Multilayer Woven Research Articles

Opportunities with Multi-Layer Weave Structures in Woven E-Textile Design

Most textiles in day-to-day use are products of weaving. The versatility of this manufacturing technique, which readily supports a multi-layered structure, inclusion of several yarn types, malleability and other valuable characteristics, has attracted attention from HCI researchers intrigued by its potential to expand the interaction capabilities of e-textiles. Research nonetheless has barely scratched the surface of the wealth of weaving techniques and woven structures available. Therefore, a design-research project anchored in practice investigated how touch-sensitive e-textiles’ capabilities might be enriched via advanced multi-layer weaving techniques. The research process, which drew inspiration from literature both on textile design and on woven e-textiles, produced 25 distinct e-textile samples. Results from evaluating the structural properties, electrical capabilities and overall utility of each point to numerous unexplored opportunities from woven multi-layer e-textiles. Even holding potential for entirely new forms of interaction, these represent promising starting points for in-depth investigation.

Computational modelling and experimental validation of pressure drop through multi-layered woven screens for polymer melts

Woven screens are commonly used in filtration processes that involve molten polymer. Predicting the initial pressure drop across these screens is crucial for selecting an appropriate filtration system as it directly affects the efficiency and cost-effectiveness in industrial processes. Existing computational models for predicting pressure drop through woven screens have not been developed for multi-layered configurations. This study develops an accurate and reliable methodology for using computational fluid dynamics (CFD) to model the pressure drop across a multi-layered screen. The computational model is validated through an experimental set-up.

Rigid-flexible coupling dynamic modelling and dynamic accuracy analysis of planar cam four-bar mechanism with multiple clearance joints

Combination mechanism of conjugate cam and four-bar is a complex type of multi-body system, in which the coupling problems such as cam profile law, flexible deformation of connecting rods, and multiple joint clearance collision make it difficult to model and optimise its dynamics. Just as the beating-up mechanism of high-speed rapier looms for multi-layer weaving is a representative conjugate cam four-bar mechanism. In response to the current development of textile machinery in the direction of high-speed and precision, and in order to improve the work efficiency and operational accuracy of the conjugate cam four-bar beating-up mechanism, the following work is done for the purpose of taking into account the multi-joint clearance and the flexible rod based on the mechanism. Firstly, based on Kane's equation, a multi-body dynamic model with multiple clearances is established combined with clearance collision theory. Secondly, a dynamic model of a rigid-flexible coupling system with multiple revolute clearances is established using finite element method combined with modal synthesis technology. Subsequently, the variables separation method and mode superposition method are used to solve the dynamic equations of the coupled system. Finally, numerical examples are used to analyse the effects of clearance quantity, clearance size, mode truncation order, cam speed, and component material properties on the dynamic response and accuracy of the system. The results show that, in the rotational speed range of 600–800 rpm, the dynamic performance of the system is little affected by the speed; Through comparative analysis of multiple materials, it is found that selecting carbon fibre composite materials has the smallest impact on the motion accuracy of the system. In this paper, the clearance collision model, finite element model and rigid-flexible coupling dynamic model are integrated, which are applied to the cam-linkage combined multi-body mechanism, and the dynamic problems of the actual machine are analysed and solved.

Robust all-fabric e-skin with high-temperature and corrosion tolerance for self-powered tactile sensing

Electronic skins (e-skins) for monitoring human and robot activities under extreme circumstances are significant for human-machine interaction in multiple scenarios, which is challenging to realize on fabric/textile materials. Herein, a core filling-encapsulation strategy for multi-layer weaving is explored to achieve a triboelectric triple-layer sandwich woven e-skin (TSW e-skin) for durable self-powered sensing in extreme environments. To construct a robust structure with environment adaptability, ultra-high molecular weight polyethylene (UPE) fibers or polyimide (PI) fibers are integrated into the triple-layer sandwich woven to provide mechanical/thermal/chemical stability, and carbon fibers (CF) are protectively embedded as a core layer for electricity collection, heat management and adaptive sensing. Hydrophobic encapsulation is improved by polydimethylsiloxane (PDMS) thin coating with morphology and mechanical compliances. The TSW e-skin demonstrates excellent mechanical strength (∼20 MPa) and thermal stability (154.5 ℃), durable superhydrophobicity (>150°), and corrosion resistance (pH 1–13), which demonstrates an open-circuit voltage of 53 V and maintains electrically stable at above 150 ℃. The weaving structure enables the e-skin regulatable electrode patterns for sensitive motion perception and touch identification for human and robotic limbs, with real-time tactile feedback even under extreme scenarios. This robust all-fabric e-skin proposes a common strategy for human-robot perception in harsh environments.

