Bonding

Techniques
 STITCH BONDING SYSTEM
Stitch bonded fabric is defined as a fabric in which fibres,
yarns, fibres and yarns, or fibers and a ground fabric are held
together by subsequent stitching or knitting-in additional
yarns
The Textile Institute defines stitch bonded or ‘sew knit’
fabric as a multicomponent fabric;
one component is a series of interlooped stitches running
along the fabric length
Other component is a fibre web, yarn or preformed fabric
 Stitchbonding

Stitchbond is a nonwoven construction where the

fabric is formed by stitching or knitting the fibers
to form a fabric with the appearance of a knit
fabric.
In the most common cases it involves warp knitting
of yarns through a fibrous mat.
It can also be knitting of fibers without yarns or
knitting of yarns around laid warp and filling yarns
which do not interlace with each other.
 Stitchbonding
Fabrics are predominantly made of polyester fibres of
various linear density (from 0.33-1.7 tex)
Depending on the sphere of application and demands of a
customer, viscose fibres, cotton and other kinds of fiber
raw materials can be used in production.
By means of varying the fibres, the weight and the width of
a fabric, the length of a stitch and the size of loops it is
possible to modify the fabric according to the demands of
the customer and the specific sphere of application.
If necessary, the fabrics can be further finished - dyed,
printed, bonded.
Stitchbonding machine
1. needle motion
2. knockover and support combs
3. guide bar
4. device for transport of the web
5. fabric draw-off from the needle
motion and fabrics take-up
6. device for feeding and guiding the
warp threads
Stitchbonding stages

1. penetration
2. lapping
3. closing
4. knocking-over
5. take-down
Main groups are
1. Warp Knitting- loop are formed
longitudinally or warp wisely
2. Stitch bonding - allows to produce
textile fabrics either to the stitch
bonding (creates loops of threads) or
web knitting process (loops of fibres)
3. Weft Knitting – loops are formed at
the needle one after the other
 STITCH BONDING SYSTEM

MALIWATT
Bonding the fibre web into a loop
system of threads
The horizontal compound needle and
closing wire system, which operates in
conjunction with the knock-over
sinker and the supporting rail,
penetrates through the substrate which
is normally a cross-laid web.

The sheet of stitching yarn, which is

inserted via the guides into the open
hooks of the compound needles, forms
stitches that penetrate the web.
Degree of bonding depends on
◦ Number of loops of threads per unit area , which
is made by number of density of wales and
course density .
 Pillar structure - open

Other structures are

1. Cord stitch
2. Velvet stitch
3. Atlas and
4. inlay
In combination with particular threading-in such as filet-stitch,
openwork structures can be manufactured. (6.38a)
Using pile sinkers instead of needle leads, web stitch bonded
materials with pile can be created, which allows colour patterns
(6.38b)
MALIWATT PRINCIPAL AND APPLICATION
Soft furnishings, upholstery fabrics for
mattresses and camping chairs, blankets
Transportation cloth.
Cleaning cloths, fabrics for hygiene and
sanitary purposes.
Secondary carpet backing.
Lining fabrics, interlining for shoes and
apparel.
Adhesive tapes (e.g. Those used for
harnessing electric cables in
automobiles).
Velcro-type fasteners.
Laminating fabrics, coating substrate.
 MALIVLIES
Fibres of the web are used to form the loops.
Thread less textile manufactured without any
additional binding the loops, which connect the
fibrous fabric, are made from the fibers of the
fabric itself.
As the compound needles move back to their
knock-over position, fibers lying across the front
of the web are hooked by the open hooks of the
needles, held within the needle hook by the
closing wires and pulled through the web
thickness.
As these fibers are pulled through the stitches
formed by fibers on the previous course, which are
still hanging on the needle stems, the newly
formed stitches are pulled through the existing
stitches.
A loop structure that resembles the technical face
of a warp-knitted fabric is produced on the side
facing the knock-over sinkers
MALIVLIES
 MALIVLIES

In the loop web knitting process, long fibres are preferred
Longer the fibres, more they contribute to loop formation or better is the tying up
in the loops
Due to low flexibility, brittle fibres such as glass or carbon are less suitable
 MALIVLIES Fabric characteristics

They are characterized by

 High voluminosity
 Softness
 Good absorbent behaviour
 Good elasticity
 Good air permeability

They usually show higher strength in crosswise direction

 MALIVLIES Applications

Interlinings of cars (headliners, rear and side linings)

