The Weave - our superior weaving method
Weaving is accomplished on site, in our own facility, on new state of the art narrow fabric weaving looms. Yarn is delivered directly from our creel to our loom through a tension equalizer so that the finished weave is straight and each warp is of equal tension. This is very important, so any tensional load applied to the weave when it is in service is distributed equally. When this is done incorrectly, individual warps will get overloaded and breakage of the filaments that make up the yarn will occur, compromising the ultimate load rating of the webbing.
The webbing structure is made up
of warp and weft yarn. There
are about 1300 filaments per cm
width of webbing.
We use a high density, tight weave that prevents either the warp or weft threads from being displaced when under load, particularly where the webbing is cut or punched. If the threads making up the weave have room for displacement, the whole weave integrity is affected.
We have adopted a very flat
weave compared to a bulky
weave on the right.
We have adopted a very flat (non-textured) weave to reduce the webbing thickness without reducing the amount of yarn used and hence the strength remains very high. We can do this because our HiBOND3™ technology is that good we don’t rely on weaving texture to key in to. Others need to employ methods like adding cotton or using heavily textured weaves to achieve a bond that still falls well short.
HOW MANUFACTURERS SAVE ON COSTS.
REDUCED YARN CONTENT
Cheaper products skimp on the weaving by using a low-density weave, which destabilizes easily.
It is often used in combination with heavily textured weave to bulk up the look of the weave.
Bulky weave is not necessarily strong weave; it may be hiding a lack of content.
HEAVILY TEXTURED WEAVE AND LIQUID PLASTISOL
Heavily textured weave is also employed as a means to allow the polymer coating to key into the webbing better and hence improve the bond strength. This makes for more bulky webbing with more included air pockets within its structure. Quite often this is paired with very liquid (runny) Plastisol because it can travel further into the webbing structure during coating which is done by passing the webbing through the Plastisol when it is in it's liquid form without any added pressure. To achieve a very liquid Plastisol, higher concentrations of plasticizer are added which reduces the actual PVC content of the formula. Unfortunately it is the PVC content that is what you are actually welding and the plasticizer migrates out of the compound over time as well. We do not water down our polymer in this way and our polymer has 100% of it's active ingredients. We can do this because we use extreme pressure to inject our polymer into the weave.
We do not water down our polymer and our polymer has 100% of it's active ingredients.
INCLUDING COTTON CONTENT
Some manufacturers also include 35% or more cotton into their weaves. Cotton has 1/3 the tenacity (strength) of our high tenacity polyester yarn and the cotton threads have a bigger cross section causing bulky weave.
There is a second reason for including cotton into the weave. Manufacturers can have difficulty with the polymer to webbing, bond strength. Cotton being a natural fiber is very hairy. This allows the polymer coating to hold onto the cotton content of the webbing to improve this. This is a very cheap way to improve the bond strength. This improvement achieved is at the cost of the webbing breaking strength. While HiBOND3™ is expensive technology for us to use, the quality of our product makes up for this.
By adding 35% of cotton, you end up with a 25% loss in strength and a bulky webbing, all to give the polymer coating something to hold onto.
Bottom 3 pictures - Show the bond in action. The weak bond tries to hold the surface. The cotton bond only holds on to the cotton fibers, which are weak, and break easily. The HiBOND3™ technology used in WeldTECH™ is well impregnated and doesn't want to let go. Right middle picture - shows polymer that has been torn apart and left in the webbing structure. The top series - Show what the polymer interface looks like after the bond is broken. You can see the broken cotton fibers and how torn apart the WeldTECH™ product is due to the HiBOND3™ technology.