knitting and laying-in bars, (3) using ply yarns instead of single yarns, (4) using yarns with a higher denier or lower cotton count et cetera.
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From a finishing standpoint, fabric weight can be increased by: (1) increasing the amount of latex backing used, and/or (2) minimizing shearing. Table 12 illustrates basic knitting information about two examples of 6 bar plush fabrics. It will be noted that fabric B has a longer lay-in and this not only adds weight, cost and rigidity to the fabric but the longer lay-in increases the split resistance of the fabric when it is manipulated around the contours of a automobile seat. It can also be seen that the open loops on one knitting bar allows for more pile yarn movement than the closed loops of the other knitting bar and such a difference can sometimes cause yarn movement during shearing and shiners in the fabric. Table 12: Structural Notations for Two Selected Automotive Two Pile Bar Plush Fabrics Fabric A Bar 1 Bar 2 Bar 3 Bar 4 Bar 5 Bar 6 8-8/0-0/0-0/8-8/ 0-2/2-2/2-0/0-0/ 0-2/0-2/2-0/2-0/ 0-2/0-2/2-0/2-0/ 0-0/0-2/2-2/2-0/ 8-8/8-8/0-0/0-0/ Fabric B 10-10/0-0/0-0/10-10/ 0-2/2-2/2-0/0-0/ 0-2/0-2/2-0/2-0/ 0-2/0-2/2-0/2-0/ 0-0/0-2/2-2/2-0/ 10-10/10-10/0-0/0-0/

3.7 Warp Knitted Medical and Automotive Spacer Fabrics As noted, another application of knitted support fabrics are spacer fabrics produced on double needle bar raschel machines (although some spacer fabrics are being produced on double needle bar tricot (simplex) machines now). Such raschel fabrics are now beginning to be used in hospital and home situations where people are restricted to staying in a bed for long periods of time and where there is little to no activity. In effect, such fabrics form a resilient layered fabric which is placed between the top of the mattress and the person laying in bed and help to prevent the formation of bed-sores and their effects. Spacer fabrics used in medical support applications are characterized by having two distinct layers of fabric separated by a set of mono-filament nylon yarns using 2 or 3 pile yarn bars. As such, a fabric structure is created that is light-weight, very resilient, potentially very warm, quite soft, air permeable and durable. The ready wicking of moisture which occurs easily in such fabrics is also an advantage. Fabric resiliency can be enhanced by: (a) the number of mono-filament yarns available per square inch, (b) the denier of each mono-filament yarn, (c) the cross-sectional shape of the mono-filaments (usually round), and (d) the distance between the two fabric layers. In addition, for functional or aesthetic reasons, various designs can be imparted to one or both of the two fabric surfaces. For example, a solid two bar fabric design that is capable of being
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brushed is possible on one fabric surface whereas a mesh or open-work fabric design can be knitted on the other side of the fabric. Although the technology for the production of narrow and full width spacer fabrics has been around for many years, it is only in recent times that there has been a renewed interest in such fabrics as a substitute for neoprene based products. Such fabrics are characterized as being two separate fabrics jointed together by yarns which bridge the two fabrics in much the same way as a filling separates the two pieces of bread in a sandwich. Both fabrics may have the same or different constructions and range from openwork and/or loose constructions to full set and tightly knitted constructions. The spacer yarns are normally monofilament nylon. Although not discussed in this paper, other typical applications for spacer fabrics include, drainage mats, wall sound-proofing fabrics, goalkeeper gloves in soccer or more recently seat cushions and seat pocket fabrics in the automotive industry or bed sheeting and other bed liner products in the healthcare field. When used in automotive upholstery and orthopedic products there is air, heat and moisture transfer which are additional advantages to the softness, resilience, anti-static and anti-microbal characteristics offered by such structures. Spacer fabrics are also used in shoe, fashion and sportswear applications. Table 13: Raschel Knitted Spacer Fabric Applications Automotive And Healthcare Applications Of Spacer Fabrics seats seatbacks headrests sheeting mattress padding Beneficial Properties Of Spacer Fabrics Light weight Resilient Compressible Designable No fogging Light fast Conductive
Note: Table 13 outlines several raschel spacer fabric applications and properties. By the author.

4 Summary
It is obvious that in recent years knitting has made tremendous inroads in meeting the need for emerging and numerous niche market applications in non-traditional textile related fields. This has been done not only to meet the needs of evolving markets but
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also to cope with the threat posed by a surge of products being produced in low wage and/or low tech countries. Incorporating only a few examples, this paper has briefly addressed only two of many potential niche product areas where knitted products can make a significant contribution.

5 References
ANAND, S. Developments in technical textiles Part 1. Knitting International, p. 32-35, July, 2000. BAYER FASER GmbH. Dorlastan in the Hosiery Industry. Dorlastan Product Information Publication. DU PONT TECHNICAL INFORMATION. Lycra sandex in circular knit fabrics. Dec. 1981. (Bulletin L-98). DU PONT TECHNICAL INFORMATION. Manufacture of single and double covered yarns of Lycra. May 1974. (Bulletin L-79). RX TEXTILES. Disponvel em: <http://www.rxtextiles.com/rxtextiles/orthotics/main.html> SMITH, G. N. C. State University. Lecture notes. TYTEX GROUP. Disponvel em: <http://www.tytex.com/index.html>

Biographical Notes Gary W. Smith

Ph.D. in knitting from Leeds University in England (1980), master degree from the North Carolina State University (1969), and Bachelor in Science at North Carolina State University (1966). He has been granted with several awards, and he has written various books including: "Elements of an Apparel Quality Control Program (1986), "Controle de Qualidade na Indstria de Malhas III (1989), and "World Class Manufacturing" (1990). Nowadays, Gary W. Smith is an Associate Professor of Textile Apparel and Management at the North Carolina State University. Email address: gsmith@ncsu.edu Link curriculum: http://www.tx.ncsu.edu/faculty_center/directory/detail.cfm?id=109#biogr aphy

Jos Felisberto Cardoso da Silva

Graduated as professor of the part of formation of technician education Knitting and Apparel license. He is textile technician of knitting and
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apparel, and he wrote the books Tecnologia das Mquinas Circulares de Grande Dimetro and Controle da Qualidade no Processo - Mquinas Circulares. He attended several courses in the knit ting field: International Institute for Cotton (England and SENAI/CETIQT Brazil), International Institute for Cotton (England), North Carolina State University (U.S.A.), SHIMA SEIKI (Japan).

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