Textile Structure
how cloth is put together
Concept

Abrasion — where it appears

Wear from rubbing, which happens where a thread stands proud of the surface rather than where the eye expects it. It happens where a float stands proud, so the weave decides where the wear is and the yarn decides how long it lasts.

Named by 23 essays across 7 fields — each of them below, with the objects they name alongside it.

Where the floats are in the 5-end satin. Every longest run of warp on the face, marked. A float is smooth because nothing interrupts it, which is the same reason it snags: there is a length of thread lying on the surface with nothing holding it down.

The float decides

How far a thread runs on the face before it goes under is one number, and it sits behind lustre, drape, snagging, abrasion, tear strength and how densely the cloth can be set. Almost nothing else in the subject has that reach.

weaves · Float Balanced, and not. Three weaves in section along one warp end, with the share of the face each thread system takes. The share is the mean of the matrix; what follows from it — which system wears, which carries the colour — does not follow from the matrix at all.

Balance, and what an unbalanced cloth does

How much of the surface each thread system takes is the mean of the weave matrix, and it is one of the very few quantities in this subject that can be read straight off. Almost nothing that follows from it can.

setting · Cover What one cut costs. The length of thread set loose by a single abrasion cut through a warp float, with each weave measured at the densest setting that weave allows in the same yarn. The bars are inches of freed thread; the note beside each is the float in picks and the setting that float permits.

Floats and abrasion

A satin is said to wear badly. It does not wear quickly — its flat face spreads the rubbing over more thread than a plain weave's crowns do. What it does is fail badly, and those are different quantities moving in opposite directions.

weaves · Float single float as an array. One cell per needle per course, over 2 repeats each way. K knits a new loop and casts the old one off, T tucks the yarn into the loop below without casting off, M misses the needle and floats past it. The margins carry the two conditions: a wale with no K in it never casts off, and a course with no K in it is never caught by anything. Both hold here.

The float in a knit

Five rungs of this anchor have taken the float to be a length of thread on the surface with nothing holding it down. A knit has one too, and it behaves the same way in the light and the opposite way in the hand — because a woven float lengthens its thread and a knitted one shortens its fabric.

knits · Float What a raising machine can catch in a 3/1 twill. The draft with every weft float long enough for a raising wire to lift marked on it. The teeth need an unsupported length of thread on the surface, so a cloth in which every thread is bound at every crossing offers them nothing at all — which is why a napped fabric is always a twill or a satin and never a plain weave.

Raising spends the cloth's strength

Fibre standing up on the surface is fibre no longer in the load path. A nap is warmth bought with tensile strength, and the exchange rate runs along the same axis as everything else the float decides — which means a fabric cannot be optimised for both ends of it.

finishing · Nap The strain across a harness. The warp strain each shaft of a 24-shaft harness puts into its own ends, from 0.460 per cent at the front to 1.728 per cent at the back. Shafts within a budget of 1.0 per cent are drawn in one colour and those outside it in another; the budget is reached at shaft 13.

The back shaft works hardest

How hard the loom is on a warp end is the product of two numbers from different worlds — how often its column changes sides, which is a property of a binary matrix with no millimetre in it, and the strain of the shaft it happens to be on, which is a property of a machine with no weave in it. Neither knows about the other, and the threading that joins them is a decision nobody makes on structural grounds.

mechanics · Shed What holds a tuft in, in newtons. The withdrawal force of a V-fastened and a W-fastened tuft over the reported range of yarn-on-yarn friction, on a duck ground with 1.00 N in each pick. Each is the friction at the wraps, with each wrap's share dragged around every wrap between it and the pulled end — a capstan series rather than a single factor. W runs from 0.79 to 6.84 N and V from 0.15 to 0.41. Both are an order of magnitude below what a carpet is specified at, which is a finding about carpets rather than about the model. What the chart cannot show is the backing, which is where the rest of a tufted carpet's anchorage comes from.

What holds a tuft in, in newtons

The pile ladder computed a tuft's anchorage as a capstan ratio and said, correctly, that a ratio was all it could offer. A ratio multiplies a tension and there was no tension anywhere on this site. There is one now — and the answer, put beside what a carpet is actually specified at, falls short by a factor of three.

fancy · Pile Three kinds of surface, and only one of them starts open. The bearing curves of a 2/2 twill in sheeting, of a terry loop pile, and of a cut corduroy pile of 30 tex, over the first six per cent of a cloth's thickness. The woven curve opens as the square root of the depth and the loop pile's does the same, because a loop's top is a curved thread like any other. The cut pile does not open: it is a flat line at 5.2% of the plan, from a depth of nothing, because a blade severed every tuft in one pass and left every end in one plane. That is not a larger contact area, it is a different kind of contact area — one that does not vanish as the load goes to zero, which is a property no woven surface has.

