Overview on Distance Fabrics

Weaving in its familiar planar patterns has existed since the beginning of civilization. It can

be done not only in two dimensions but in three-dimensional space is new or merely the

uncovering of someone else's ancient idea, now getting a shape. The cloth can be produced

not only in one direction but thicker cloth is also produced with combination of 3 threads.

Distance fabrics are one step ahead in this area, which is different from double cloth fabrics

Double cloth fabrics have three yarn systems: pile warp, backing warp and weft. With the

double cloth weaving process, two superimposed backing fabrics are woven simultaneously,

while the pile warp is connecting both fabrics together. The so obtained double fabric is split

on the double rapier weaving machine by the pile cutting motion into a top and bottom fabric.

When the pile cutting motion is not used, the distance fabrics, transportation fabrics and other

technical fabrics are produced on machines. The weaving process gives the opportunity to

create dense top and bottom layers with almost stretched fibres, and with connections

between those layers.

WEAVING PROCESS OF DISTANCE FABRICS

Distance fabrics consist of a top and bottom woven fabric bonded together by vertical pile

yarns. These pile yarns are woven into the top and bottom fabrics forming an integral

sandwich structure. In the weaving process, Two or more wefts are inserted simultaneously in

superimposed sheds. The distance warp, which is equivalent to the pile warp in the double

cloth principle, is interlacing top and bottom fabrics, which are not split. The entire fabric is

taken-up and is wound on one roll.

The backing warp ends and wefts form the textile faces and the distance warp ends connect

both textile faces together. To form clean sheds and to keep their distance at constant level, in

some cases gauges or lancets are used. Lancets are metallic strips which are inserted from the

spread rolls into the harness and reed, between top and bottom fabric into the jaw of top and

bottom rail. The height of the gauges determines the lowest fabric face distance and forms the

step by which the textile face distance can be changed. The textile face distance is

programmed with the binding sequence of the distance warp ends. This programming is done

by a three position shedding by dobby or Jacquard head. The distance warp ends are woven

into the face fabrics on a sequence of a number of designated as face connecting points.

Between this face connecting points, the distance warp ends are not woven into the face

fabrics, but interlaced on catching wefts or false picks laying on the top and bottom of the

lancets.

Ref: www.texdata.com

This is done on a double rapier weaving machine inserting simultaneously two fillings. Pile

yarns are used to connect the top and bottom fabric. Numerous technical fabrics are woven

on this principal ie, distance weaves, multiple layer weaves, geotextiles, filter fabric, etc.

Distance fabrics consist of a top and bottom woven fabric bonded together by vertical pile

yarns. These pile yarns are woven into the top and bottom fabrics forming an integral

sandwich structure.

Double cloth fabrics have three yarn systems: pile warp, backing warp and weft. With the

double cloth weaving process, two superimposed backing fabrics are woven simultaneously,

while the pile warp is connecting both fabrics together. The so obtained double fabric is split

on the double rapier weaving machine by the pile cutting motion into a top and bottom fabric.

When the pile cutting motion is not used, the distance fabrics, transportation fabrics and other

technical fabrics are produced on machines. The weaving process gives the opportunity to

create dense top and bottom layers with almost stretched fibres, and with connections

between those layers.

The multiple rapier machines is very suitable for the production of multiple layer weaves for

strengthening of conveyer belts, light weight plates and ballistic protection plates.

The multiple rapier weaving machines have a great advantage in production, because

typically in this case production speed is defined by the materials used, so by having more

than one weft inserted simultaneously, the weaving production is multiplied without change

of machine speed. Also in some cases the use of multiple rapier allows to let some critical

yarns pass into the fabric between the rapiers, so without lifting the yarns up and down.

Multiple layers weaves can also be woven in special constructions. Out of these constructions

textile profiles are made. In this way a multiple layer weave is changed into a profile after

impregnation and then hardened.

Ref: www.vandewiele.com

.

Ref: www.texdata.com

Therefore a special technique is applied in which the connecting parts are woven in a normal

way, but then the fabric is moved backwards to bring together the picks of the outer layers

Structures with triangle shaped cross sections are possible and have an increased stiffness.

