The two industries

Occasionally parts of both knitting techniques are combined in a single machine; generally, however, the techniques have tended to diverge to produce entirely separate industries each having its own specialist technology, machine builders, fabric characteristics and end-uses.

6.2.1 Weft knitting

Weft knitting is the more diverse, widely spread and larger of the two sectors, and accounts for approximately one quarter of the total yardage of apparel fabric compared with about one sixth for warp knitting. Weft knitting machines, particularly of the garment-length type, are attractive to small manufacturers because of their versatility, relatively low total capital costs, small floor space requirements, quick pattern and machine changing facilities, and the potential for short production runs and low stock-holding requirements of yarn and fabric.

A major part of the weft knitting industry is directly involved in the assembly of garments using operations, such as overlocking (Fig. 6.3), cup seaming (Fig. 6.4), and linking, that have been specifically developed to produce seams with compatible properties to those of weft knitted structures. There are, however, production units

Fig. 6.3 Overlook seaming [Corah].
Fig. 6.4 Cup-seaming.

that concentrate on the knitting of continuous lengths of weft knitted fabric for apparel, upholstery and furnishings, and certain industrial end-uses.

6.2.2 Warp knitting

Warp knitted fabric is knitted at a constant continuous width, although it is possible to knit a large number of narrow width fabrics within a needle bed width, usually separating them after finishing. There is considerable potential for changing fabric properties during the finishing process, as well as during knitting.

It is also possible to produce length sequences such as scarves with fringed ends, articles produced on double needle bar raschels based on the tubular knitting principle, and scalloped shaping of net designs by cutting around the outline after finishing.

British Celanese set the trend for the establishment of large, vertically-organized warp knitting plants self-sufficient in beaming, and in dyeing and finishing operations. During the 1930s they installed large plants with a total of 600 two-guide bar locknit machines, in order to convert their acetate and viscose rayon yarn into lingerie, shirting, blouse and dress fabrics. The much later introduction of continuous filament nylon and polyester yarn provided ideal raw materials for high-speed conversion into fine-gauge warp knitted fabrics.

From the mid 1950s, the patterning potential of multi-guide bar raschels has been progressively improved, based particularly on the conversion of nylon and polyester filament yarns. Thus, the lace and curtain net trade taken from warp knitting during the 1820s by twist, bobbinet and Leaver's lace machines has been extensively regained [1]. Warp knitting suffered in the swing of fashion away from continuous filament synthetic yarns towards blended spun yarns in solid fabrics, so there has been a tendency for the industry to seek new markets in household furnishings, car upholstery (Fig. 6.5) and industrial cloths.

Staple fibre spun yarns and textured continuous filament yarns create major difficulties for warp knitters. The precise setting of the elements, their fine gauge, the plating of two yarns in a needle hook, and the supply of parallel ends of yarn necessitate the use of fine and therefore expensive yarns. Problems can be caused by lint accumulation or filamentation, and the increased cross-sectional area caused by these seriously reduces the total length of warp yarn that can be accommodated on a specific warp beam flange diameter, thus increasing handling costs and machine down-time. For example, increasing the warp beam diameter from 21 to 40 inches (53 to 100 cm) enables the total length of accommodated warp to be quadrupled, but changing the yarn from 30 denier nylon to 150 denier textured polyester decreases the total length of accommodated warp ten-fold.

Fig. 6.5 Warp-knitted car upholstery [Karl Mayer].
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