http://www.innovationintextiles.com/warp-knitted-spacer-fabrics-for-a-good-nights-sleep/
`
`Log in
`
`Sign Up
`
`About Us
`
`Contact Us
`
`Advertise With Us
`
`Home
`
`Technology
`
`Markets
`
`Events
`
`Reports
`
`FREE
`Get your FREE
`membership.
`
`HOME > FIBRES, YARNS & FABRICS > WARP-KNITTED SPACER FABRICS FOR A GOOD NIGHTS SLEEP
`
`22nd February 2011, Obertshausen
`Warp-knitted spacer fabrics for a good
`nights sleep
`
`0 comment
`
`With testing for resistance to dust mites, compression testing for
`
`1 of 7
`
`IPR2017-00351
`Fredman EX1035 Page 1
`
`

`
`http://www.innovationintextiles.com/warp-knitted-spacer-fabrics-for-a-good-nights-sleep/
`
`performance, and comfort tests that simulate what actually
`occurs during sleep – the peaceful, easy going times are surely
`well and truly over for the bedding sector. Well-thought-out
`systems for mattresses create both a pleasant, comfortable
`climate under the covers and allow a healthy posture when
`lying down, to enable the body to recover completely over a
`period of at least eight hours. Leading textile machinery
`manufacturer Karl Mayer has some solutions..
`
`According to the German warp knitting machine manufacturer,
`what might sound like a daydreamer’s wish list, can be met easily but effectively by warp-knitted spacer fabrics.
`The voluminous fabrics are specifically designed to be compression-resistant, breathable and effective in dealing
`with moisture. In addition, perspiration and water vapour can be consistently wicked away through the 3D
`construction and the structure of the fabrics’ cover faces.
`
`Karl Mayer says the potential offered by the production process to incorporate zones of different hardness also
`make spacer textiles the preferred choice for combining with other materials – a development which it as a
`manufacturer of machines for producing spacer textiles, has taken into account.
`
`The company’s efficient, double-bar HighDistance HD 6 EL 20-65 and HD 6/20-35 machines are now available to
`the mattress industry for producing high-quality, functional, three-dimensional cushioning and padding materials.
`On the other hand, Karl Mayer says, the RD 6/1-12 and RDPJ 7/1 are both perfect for producing entire mattress
`covers or sections of mattress covers. They are also equipped with two needle bars and can therefore make 3D
`constructions. In addition, the company’s TM 2 tricot machine, which operates at a high productivity rate, is
`available for producing two-dimensional cover fabrics.
`
`Breathable cushioning elements
`
`Conventional mattresses are as diverse as the body shapes of
`their users. Some are made from spring interiors, latexes or
`foams, and then there are the unconventional types, such as
`waterbeds, air core mattresses, futons and, of course, mattresses
`that are a combination of these. Combining different materials is
`said to be becoming more and more important.
`
`Mattress manufacturers are said to be increasingly using
`
`PRINT
`
`SHARE VIA
`
`RELATED NEWS
`
`Textile Exchange’s Market
`Reports show companies
`driving industry
`transformation
`
`Anti-dust mite textiles may
`help relieve neurodermatitis
`symptoms
`
`Monforts to present latest
`stenter for filter materials at
`Filtech
`
`Primaloft launches Primaloft
`Gold Insulation Eco with 55%
`recycled content
`
`Cinte Techtextil China to
`welcome new European
`exhibitors
`
`FIBRES, YARNS & FABRICS
`
`MEDICAL, HEALTH & HYGIENE
`
`INTERIORS
`
`2 of 7
`
`IPR2017-00351
`Fredman EX1035 Page 2
`
`