Multilayer woven scaffolds with gradient degradation and nano guidance properties for tendon reconstruction: Continuously promoting tissue infiltration and inducing tissue alignment

Limited tissue infiltration and disordered collagen alignment are primary factors in tendon repair failure. This study introduces a multilayer-induced scaffold (IS@DN) for tendon repair, combining gradient-degraded layers (DLs) and nano-guided layers (NLs). DL degradation creates 3-D pore channels for cell infiltration, while NLs offer continuous contact guidance for cell alignment. Enhanced cell penetration and alignment within the scaffold promote orderly collagen regeneration. IS@DN demonstrates suitable mechanical properties and degradation-enhanced porosity, promoting cell and collagen infiltration. Sequential exposure of NLs facilitates continuous alignment of cells and collagen fibers. At a macro level, IS@DN effectively regenerates the rat Achilles tendon, restoring 91.37 % of its native failure load. This integrative approach, incorporating gradient degradation and nano guidance, holds considerable promise for clinical tissue regeneration.

Incorporating Variable Porosity into the Determination of Effective Permeability in Interchanging Double Cloth Woven Fabrics Using Darcy's Law.

Woven fabrics are widely used for thermal protection due to their porosity, which provides thermal insulation and breathability. This research focuses on investigating the influential parameters in the thermal protective properties of layer interchanging double cloth, including the woven structure and varying yarn fineness. The properties affecting the protective properties and comfort of multilayered woven fabrics include the fabric thickness, fabric porosity, and air permeability. Darcy's law is applicable for determining the effective air permeability of woven fabrics. By understanding and controlling fabric porosity, it becomes possible to develop thermal protective clothing that combines improved comfort, cost-efficiency, and effectiveness. This study represents a novel approach for the clarification of airflow permeability behavior in complex structures of elastic multilayer woven fabrics using Darcy's law. This innovative approach expands the understanding of permeability in fabrics beyond single-layer fabrics with vertical pores or 3D fabrics used in resin injection processes.

A yarn hanging model for estimating the applied initial warp tension in the multi-layer weaving process

Carbon fiber warp yarns tend to hang due to the gravity in the multi-layer weaving process, which leads to chaotic shedding and impairs fabric quality. The hanging shape of carbon fiber warp yarns is mainly determined by the applied initial warp tension in the weaving process, and excessive warp tension increases the friction between the yarn and the heald frame, resulting in yarn wear. A yarn hanging model based on catenary theory was established to estimate the applied minimum initial warp tension that could ensure clear shedding in the multi-layer weaving process. The relationship between the warp hanging shape and various weaving process parameters (warp tension, yarn specifications and the size of shedding) was obtained. According to the weaving conditions, the applied initial yarn tension could be estimated using the model before manufacturing. Multi-layer yarn hanging experiments were conducted using different specification carbon fibers and yarn tension, and the theoretical predictions and experimental results were compared. The results showed that the yarn hanging model could well simulate the actual hanging characteristics of carbon fiber warp yarn under different tension. The research results provide a tool for estimating the applied initial warp tension in the multi-layer weaving process.

Experimental study on the morphology of three dimensional multilayered interlaced basalt woven reinforcements for composites

This study explores and discusses the morphology and microstructure of three-dimensional (3D) multilayered interlaced woven reinforcements for composites. Moreover, this study aims to analyze the differences in the internal geometry of woven reinforcements with different frequency and distribution of connecting points in multilayered woven reinforcement made from basalt fibers. X-ray microcomputed tomography images and the NIS-elements software were used to analyze the microstructure of five different fabrics with connecting points ranging from 1 cm × 1 cm to 5 cm × 5 cm. In the conclusion, the three basic objectives of the study are evaluated: (1) the difference between the upper and lower fabrics in a two-layer reinforcement with difference in the distribution and frequency of connecting points in the fabric area, (2) the shifting of horizontal and vertical fabric layers and mean skewness of contour functions of all tested reinforcements, (3) the thickness, packing density, and volumetric porosity of reinforcements to predict composite behavior during composite preparation.