A pile is the only surface with no crowns

Every other fabric touches on the tops of curved threads, so its contact vanishes as the load goes to zero and the pressure on what is touching rises without limit. A cut pile touches on flat ends left in one plane by a blade — so its contact is finite at no load at all, its pressure concentration is bounded, and it is the only fabric whose abrasion mass loss is an honest measure of its damage.

fancy · Pile Folding, and what it takes out of the singles. Two 20 tex singles spun at 800 turns per metre and folded the other way at 460 — a ratio of 0.575, which is the trade's own and is a measurement rather than a derivation. A single held at its ends and wound round its neighbour turns about its own axis once for every turn of the fold, so it is left with 340 turns per metre of its own: its surface fibres lie at 10.1° to its axis rather than the 22.8° they were spun at. Folding untwists. The short strokes are drawn at that residual angle; the two long curves are centre lines and are not the yarn — each strand is itself a bundle of 118 fibres, and the residual angle is what holds them.

A sewing thread is a different animal

It is folded, balanced, lubricated and finished, and every one of those is an answer to a requirement no weaving yarn has. The lubricant is the interesting one: it makes the thread sewable by lowering the friction that was holding its own fibres together.

applied · Seams A cloth loses its strength long before it loses its mass. Rubbing a 2/2 twill in sheeting down, plotted against how much of its own solid volume has gone. The lower curve is the fraction of the plan the rubbing is touching; the upper is the fraction of the warp's section that has been cut away. They are wildly different because the wear is spread and the damage is concentrated: material comes off the whole surface, but it comes off every thread at the same place, and a thread breaks at its thinnest place. At one per cent of the mass gone the section is already 5% smaller. That is why a fabric that looks barely worn fails a strength test, and why abrasion resistance measured as mass loss and abrasion resistance measured as residual strength are two different quantities that are quoted as one.

A cloth loses its strength before its mass

Rub a fabric and it sheds material from all over its surface, but it sheds it from every thread at the same place — and a thread breaks at its thinnest place. So the strength gone is always several times the mass gone, the ratio is computable from the bearing curve, and it is worst for the weave whose crowns are points.

applied · Damage A seam stands 763 µm proud of a cloth 382 µm thick. A 10 mm seam allowance of 3 plies in a 60 mm panel of one, in sheeting. The seam stands 763 µm above the body of the garment — which is 102 times the depth at which the body cloth first comes into contact with anything at all. So a flat surface rubbed across this garment touches only the seam, over 16.7% of the area drawn, until it has crushed a whole thickness of fabric. Everything this collection computes about where wear lands on a woven surface applies inside that 16.7%, and the other 83.3% is not being touched.

A seam stands proud and wears first

A seam allowance is three plies where the garment is one, so it stands three quarters of a millimetre above a cloth whose own surface has a few micrometres of contact in it. Anything flat rubbed across the garment touches the seam and nothing else — all of the wear on two or three per cent of the area, until a whole thickness of fabric has been crushed.

applied · Seams A hair layer is a balance, so singeing does not stay done. The hair population of a 20 tex cotton yarn under rubbing, started from a singed cloth and from an unusually fuzzy one. Abrasion does two opposite things: it frees ends that spinning left buried, from a supply of 2.23 per millimetre in the surface shell, and it removes hairs that are long enough to be caught. Where the two meet is a fixed point at 1.43 per millimetre, and the cloth goes there from either side with the same time constant — 248 cycles to halve the distance, whichever direction it is travelling. A singeing is therefore undone in a few hundred rubs, because the flame changed the stock and not the balance. What is predicted here is that a fixed point exists, that it does not remember the starting state, and that one rate serves both directions; where it sits relative to the spun level needs two rates the model does not supply, and it is set to reproduce the one thing everyone has noticed, which is that fabrics get fuzzier as they are worn.