`
`http://www.innovationintextiles.com/warp-knitted-spacer-fabrics-for-a-good-nights-sleep/
`
`FREE
`weekly
`e-newsletter
`The week's key stories,
`direct to your inbox.
`Be the first to know.
`
`Enter your email here
`
`Subscribe
`
`Expert Opinion
`
`warp-knitted spacer fabrics combined with other materials to
`ensure that their products meet ergonomic requirements.
`However, Karl Mayer says, they are usually only used as the
`cushioning/padding element, which does not fully utilise their ability to optimise the sleeping climate. The
`functional 3D fabrics are usually located in a foam frame or used as a continuous layer between layers of foam, and
`are only rarely used as the surface against which the person lies, according to Karl Mayer. Nevertheless, Karl Mayer
`says, 3D warp-knitted fabrics are making inroads into the actual mattresses themselves. Some manufacturers are
`already making their mattresses entirely out of spacer textiles and the Southern European and Asian
`manufacturers are leading the way in this.
`
`Karl Mayer launched a new double-bar raschel machine designated the HD 6/20-35, aimed at this segment of the
`market specialising in thicker, warp-knitted spacer textiles to coincide with the opening of this year’s ITMA
`ASIA+CITME trade fair. The company says it can now react quicker to growing demands by supplying efficient
`machines. The HD 6/20-35 is the basic version of the HD 6 EL 20-65, which is already said to be well established in
`the market, and completes the range of HighDistance machines. Whereas the full-size HD machine, which has a
`distance between the knock-over comb bars of 20-65 mm, can produce fabrics with a final thickness of 50-55 mm,
`the new machine produces spacer fabrics with a thickness of 18-30 mm and has a distance between the knock-over
`comb bars of 20-35 mm.
`
`According to Karl Mayer, regardless of their format, all 3D warp-knitted textiles produced on the HighDistance
`machines have extremely reliable performance characteristics. As far as mattresses are concerned, this means that
`they must have stable compression values, specific spot elasticity and exceptional ventilation characteristics –
`functional characteristics that can be produced economically by using efficient production machines.
`
`Debra
`Cobb
`
`1st July 2016
`Expert Opinion
`
`The Renewal Workshop:
`Connecting Brands to the
`Circular Economy
`The Renewal Workshop will
`create a new category of
`product called Renewed
`Apparel, said Jeff Denby, the
`co-cre
`
`3 of 7
`
`At a working width of 110 inches and a gauge of E 12, the HD 6/20-35 can achieve a maximum production speed of
`300 rpm or 600 courses/min. The thicker spacer fabrics can be produced at a maximum speed of 200 rpm, which is
`400 courses/min.
`
`Side borders and entire mattress covers
`
`“The mattress cover has a pronounced influence on the initial
`perception of comfort when the person first lies down, and
`should therefore be very soft – a requirement that is usually met
`by conventional mattresses having multilayer constructions,” Karl
`Mayer explains.
`
`“In this case, the conventional combinations usually consist of a
`
`IPR2017-00351
`Fredman EX1035 Page 3
`
`

`
`http://www.innovationintextiles.com/warp-knitted-spacer-fabrics-for-a-good-nights-sleep/
`
`Russia aims to
`attract foreign
`investment in
`national technical
`textiles industry
`Eugene Gerden
`
`How DNA is Taking
`the Guesswork Out
`of Premium Cotton
`Branding
`Debra Cobb
`
`smooth surface combined with nonwoven waddings or foams.
`The main disadvantage of joining them together by laminating
`or quilting processes is that the removable covers are difficult
`to clean and their elasticity is poor. Furthermore, the exchange
`of air with the surrounding environment is hampered by the
`high density of the material. The only breathable areas in the mattresses are usually those with side borders made
`from thin, warp-knitted spacer textiles having mesh constructions.”
`
`“Modern designs are becoming increasingly popular for patterning the outer sides of the textile. In this case, the RD
`6/1-12 and the RDPJ 7/1 double-bar raschel machines offer numerous possibilities. The RD 6/1-12 produces thin,
`3D warp-knitted textiles with a distance between the knock-over comb bars of 1-12 mm; it can therefore work a
`wide range of different lappings, and is also extremely productive. This high-speed machine can reach a maximum
`operating speed of 475 rpm or 950 courses/min,” Karl Mayer says.
`
`All Experts >
`
`Even wider pattern range
`
`Events
`Calendar 2016
`
`30 July - 1 August 2016
`Hofheim-Wallau
`Innatex
`
`3-6 August 2016
`Salt Lake City, UT
`Outdoor Retailer
`Summer Market 2016
`
`3-5 August 2016
`Dartmouth, MA
`American Flock
`Association triennial
`
`4 of 7
`
`According to Karl Mayer, the RDPJ 7/1 can produce an even
`wider range of patterns. The creative, double-bar raschel
`machine is said to combine maximum efficiency and flexibility,
`and the distance between the knock-over comb bars can be
`varied from 2 to 8 mm. It can also process a wide range of
`different materials and produces jacquard patterns.
`
`The machine’s EL control facility enables an even wider variety of
`spacer textiles to be produced. The machine’s electronic facilities
`permit alternating 2D and 3D zones as well as different lappings
`to be worked, which influences the characteristics of the fabric.
`The modifications mainly relate to the pile strength and the
`elongation values in the lengthwise and crosswise directions. The
`RDPJ 7/1 can be used to produce attractive, all over patterns, mattress borders whose contours match those of the
`end product in the appropriate widths, lettering, different lappings, and functional elements, such as buttonholes
`and pockets.
`
`As well as being used in the side borders, the soft, low-dimensioned, attractive, warp-knitted spacer fabrics
`produced on Karl Mayer’s double-bar raschel machines can also be made into entire mattress covers. These
`functional cover fabrics, with their airy construction, are said to optimise the sleeping climate and they can be
`
`IPR2017-00351
`Fredman EX1035 Page 4
`
`