Textile wall coverings and furnishing
Felts
Packaging
Insulations
Absorbing and polishing cloths
Filter fabrics
Geotextiles
Coating substrates
Medical, hygiene and sanitary products
Laminating and bonding
 MALIMO
Plain overstitching of loose yarn sheets laid on
top of one another (weft and warp yarns –
featuring manifold possibilities of modification)
 MALIMO
 Plain overstitching of loose yarn sheets laid on top of one another (weft and warp
yarns – featuring manifold possibilities of modification).
 MALIMO
 different versions and auxiliaries have been developed to produce technical
textile fabrics using these machines
Weft yarns can be fed from
stationary package creel located at
the side of the Malimo machine
End of weft yarn is held by a
clamp, which is stationary in
running direction
After reaching the other side, weft
yarn is again clamped, where they
are cut
With each movement of weft
carriage, 18 weft yarns are drawn
off and inserted into the clamp
Multiaxial weft insertion
It enables a diverse variety of yarn
types and linear densities to be
processed in many constructional
variations
Applications
1. Inflatable structures like airships
and boats, flexible roofing
membranes
2. Rotor blades for wind power
stations
3. Moulded parts of automotives
4. Aircraft and ship building
5. Equipments for skis,
snowboards, surfboards
Multiaxial weft insertion
Malimo - areas of appilcation
Industrial textiles: composites for high-tech areas
(fiberglass, carbon, Kevlar, HD-PE), sandwiche
nonwovens, geotextiles, insulating materials, laminating
substrates, packing textiles
Furnishing fabrics, home and household textiles:
furnishing fabrics,
upholstery fabrics,
textile wall coverings,
cleaning and polishing
cloths
Malipol
Malipol stitch bonding
systems have the following
main elements:
◦ pile yarn
◦ ground fabric
◦ stitch bonding head
◦ fabric take-down and batching
The compound needles penetrate the ground fabric and
the stitching or pile yarn is overlapped in the needle hook.
The pile yarn is also laid on top of the pile sinker at the
same time so that a tricot movement is used to create the
pile and knit the yarn into the ground structure.
Malipol
Malipol - areas of application
blankets
cleaning textiles (wiping mop)
pile fabric for velcro fastening stripes
bathroom sets
one-sided terry fabric
 Voltex
High pile or high plush fabrics based on two principal
reformed elements, a ground fabric and a web, which
are continuously introduced.
No stitching yarn or yarn preparation, such as winding
or warping are required.

Applications: lining fabrics, imitation furs, soft-toy

plush, shoe uppers and shoe lining, floor coverings
and upholstery fabrics.
Voltex
Kunit
Fibres are fed to the stitch bonding head in the form of either a
thin web or a batt. Voluminous, three-dimensional pile fabrics
can be produced that have a distinctive folded pile; the pile
can have a variable thickness and density if required.
It uses a brushing bar in conjunction with the stitch-forming
elements, whose oscillating path may be varied between 6 and
51 mm by exchanging the cams.
Kunit

1. Compound needle bar

2. Closing wire bar
3. Knockover sinker bar
4. Supporting bar
6. Kunit-fabric
7. Fibre web
9. Brush bar
 Kunit
No finishing is required for many applications or when the
fabrics are to undergo further processing on the Multiknit
machine.
Finishing processes applicable to Kunit materials are back-
coating, raising, polishing and shearing, tumbling to
achieve surface effects, coating and laminating with other
substrates.

Applications: linings, soft-toy fabrics, filtration media

(particularly depth filters), covering materials for polishing
discs, coating substrates and as upholstery materials for
car interiors.
Multiknit
The base materials are one or two textile fabrics with
open-pile structure, preferably Kunit nonwovens.
In the end product, the two nonwoven surface textiles are
interlaced by fibers, forming an uniform and tight surface,
being connected by almost vertically arranged fibers.
Special advantages are high degree of volume (bulkiness)
and elasticity of compression
Multiknit

1. Compound needle bar

2. Closing wire bar
3. Knockover sinker bar
4. Supporting bar
5. Counter retaining bar
6. Kunit-fabric
8. Multiknit-fabric
10. Additional base cloth
KSB PROCESS
 KSB PROCESS
Also known as Kunit layer bonding
process
Two fabrics with pile layers are
bonded
Compound needle takes the pile
fibres of both fabrics to make
them in the middle, into a third
layer of loops
 THERMAL BONDING PROCESS
A process in which a web consisting of
thermoplastic and non-thermoplastic fibers
was made and then heated to the melting or
softening temperature of the constituent
thermoplastic fibers followed by cooling or
solidify the bonding area.
Thermal bonding processes include :-
Calendar bonding
Through-air bonding,
Infrared bonding, PRINCIPAL OF THERMAL BONDING

ultrasonic bonding.
 THERMAL BONDING PROCESS
Principle Features
The formation of a bond during thermal Thermal bonding requires a
bonding follows in sequence through thermoplastic component to be present in
three critical steps:- the web in the form of homophile fiber,
powder, film, hot melt or as a part
Heating the web to partially melt the (sheath) of bi component fiber.
crystalline region,
The thermoplastic component becomes
Repetition of the newly released chain viscous under the application of thermal
segments across the fiber-fiber interface energy.
Subsequent cooling of the web to re- The polymer flows to fiber-to-fiber
solidify it and to trap the chain segments crossover points where bonding regions
that diffused across the fiber-fiber are formed.
interface.
The bonding regions are fixed by
subsequent cooling. The thermal bonding
process is environmental-friendly
 CALENDAR BONDING PROCESS
Introduction Working Principle
 As the web passes between the
In thermal calendar bonding
process, the fibrous web containing calendar nip, fibres are heated and
thermoplastic fibres is passed compressed.
through a heated calendar nip that is  This causes the binder fibres to
created by two rolls (cylinders) become soft and tacky and induces
pressed against each other polymer flow in and around the base
fibres.
One or both rolls are heated
 The fluid polymer tends to collect at
internally to a temperature that
usually exceeds the melting point the fiber crossover or contact points
temperature of the binder fibres to and bonding sites are formed.
ensure there is sufficient hear  Cooling leads to solidification of the
transfer to induce softening at the polymer and bonding
prevailing line speed.
 THROUGH AIR BONDING MACHINE
The main component of this system
is an air permeable drum with a high
open area onto which the web is
transferred and supported by a
travelling/carrying wire.
Types Of Through-air Bonding
Machine
Though air bonding machine
Perforated conveyor (flat bed)
through air bonding machine
Impingement (air jetting) through
air bonding machine
THROUGH AIR BONDING MACHINE

Ultrasonic Bonding Process