A hair layer is a balance, not a stock

Singeing takes under one per cent of a cloth's mass and changes its lustre, its friction, its printability and its pilling. It also does not stay done, because rubbing frees fibre ends as fast as it breaks them off, and a flame changes the stock while leaving the balance exactly where it was.

finishing · Hairiness How much of an abrasion loss is not damage. The share of a reported abrasion mass loss that is hair rather than cloth, for sheeting as woven and raised 64-fold. The first material off a fabric is its hair layer, which is 0.107% of a bare cloth's mass and 6.84% of a napped one's — and which regenerates, so it keeps coming off. A bare cloth is through it by 5344 cycles and the test then reaches the crowns, where the loss means damage. A napped cloth is not through it by 342000, which is more cycles than any standard test runs, so a Martindale on a fleece never measures the fabric at all. Two cloths taken to the same mass loss have therefore not lost the same thing, and the more heavily napped one may not have been damaged. a-cloth-loses-its-strength-before-its-mass made the same point about a different pair of quantities; this is the same failure one layer further out.

Abrasion takes the hairs first

An abrasion test reports milligrams lost against cycles, and the first milligrams off any fabric are not fabric. On a bare cloth that stage is over in a few thousand cycles. On a napped one it is not over by the end of the test, so a Martindale on a fleece never measures the fleece.

applied · Damage The strong fibre is the one that pills. Standing pills per unit area by fibre, relative to wool, at one and the same fuzz supply — every row is the same cloth raised the same amount, so the only thing varying is how long a pill survives once it exists. A pill is not made, it is kept: rubbing generates it and rubbing breaks the fibres that tie it down, and a tie survives in proportion to how much force it takes to break. So polyester carries 18 times wool's standing population from the same generation rate, and the ordering here is exactly the ordering of tenacity and nothing else. Wool sheds its pills because wool's ties break. No two real fabrics have the same fuzz supply, which is why a wool knit still pills more than a cotton shirting in practice — the comparison drawn here isolates the tie and says nothing about the generation, and reading it as a ranking of fabrics would be wrong.

A pill is anchored, not made

Every account of pilling starts with how a ball of fibre forms and stops there, which explains why fabrics pill and not why some of them stay pilled. A pill is not a thing that happens; it is a standing population, and the number on a fabric at any moment is a generation rate times a lifetime.

applied · Pilling A knot, and the tension falling through it. A 20 tex cotton thread wrapped through 1 turn at a bend radius of 1 yarn diameters, with a coefficient of friction of 0.30. The wrap is drawn as a spiral because a thread taken round a pin comes back beside itself rather than onto itself. The marks round it are the fraction of the entry tension still there: 100%, 69%, 47%, 32%, 22%, 15%. The bend has already spent 3.6% of strain at the outside of the thread before any of that happens, against a breaking strain of 6.6%. So the largest total is at the entry, before the knot has done any gripping at all — which is where a knot in a real yarn is observed to break, and why a knot's efficiency is a property of its first bend rather than of the knot.

Where a knot breaks

It breaks at the entry, before the knot has done any gripping at all. Two quantities run along a knot's path and only one of them rises; the other falls from the first millimetre; and their sum is largest where the thread arrives.

applied · Damage A 100-gram bouclé in section, with the depth to its own load path. A bouclé cloth of 100 grams a square metre in section: the core and binder along the bottom, carrying everything, with the effect thread's loops standing 0.31 millimetres above them. The cloth's surface is the loops and nothing else — its loop envelope is 12.6 times its count diameter — so a rubbing surface meets effect thread first and reaches the core only after that depth. 60.7 per cent of the yarn's mass is effect thread on no load path and 39.3 per cent is core and binder. What the section cannot show is the third dimension: the loops of neighbouring yarns lie between these and are pressed by them.

A bouclé wears from the loops down

A cloth loses its strength before its mass, because a woven cloth's crowns are the very threads that carry the tension. A bouclé inverts it exactly. Its surface is its loops, its loops hang off a core that carries everything, and 61 per cent of its yarn is on no load path at all — so a rub takes three tenths of a millimetre of thread that does nothing before it reaches anything that does, and the cloth is ruined to look at while it is still as strong as it was woven.

fancy · Fancy yarn What each further binder takes off a snag. How far a snag drags thread through a bouclé, in binder points, against how many binders the yarn carries: 1, 7.43 points; 2, 3.72 points; 3, 2.48 points; 4, 1.86 points; 6, 1.24 points. The relation is exactly inverse, because the grip is the exponential of the wrap angle and the reach is a logarithm of it, so the second binder removes 3.72 binder points and the third a further 1.24.