`
`http://www.innovationintextiles.com/warp-knitted-spacer-fabrics-for-a-good-nights-sleep/
`
`Flock School
`
`9-12 August 2016
`Blumenau
`Febratex 2016
`
`5 of 7
`
`washed and dried easily, and then put back onto the mattress again with no problems. Karl Mayer says, the thin, 3D
`warp-knitted fabrics can also be quilted easily in the designs typically used for padding or cushioning materials.
`
`According to Karl Mayer, in addition to voluminous mattress covers, flat covering materials with printed designs
`are also an up-and-coming trend. Karl Mayer’s TM 2 machine is said to be ideal for producing these stable, dense
`fabrics; the TM 2 is a two-bar tricot machine which is fast and flexible and produces top-quality products.
`Depending on the lapping and yarn used, the TM 2 can operate at speeds of up to 2500 rpm.
`
`“ With their exceptional breathability and cushioning that corresponds to the shape of the body, warp-knitted
`spacer textiles provide a high level of comfort and enable the sleeper to rest and recover by guaranteeing deep,
`sound and healthy sleep – the perfect solution for getting a good night’s sleep!” says Karl Mayer.
`
` 
`
`Author:
`Innovation in Textiles
`
`Please sign in to setup categery email alerts
`
`MORE: BY THIS AUTHOR
`
`MORE: IN THIS CATEGORY
`
`OTHER: RELATED NEWS
`
`Curt G. Joa Europe relocates to Mayen
`
`SGL Group ceramic component reaches
`Jupiter’s orbit in Juno spacecraft
`
`Textile Exchange’s Market Reports
`show companies driving industry
`transformation
`
`Textile Exchange’s Market Reports
`show companies driving industry
`transformation
`
`Spacer fabrics feature at technical
`textiles symposium
`
`Anti-dust mite textiles may help relieve
`neurodermatitis symptoms
`
`Monforts to present latest stenter for
`filter materials at Filtech
`
`Reach tens of thousands of technical
`textiles buyers
`
`Eschler warp knitted solutions at
`Techtextil
`
`
`
`
`
`
`
`
`
`
`Google +
`
`
`
`StumbleUpon
`
`
`
`
`
`Comments
`
`IPR2017-00351
`Fredman EX1035 Page 5
`
`

`
`http://www.innovationintextiles.com/warp-knitted-spacer-fabrics-for-a-good-nights-sleep/
`
`Be the first to comment on Warp-knitted spacer fabrics for a good nights sleep
`
`Sign in | Register
`
`Display Name
`
`Type your comment here
`
`6 of 7
`
`IPR2017-00351
`Fredman EX1035 Page 6
`
`

`
`http://www.innovationintextiles.com/warp-knitted-spacer-fabrics-for-a-good-nights-sleep/
`
`About Us
`
`Contact Us Why Innovation in Textiles
`
`Advertise with us
`
`Terms & Conditions
`
`Privacy
`
`Knitting Technology
`
`© copyright Innovation in Textiles
`Innovation in Textiles is an online publication of Orange Zero Ltd.
`PO Box 271, Nantwich, CW5 9BT United Kingdom Registed in
`England No 0468761
`
`7 of 7
`
`IPR2017-00351
`Fredman EX1035 Page 7