Investigation on the sound absorption of multilayered woven and nonwoven fabrics with different bonding conditions

AbstractIn this study, multilayer composite was fabricated by the lamination of woven and nonwoven fabrics for sound absorption applications. These fabrics exhibited different weaving densities and thicknesses, and were compounded through different methods including adhesives bonding, stich bonding, and facile plying‐up. The structure, mechanical, and sound absorption properties of laminated composites were investigated. It was found that the construction form plays an important role for enhancing the properties of multilayered composite. The sound absorption efficiency of multilayered composite can be improved by optimizing the combination of woven and nonwoven fabrics. This work has provided a valuable reference for the future development of sound absorption materials, and is also benefit for the utilization of textiles in noise reduction engineering.

Numerical Investigation of Multi-scale Characteristics of Single and Multi-layered Woven Structures

Resin flow through multi-ply woven fabrics is affected by the fibre orientation and laminate stacking sequence during the impregnation process. This is characterised by permeability, which measures the ability of transferring fluids within a 2D or 3D layered woven fibre architecture (i.e., through a porous medium). The work aims to investigate the feasibility of characterising macro-scale flow permeability via the micro-meso-scale (dual-scale) permeability across and along woven yarns, with different structures of yarn nesting, non-shifting, and ply orientation. The permeability characterisation is performed using Ansys-Fluent software package where textile architectures and resin flow in porous media are simulated. The results show that in- and out-plane permeability of the nested, non-shifted and oriented single-ply woven preforms are different than that corresponding to multi-layered plates, making them only applicable for dual-scale permeabilities. However, with a number of plies in the multi-ply woven fabrics — e.g., 9-ply and 5-ply, for in- and out-of-plane flows, respectively — the dual-scale permeabilities can be extended to macro-flow making them applicable at all scales (multi-scale flow). The calculated in-plane multi-scale permeabilities are then used in the 2D simulations and compared with the analytical solution of the Darcy’s equation, which resulted in a very good agreement.

Biomimetic Approach for the Production of 3D Woven Spherical Composite Applied in Apparel Protection and Performance

Current sports bras are typically manufactured via a cut and sew process resulting in a high volume of post-production material waste. Seams derived from this cut and sew process are known to irritate the skin during exercise. This irritant discomfort seriously affects the dynamic comfort during exercise, hindering limb movement and displacement of the female breast. It implies a need for an alternative textile manufacturing process for a seamless sportswear-sports bra to combine the surface aesthetics with biomimetics together with anthropometry and ergonomic data. Tailoring the two yarn interlocking directions (0/90°) within the compound structure of a multilayer multilevel weave architecture provides a construction process to the production, the weaving, of seamless 3D woven spherical forms. Seamlessly shaped wovens in this paper are underpinned by biomimetic anthropometry and real-time data to produce variable spherical forms that mould and support a given set of 3D geometries. Upon completion of the weave generation using specialised weave software, the production parameters are completed upon transfer to the combined weaving technology, Mageba-Staubli Unival 100 (MS-100). The 2D on-loom woven fabric converts to a 3D shape upon removal and by pulling-pushing-unfolding the woven fabric (2D-to-3D). The scope of end applications within the sportswear-sports bra sector (but not limited to) enables a framework for the generic design geometries and production principles.

The Influence of Structure of Multilayer Woven Fabrics on Their Mechanical Properties

Multilayer woven fabrics used for conveyor belts must be characterized by high mechanical strength. The design process of multilayer woven fabrics for such application requires taking into account the structural characteristics of the fabric, which allows to adjust the final product properties to the dedicated use. The geometry of warp threads—means stuffer and binding is the decisive aspect, which influences the strength properties of multilayer woven fabrics and materials made with their use as well. The aim of this work was to examine the possibility of shaping mechanical strength and bending rigidity of multilayer woven fabrics by changing the order of introducing weft threads into individual layers. The eight variants of multilayer woven fabrics were manufactured using laboratory harness loom. They were produced using different structural models in two weft variants, then tested. The mechanical features were determined, such as breaking force, recovered and unrecovered elongations in cyclic tensile test, stiffness rigidity. The analysis of the obtained results confirmed, that both the model and the order in which the weft threads were introduced into individual layers influence the mechanical strength and bending rigidity of multilayer woven. It was found, that the strength properties characterized by the above mentioned indicators are influenced by the number of threads weaved as both the stuffer and binding warp.

