Patent Abstract:
Forming fabric that includes a top layer including top weft yarns and a bottom layer including bottom weft yarns. Binding warp yarns weave with the top weft yarns and bind to the bottom layer. This Abstract is not intended to define the invention disclosed in the specification, nor intended to limit the scope of the invention in any way.

Full Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention relates generally to papermaking, and relates more specifically to multilayer fabrics employed in papermaking. The invention also relates to the binding of multilayered forming fabric with warp yarns. The present invention also relates to. multilayer papermaker&#39;s fabrics that utilizes warp yarns to bind top and bottom layers such without disrupting the top fabric surface. The invention also provides for a fabric which utilizes a condensed sequence of warp knuckles in a weft float dominate structure in order to provide space in the weave for the binding warps to smoothly transition from the top layer to the bottom layer. The invention also provides for a fabric wherein the warp knuckles of several repeats of a weft float dominate pattern are condensed into a plain weave sequence that allows space for warps to float under the wefts for a distance. 
         [0003]    2. Discussion of Background Information 
         [0004]    In the conventional fourdrinier papermaking process, a water slurry, or suspension, of cellulosic fibers (known as the paper “stock”) is fed onto the top of the upper run of an endless belt of woven wire and/or synthetic material that travels between two or more rolls. The belt, often referred to as a “forming fabric,” provides a papermaking surface on the upper surface of its upper run which operates as a filter to separate the cellulosic fibers of the paper stock from the aqueous medium, thereby forming a wet paper web. The aqueous medium drains through mesh openings of the forming fabric, known as drainage holes, by gravity or vacuum located on the lower surface of the upper run (i.e., the “machine side”) of the fabric. 
         [0005]    After leaving the forming section, the paper web is transferred to a press section of the paper machine, where it is passed through the nips of one or more pairs of pressure rollers covered with another fabric, typically referred to as a “press felt.” Pressure from the rollers removes additional moisture from the web; the moisture removal is often enhanced by the presence of a “balt” layer of the press felt. The paper is then transferred to a dryer section for further moisture removal. After drying, the paper is ready for secondary processing and packaging. 
         [0006]    Typically, papermaker&#39;s fabrics are manufactured as endless belts by one of two basic weaving techniques. In the first of these techniques, fabrics are flat woven by a flat weaving process, with their ends being joined to form an endless belt by any one of a number of well-known joining methods, such as dismantling and reweaving the ends together (commonly known as splicing), or sewing on a pin-seamable flap or a special foldback on each end, then reweaving these into pin-seamable loops. A number of auto-joining machines are available, which for certain fabrics may be used to automate at least part of the joining process. In a flat woven papermaker&#39;s fabric, the warp yarns extend in the machine direction and the filling yarns or weft yarns extend in the cross machine direction. 
         [0007]    In the second basic weaving technique, fabrics are woven directly in the form of a continuous belt with an endless weaving process. In the endless weaving process, the warp yarns extend in the cross machine direction and the filling yarns or weft yarns extend in the machine direction. Both weaving methods described hereinabove are well known in the art, and the term “endless belt” as used herein refers to belts made by either method. 
         [0008]    Effective sheet and fiber support are important considerations in papermaking, especially for the forming section of the papermaking machine, where the wet web is initially formed. Additionally, the forming fabrics should exhibit good stability when they are run at high speeds on the papermaking machines, and preferably are highly permeable to reduce the amount of water retained in the web when it is transferred to the press section of the paper machine. In both tissue and fine paper applications (i.e., paper for use in quality printing, carbonizing, cigarettes, electrical condensers, and like) the papermaking surface comprises a very finely woven or fine wire mesh structure. 
         [0009]    In prior art fabrics, there is typically not enough space within the weave pattern for top warps to bind to the bottom wefts without disrupting the top fabric surface. Such fabrics also do not typically provide space in the weave for the top warps to smoothly transition from the top layer to the bottom layer. Such fabrics also do not typically provide space for warps to float under the wefts for a distance. 
       SUMMARY OF THE INVENTION 
       [0010]    The fabric of the present invention may be made using the prior art methods described above. The invention also provides for a multilayer fabric employed in papermaking. The invention further also provides for the binding of multilayered forming fabric using warp yarns such as warp yarns that weave in the top layer. The present invention also relates to multilayer papermaker&#39;s fabrics that utilizes warp yarns to bind top and bottom layers such without disrupting the top fabric surface. 