APPLICATIONS OF DISTANCE FABRICS

Two-face fabrics are defined by the choice of warp yarn type, weave structure, connecting

warp system and the finishing matching the respective field of application. The space

between the two faces can remain empty or can be filled. Nowadays, two-face fabrics with

face distance of 15 mm up to 1000 mm are produced. Many finishing operations are

available: impregnation, plastic and metallic coating and foaming. Thermo hardening and

thermoplastic resins can be applied.

Distance fabrics woven with glass yarns are impregnated with thermoset resin. Due to the

capillary forces, the distance fabric rises to the preset pile height. A strong and light sandwich

laminate is formed. The excellent mechanical properties of this light sandwich has many

applications in the composites industry: Light partition walls and hardtops, double wall for

storage tanks, light high speed crafts, bus panels and roofing, trucks side skirts, horse trailers,

windmill wings.

Sandwich fabrics

Sandwich fabrics find applications in partition walls and covering systems as noise or as heat

barriers. The distance and backing materials are polyester HT yarns. The distance between

faces is 50 mm to 200 mm.

Cement bags.

Cement bags are used in concrete constructions, in dike and slope constructions. Textile face

distance ranges from 10 to 20 cm. For backing warp and distance warp yarns polypropylene

is used in low tenacity applications and nylon HT is used for high tenacity applications.

Bending resistant sandwich panels

Bending resistant sandwich panels find application in automotive, marine and aviation

construction as reinforced light weight walls.

Ref: www.vandewiele.com

Warp and weft are glass. This fabric is impregnated with resin and is cured. The thickness

ranges from 3 to 28 mm. The panels have a light specific weight and have excellent bending

strength and stiffness. These distance fabrics are also applied in the field of gas and fluid

containers.

Flexible two-face fabrics

Flexible two-face fabrics find application as

Air duct for air conditioning.

Waste industry as protective layer against penetration of harmful materials into the

ground.

Inflatable air bags for lifting heavy loads as pressing forms and air crafts,

Inflatable tumbling mats for gymnastics.

Temporary inflatable structures as boats and shelters .

By choosing the right material and number of connections for the distance warp, a two-face

fabric with elastic compression properties can be made.

Advantages

Reduction of confection steps,

Stability of the product,

Possibility to add other functions.

Applications are in the field of sports (shoes, saddle fabrics for horse, in the medical field

(mattresses with extra functions, e.g. cooling or heating)

Long pile fabrics

Long pile fabrics are made on multiple rapier weaving machines. The connecting yarns are

cut on the machine by the integrated cutting system. Typically two fabrics of up to 40 mm

pile height can be made simultaneously without lancets. Apart from the application in

clothing, long pile fabrics have technical applications in the production of paint rollers,

cleaning brushes and polishing mats for automotive and machinery industry.

Ref: www.vandewiele.com

Artificial grass

Artificial grass is woven double shed carpet weaving machine in 5m or 15’ pile width. Two

grass carpets, each up to 70mm pile height, are woven simultaneously. Advantages of this

process, compared to other production methods, are: better pile fixation (no extra backing

needed), better water infiltration, straight pile, design possibilities (jacquard weaving), better

pile distribution so that less pile material (-15%) is needed to obtain a product with

comparable properties.

Ref: www.texdata.com

In distance fabric With lancets and false picks, distance fabrics between 15 and 500 mm or

even more can be woven. Typical applications for flexible distance fabrics are lifting bags,

inflatable boats and shelters, reinforcement of dykes after filling with pebbles and concrete,

thermal insulation after filling with polystyrene. Multiple layer weaves are also woven at

higher production rates as two fillings are inserted simultaneously

CONCLUSION

The Distance fabrics schematic allows initial assessment of architecture performance. Real

time dynamic movement of the viewpoint allows the woven preform to be analysed from all

angles. Rotate an individual or selection of groups, to view interlacings from the top, through

the cross-section, from beneath, in warp or weft directions or from a corner. Distance fabrics

are an ideal tool new fabric development. Thus Distance fabrics are having a booming market

and will add value to the new market due to versatility in use.

REFERENCE

www.texdata.com

www.vandewiele.com

Applications of distance fabrics and multiple layer weaves in technical textiles by

Van de Wiele Group & Dominique Maes – Manager Technology & Intellectual Property of

the Van de Wiele Group