Electrical activation and shape recovery control of 3D multilayer woven shape memory polymer composite incorporating carbon fibers

Three-dimensional (3D) reinforced preforms have enormous potential for the development of functional composites by taking advantage of the capabilities of 3D multilayer woven preform design and polymer shape memory behavior. This work aims to investigate the shape memory behavior of thermally active 3D multilayer composite by experimental measurements. The multilayer SMP composite samples comprising an active layer made of carbon fibers are first synthesized. By Joule effect, an internal heat source is created inside the multilayer composites using the active carbon layer. The electrical actuation test results by large bending test method showed that the responses of the SMP composite samples were accurate and the performance was repeatable. This achievement may lead to the application of multilayer SMP composites as electroactive actuators.

Fabrication of interdigitated capacitor on fabric as tactile sensor

Smart textile has opened a new paradigm of application. Therefore, interest in developing a textile-based sensor system to interact with a machine has been elevated significantly. Touch and pressure are vital interests for multipurpose use, leading to the prior work on developing textile-based sensors using embroidery, multi-layer weaving, and different printing processes. The complexity of those works requires an additional setup and machines for the application. This paper presents a novel approach to developing a low-cost and scalable tactile sensor to sense touch and conjugated pressure exerted over the fabric by means of capacitance variation using commercial stainless-steel thread and low-cost lockstitch sewing machine. The research focused on determining the distinct possibility of sensing the touch stimuli and finger pressure as the capacitance range variation and finding out the allusive structural variables of interdigitated capacitor (IDC) and parallel plate capacitor (PPC) of the sensor. For IDC, the mean capacitance variation found 1.28 pF/gm, whereas 0.81pF/gm found for the PPC structure. For both cases, 11.3 gm measured as the least possible sensing pressure. The repetitive percentage (%) of the sensor (IDC) found 97.91 after testing 1016 consecutive finger pressings cycles. The research demonstrated a circuit where the capacitance range was segmented into five slots assigning individual LEDs to sense the different ranges of touch and pressure. The capacitance range (<20pF–600pF<) facilitates the sensor to use in touch-sensitive multimodal switching and physiological monitoring where tactile information can create smart textile system intelligence.

Investigation of the damp-heating processing of multilayer fabric

With the global industrial technology development, technological processes in the textile and clothing industry areconstantly evolving. These rapid rates of development necessitate the need for continuous research and analysis toestablish optimal operating modes for various technological processes. The damp-heating processing/DHP is one of themain technological processes in the sewing industry. The quality of the sewing article depends to a large extent on thequality of the performance of operations in the damp-heating processing. The wide variety of textile materials, each withdifferent composition, structure and properties, is a prerequisite for conducting extensive research to refine manageablefactors of the DHP process. In recent years, textile materials with an increasingly complex structure and multi-component composition have become increasingly important. Of particular interest are the so-called double wovenfabrics. Therefore, the subject of this study is the damp-heating processing of an innovative textile fabric tissue –amultilayer weave type “double cloth”. One of the main controllable factors of the damp-heating processing is the amountof moisture introduced into the processed textile materials. The aim of this paper is to determine the limit values for theamount of steam used in the damp-heating processing of a tissue –a multilayer weave type “double cloth”.

Investigation of the damp-heating processing of multilayer fabric

With the global industrial technology development, technological processes in the textile and clothing industry areconstantly evolving. These rapid rates of development necessitate the need for continuous research and analysis toestablish optimal operating modes for various technological processes. The damp-heating processing/DHP is one of themain technological processes in the sewing industry. The quality of the sewing article depends to a large extent on thequality of the performance of operations in the damp-heating processing. The wide variety of textile materials, each withdifferent composition, structure and properties, is a prerequisite for conducting extensive research to refine manageablefactors of the DHP process. In recent years, textile materials with an increasingly complex structure and multi-component composition have become increasingly important. Of particular interest are the so-called double wovenfabrics. Therefore, the subject of this study is the damp-heating processing of an innovative textile fabric tissue –amultilayer weave type “double cloth”. One of the main controllable factors of the damp-heating processing is the amountof moisture introduced into the processed textile materials. The aim of this paper is to determine the limit values for theamount of steam used in the damp-heating processing of a tissue –a multilayer weave type “double cloth”.