The second binder buys half of everything

A bouclé's loops are held by their binder, and a snag drags thread from one loop to the next until the thread breaks. The essay before it left that reach at seven binder points on one binder and said a second would square the grip. It does — and because the grip is exponential in the wrap and the reach is a logarithm of it, the reach is exactly inverse in the binder count: 7.43 points, then 3.72, then 2.48. Half of everything any number of binders can buy is bought by the second one, which is how many the trade uses.

fancy · Fancy yarn A ring-dyed yarn worn flat, step by step. One cotton yarn dyed in a ring 20% of its radius deep, cut flat from the top by an abrader to five depths: worn to 10% of the radius, 1.9% of the yarn has gone and 0% of its width is white; worn to 20% of the radius, 5.2% of the yarn has gone and 0% of its width is white; worn to 30% of the radius, 9.4% of the yarn has gone and 39% of its width is white; worn to 45% of the radius, 16.8% of the yarn has gone and 58% of its width is white; worn to 70% of the radius, 31.2% of the yarn has gone and 74% of its width is white. The olive line is the cut face and the red bar above it is the part of the face that has reached the undyed core. Nothing is white until the cut passes the ring, and then the white arrives quickly. The section is a circle and the ring's edge is drawn sharp; a real yarn is neither, and its fibres migrate, so the core's edge is ragged.

A ring-dyed yarn whitens all at once

Rub a yarn that is dyed in a ring, and for a while nothing shows. The abrader takes off blue fibre, the cut face is blue, and the yarn looks as it did. Then the cut reaches the undyed core, and the white arrives with a vertical tangent, as the square root of the wear past the ring: one per cent of the radius more and an eighth of the width is white. A ring a fifth of the radius deep hides the first five per cent of the yarn's loss and shows half its width white by thirteen. A yarn dyed through never shows white at all. Denim's high-contrast fading is that threshold, drawn over a cloth.

finishing · Dyeing Two ring-dyed faces worn to 5% of their mass. The faces of 3/1 twill and plain woven from the same ring-dyed 50 tex warp and undyed weft, at 24 ends and 16 picks a centimetre, each worn flat by an abrader until 5% of its thread has gone, drawn over two repeats: dyed warp dark, exposed undyed core red, weft pale, holes blank; the 3/1 twill shows 30% of its covered face as exposed core; the plain shows 17% of its covered face as exposed core. A float's crown is a line and is cut along its length; a plain weave's crowns are points and are cut through as small patches. The geometry is the plain-weave solution for these counts and setts with the floats drawn over it, which is more open than a real denim; what the figure cannot show is a denim at its real density.

A float fades late and hard, a crossing early and soft

Wear a ring-dyed face flat and the white arrives where the cut first passes the ring at a crown, which is the same depth for every weave. What differs is how much cloth has gone by then and how fast the white spreads after. A plain weave's crowns are points, cut through by almost nothing: it shows white after a fifth of a per cent of its thread and never shows much. A twill's floats are lines, cut along their length: a 3/1 twill shows nothing until more than one per cent has gone, then whitens faster than any plain weave can, 39 per cent of its face by a tenth worn against plain's 24. Denim's high-contrast fade is a float's; chambray's soft one is a crossing's.

finishing · Dyeing A crease along a 3/1 twill's floats and one across them, worn alike. A strip of 3/1 twill of ring-dyed 50 tex warp and undyed weft folded round a 2 mm radius, the ridge drawn across the page as a dashed line, worn by a flat abrader 50 µm into the ridge: above, with the ridge running along the warp and its floats; below, running across them. Dyed warp dark, bared core red, weft pale. crease along the warp: 83% of the crease's length white, in runs 1.72 mm long on average, the longest 2.08 mm; crease across the warp: 31% of the crease's length white, in runs 0.15 mm long on average, the longest 0.17 mm. On a twill the white along the warp lies in lines as long as a float's crown, across it in dashes one end wide; on a plain weave, with no floats, both are short. What the drawing cannot show is the fibre a real crease tears loose, which blurs every edge here.