         [0011]    The present invention also recognizes that it is better for a warp yarn weaving in the top layer to pass between a top and bottom weft yarn before weaving or binding with one or more bottom weft yarns than for the warp yarn to pass from over a top weft yarn to directly over a bottom weft yarn without first passing between top and bottom weft yarns. 
         [0012]    By way of non-limiting example, the present invention provides for a forming fabric having a 5 shed/5 shed warp bound 3:2 weft ratio. 
         [0013]    The invention also provides for a fabric which utilizes a condensed sequence of warp knuckles in a weft float dominate structure in order to provide space in the weave for the warps which weave in the top layer to smoothly transition from the top layer to the bottom layer. The invention also provides for a fabric wherein the warp knuckles of several repeats of a weft float dominate pattern are condensed into a plain weave sequence that allows space for warps to float under the wefts for a distance. 
         [0014]    The present invention relates to a forming fabric comprising a top layer comprising top weft yarns, a bottom layer comprising bottom weft yarns, binding warp yarns weaving with the top weft yarns and binding to the bottom layer, and at least one of the binding warp yarns passing between at least one top and bottom weft yarns before passing over at least one bottom weft yarn. 
         [0015]    The fabric may further comprise at least one of bottom warp yarns weaving with non-adjacent bottom weft yarns and bottom warp yarns weaving only in the bottom layer. 
         [0016]    At least one of the at least one binding warp yarn may pass under at least two adjacent top weft yarns before passing over at least one bottom weft yarn and each binding warp yarn may bind to bottom layer by binding to non-adjacent bottom weft yarns. The binding warp yarns may weave with the top weft yarns and bind to different non-adjacent bottom weft yarns per pattern repeat. Each binding warp yarn may bind to at least three non-adjacent bottom weft yarns per pattern repeat. After weaving with the top weft yarns, each binding warp yarn may bind to at least two non-adjacent bottom weft yarns per pattern repeat before again weaving with the top weft yarns. The binding warp yarns may bind to at least four non-adjacent bottom weft yarns per pattern repeat. After weaving with the top weft yarns, the at least one binding warp yarn may pass under at least two adjacent top weft yarns before binding with the bottom weft yarns. After weaving with the top weft yarns, the at least one binding warp yarn may pass under at least two adjacent top weft yarns before binding to two non-adjacent bottom weft yarns. After weaving with the top weft yarns, the at least one binding warp yarn may pass under at least three adjacent top weft yarns before binding with the bottom weft yarns. After weaving with the top weft yarns, the at least one binding warp yarn may pass under at least three adjacent top weft yarns before binding to-two non-adjacent bottom weft yarns. 
         [0017]    The top layer and bottom layer may be bound together only by the binding warp yarns and the binding warp yarns are intrinsic warp yarns. Each binding warp yarn in a pattern repeat may weave with a plain weave with top weft yarns before binding with non-adjacent bottom weft yarns. Each binding warp yarn in a pattern repeat may weave with a plain weave with top weft yarns before binding with two non-adjacent bottom weft yarns. 
         [0018]    In a pattern repeat, each binding warp yarn may weave with a plain weave with top weft yarns, then binds with two non-adjacent bottom weft yarns, and then weaves with a plain weave with top weft yarns. In a pattern repeat, the at least one binging warp yarn may bind with first and second non-adjacent bottom weft yarns and a bottom warp yarn weaves with the first and second bottom weft yarns. In a pattern repeat, the at least one binding warp yarn may bind with first, second and third non-adjacent bottom weft yarns and a bottom warp yarn weaves with the first, second and third bottom weft yarns. In a pattern repeat, the at least one binding warp yarn may bind with only first, second and third non-adjacent bottom weft yarns and a bottom warp yarn weaves with the first, second and third bottom weft yarns. In a pattern repeat, each binding warp yarn may bind with only first, second and third non-adjacent bottom weft yarns and corresponding bottom warp yarns weave only with a same first, second and third bottom weft yarns. In a pattern repeat, the at least one binding warp yarn may bind with first, second, third and fourth non-adjacent bottom weft yarns and a bottom warp yarn weaves with the first, second, third and fourth bottom weft yarns. In a pattern repeat, the at least one binding warp yarn may bind with only first, second, third and fourth non-adjacent bottom weft yarns and a bottom warp yarns weave with the first, second, third and fourth bottom weft yarns. In a pattern repeat, each binding warp yarn may bind with only first, second, third and fourth non-adjacent bottom weft yarns and corresponding bottom warp yarns weave only with the first, second, third and fourth bottom weft yarns. In a pattern repeat, all bottom warp yarns may weave only in the bottom layer to non-adjacent bottom weft yarns. 