Weavecraft

3D weaving is an emerging technology for manufacturing multilayer woven textiles. In this work, we present Weavecraft: an interactive, simulation-based design tool for 3D weaving. Unlike existing textile software that uses 2D representations for design patterns, we propose a novel weave block representation that helps the user to understand 3D woven structures and to create complex multi-layered patterns. With Weavecraft, users can create blocks either from scratch or by loading traditional weaves, compose the blocks into large structures, and edit the pattern at various scales. Furthermore, users can verify the design with a physically based simulator, which predicts and visualizes the geometric structure of the woven material and reveals potential defects at an interactive rate. We demonstrate a range of results created with our tool, from simple two-layer cloth and well known 3D structures to a more sophisticated design of a 3D woven shoe, and we evaluate the effectiveness of our system via a formative user study.

Enhancement of Mechanical and Thermal Properties of SU-8 Photoresist with Multilayer Woven Glass Fabric Based on Micromachining Technology

SU-8 photoresist has been more and more widely used as a structural material in micro electromechanical system (MEMS) because of its low cost and excellent biocompatibility. However, the inferior mechanical and thermal performances immensely impinge the reliability of the MEMS device based SU-8 and accordingly restrict its application. Here we report the mechanical and thermal performance of SU-8 reinforced by the multilayer glass fabric with the MEMS technology. The finite element simulation and specific experiment are conducted, which confirm that the reinforced SU-8 composites have a 281% increase in Young's modulus and a 64% decrease in coefficient of thermal expansion (CTE) compared with pure SU-8. Additionally, the improved mechanism has also been analyzed, including the excellent interface bonding between the SU-8 and glass fabric, and the high-bond energy of Si–O-Si chain structures in glass fabric. Furthermore, the glass fabric reinforced SU-8 could still possess a high light transmittance to maintain the ability of lithography patterning. Therefore, it is believed that the strategy proposed here may satisfy higher requirements of MEMS devices, which guarantees its practical applications in the functional microstructures.

Design and characterization of 3D multilayer woven reinforcements shape memory polymer composites

Shape memory polymer (SMP) composites are attractive and excellent smart materials due to their outstanding properties and rich functionality as they combine typical mechanical and functional properties of composites with shape memory properties. In particular, 3D reinforced preforms have tremendous potential for the development of functional composites by using the capabilities of 3D woven fabric preform design, and polymer shape memory behavior. Within that scope, this work aims to investigate the shape memory behavior and shape recovery properties of a specific type of 3D multilayer woven SMP composite in response to external stimuli. For this purpose, nine different multilayer stitched fabrics are produced with different weave structures, and different fabric thread densities using polyimide filaments. Then, a series of tests is carried out on these fabrics to evaluate their mechanical and physical properties. The layered fabric design that delivers high mechanical performance is next involved to manufacture the SMP composite samples, for which shape recovery capability is investigated. Fold-deploy and other shape memory cycle tests are performed to evaluate the shape memory characteristics. An optical 3D scanner based on fringe projection is further proposed to precisely acquire the geometry data and perform deformation analysis to quantitatively evaluate the shape fixity and shape recovery behaviors. The results from this study are very promising, demonstrating that these multilayer SMP structures can successfully be recovered following the desired design constraints without noticeable damage.

Predicting the compaction of hybrid multilayer woven composite reinforcement stacks

A meso-scale finite element modelling strategy was developed to investigate the effect of hybridisation on the compaction response of multilayer stacks combining glass and carbon dry woven fabrics. It is expected that the electrochemical-mechanical properties of emerging multifunctional hybrid composites are strongly dictated by the morphology of the compacted reinforcements, yet no investigations into their compressibility have been reported. Model predictions were evaluated against compressibility measurements for monolithic and hybrid fabric stacks. The ply offset had a major influence on the predicted internal morphologies and fibre content, contributing to experimental variability thereof. Optical microscopy and micro X-ray computed tomography imaging indicated greater likelihood of intermediate ply offsets in physical specimens, over limit case model idealisations. Compressibility was slightly reduced in the hybrid multilayer stacks studied in this work. The model outputs presented are being used to analyse the electrochemical-mechanical response of hybrid woven structural power composites.