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