The proportion of woven fabrics in the broad field of protective textiles is extremely high. By various procedures (surface treatments, fabric lamination, composite production), fabric properties that meet the requirements defined by standards are achieved. However, simultaneously, these procedures cause negative effects in the form of fabric thickness, stiffness, impermeability, non-breathability, and thus, discomfort. Therefore, there are valid and justified reasons to approach the design process of making such woven fabrics using more complex construction solutions—layer interchanging double cloth. In addition, by applying fibres with integrated desired properties and other structural fabric parameters, it is possible to influence the achievement of the properties of multi-purpose multilayer fabrics for protection, which is the aim of this research. The application and combination of aramid and modacrylic/cotton fibres and use of different yarn fineness resulted in different intensities of protection. The correlative values of mentioned parameters and thermal and thermo-physiological properties indicate their strong connection, and thus the effectiveness of the developed woven fabric samples.

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.