A crease across a twill fades in dashes

A garment is not worn flat. It is worn along its folds, where the ridge of a crease stands out and is rubbed first, so the fade follows the crease. On a ring-dyed 3/1 twill a crease running along the warp bares the cores of the floats that lie under its ridge, float by float, and reads as a white line broken only where each float dives: at fifty micrometres of wear, 83 per cent of its length is white, in runs of 1.7 millimetres. The same crease across the warp meets every float at one point and reads as a row of dots, 31 per cent white in dashes of 0.15 millimetres, one end wide. It bares much the same core. A plain weave's creases are dashes whichever way they run.

finishing · Dyeing One crease at four angles to a 3/1 twill's warp, worn alike. Four strips of 3/1 twill of ring-dyed 50 tex warp and undyed weft, each folded round a 2 mm radius with the ridge drawn across the page, worn 50 µm into the ridge by a flat abrader, 24 mm of crease each. Dyed warp dark, bared core red, weft pale. along the warp (0° from the warp): 80% of the crease white, its longest white run 2.0 mm; along the twill's line (33.7° from the warp): 100% of the crease white, its longest white run 45.0 mm; two degrees off the line (35.7° from the warp): 79% of the crease white, its longest white run 15.7 mm; along the other diagonal (-33.7° from the warp): 66% of the crease white, its longest white run 1.0 mm. Along the twill's line the white never breaks, because the crease meets the crown of every end's float in turn; two degrees off, it runs as long strokes that drift off the line of crowns and come back. What the drawing cannot show is the fibre a real crease tears loose.

A crease along the twill fades as one line

A crease along the warp of a ring-dyed 3/1 twill fades as broken lines a float long, and across it as dashes one end wide. Turn the crease to the twill's own diagonal and it fades as a single white line with no break in it at all: the fold meets the crown of one end's float, then the next end's one pick along, then the next, and every crown it meets is at the same place in its float. It is the one direction in which the weave and the crease line up — and two degrees off it the line breaks into strokes whose length is a vernier's.

finishing · Dyeing A 50 tex yarn after 1, 4, 8 dips into a fibre that fills. The cross-section of a 50 tex cotton yarn after 1, 4, 8 twenty-second dips, each fibre shaded by the dye fixed at its distance from the surface, on one scale of shade for all three. The fibre's room for dye is finite and one dip at the bath's strength fills 20% of an empty fibre's, so each dip meets less affinity near the surface than the last and carries its dye further in. after 1 dip: ring 14% of the radius deep, the surface 20% full; after 4 dips: ring 18% of the radius deep, the surface 59% full; after 8 dips: ring 24% of the radius deep, the surface 83% full. With room to spare every dip would leave the first dip's 14%. The share is assumed; nothing here measures it.

A fibre that fills dyes deeper with every dip

Dipped eight times, a ring-dyed yarn is darker than after one dip but no deeper — if its fibres have room for all the dye they are offered. They do not: every dip's dye occupies some of the fibre's room, the next dip meets less affinity near the surface, and dye that is taken up less travels further before it is taken. How much further depends on one number the dip arithmetic never needed — the share of an empty fibre's room one dip fills — and eight dips turn that number into a ring 1.15 times deeper at five per cent and 1.68 times deeper at twenty.

finishing · Dyeing A 50 tex yarn after eight dips, with its pores open and filling. The cross-section of a 50 tex cotton yarn after eight twenty-second dips into a fibre one dip fills by 20%, each fibre shaded by the dye fixed at its distance from the surface, on one scale of shade. open pores: the ring 24% of the radius deep, the surface 83% full; the dark shade's pigment, all in the pores: the ring 22% of the radius deep, the surface 83% full; pores 90% filled at a full fibre: the ring 16% of the radius deep, the surface 83% full. One dip leaves 14%. The middle section is the most a dark denim's indigo could clog its pores, every grain placed in them; the right is a clog no denim's pigment is large enough to make.

Indigo is too little to close the pores it dyes through

Each dip of a fibre that fills carries its dye deeper, because the dye already fixed near the surface leaves less room there. But indigo is fixed as a solid, and some of it sits in the pores the next dip has to travel through, so a heavily dyed skin should also hold the next dip back. The two pull opposite ways, and which wins is decided by how much pigment there is. A dark denim's indigo, every grain of it placed in the pores, fills at most a fifth of them at the surface and takes back about a seventh of the ring's deepening — under two micrometres. The surface fills at the same rate whatever the pores do, so two cross-sections still tell the two effects apart.

finishing · Dyeing

Named alongside it

The objects these essays reach for when they reach for this one.

FloatDenimBearing curveCrown lineRing dyeingCapstanDamageDye affinityFrictionHair balanceHair layerPilling

All concepts