New solutions for the manufacturing of spacer preforms for thermoplastic textile-reinforced lightweight structures

The novel woven spacer fabrics consist of upper and lower layers which are connected through internal crosslinks. The aim is to weave spacer fabrics with woven crosslinks in a single production step as near net shape sandwich preforms. By this way reproducible and automated manufacturing of sandwich preforms for composites are realized. The paper deals at first with the conception of a new weaving and take-up technology of complete spacer fabrics without subsequent textile assembly processes. Afterwards, the special technology is described, and finally the paper deals with a simulation model for the prediction of dynamic warp thread forces in order to minimize fiber damage during weaving process.