         [0019]    All of the binding warp yarns may weave only with a plain weave when in the top layer. All of the binding warp yarns may bind to non-adjacent bottom weft yarns in a pattern repeat. The binding warp yarns may bind to different non-adjacent bottom weft yarns in a pattern repeat. The top layer may have a papermaking surface and the bottom has a machine side surface. 
         [0020]    In a pattern repeat, each of the binding warp yarns may be vertically stacked with respect to bottom warp yarns. In a pattern repeat, more top weft yarns may be utilized that bottom weft yarns. In a pattern repeat, 30 top weft yarns may be utilized and 20 bottom weft yarns are utilized. In a pattern repeat, 30 top weft yarns may be utilized and 15 bottom weft yarns are utilized. In a pattern repeat, 20 top or binding warp yarns are utilized and 20 bottom warp yarns may be utilized. 
         [0021]    At least one of the binding warp yarns per pattern repeat may differ from bottom warp yarns in at least one of the following characteristics size, modulus, and material. At least one of the top weft yarns per pattern repeat may differ from the bottom weft yarns in at least one of the following characteristics size, modulus, and material. At least one of the binding warp yarns may be smaller in size than at least one bottom warp yarn. At least one of the top layer may have a different weave pattern than the bottom layer and the top layer may utilize a plain weave and the bottom layer does not utilize a plain weave. 
         [0022]    The invention also provides for a forming fabric comprising a top layer comprising top weft yarns, a bottom layer comprising bottom weft yarns, at least one binding warp yarn weaving with the top weft yarns and binding to at least two non-adjacent bottom weft yarns, and at least one bottom warp yarn weaving only with bottom weft yarns. 
         [0023]    The invention also provides for a forming fabric comprising a top layer comprising top weft yarns, a bottom layer comprising bottom weft yarns, at least one binding warp yarn weaving with top weft yarns and binding to at least two non-adjacent bottom weft yarns in a pattern repeat, and at least one bottom warp yarn weaving with the at least two non-adjacent bottom weft yarns. 
         [0024]    The invention also provides for a method of making the fabric of any of the types described above, wherein the method comprises binding together the top and bottom layers using only the binding warp yarns. 
         [0025]    The invention also provides for a method of making the fabric of any of the types described above, wherein the method comprises binding the top and bottom layers together using the binding warp yarns, wherein each binding warp yarn binds to at least three non-adjacent bottom weft yarns per pattern repeat. 
         [0026]    Additional aspects of the present invention include methods of manufacturing warp-stitched triple layer fabrics and methods of using the triple layer papermaker&#39;s fabric described herein for making paper. 
     
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         [0027]    The present invention is further described in the detailed description which follows, in reference to the noted plurality of drawings by way of non-limiting examples of exemplary embodiments of the present invention, in which like reference numerals, represent similar parts throughout the several views of the drawings, and wherein: 
           [0028]      FIG. 1  shows a weave pattern repeat of a first embodiment of the present invention; 
           [0029]      FIG. 2   a  shows a cross-section view of the repeat shown in  FIG. 1  and illustrates binding yarns  2 ,  4 ,  6 ,  8  and  10  (listed from the bottom up on the left-hand side) and bottom warp yarns  1 ,  3 ,  5 ,  7  and  9  (listed from the bottom up on the left-hand side). The top and bottom weft yarns  1 - 50  are listed right to left; 
           [0030]      FIG. 2   b  shows a cross-section view of the repeat shown in  FIG. 1  and illustrates binding warp yarns  12 ,  14 ,  16 ,  18  and  20  (listed from the bottom up on the left-hand side) and bottom warp yarns  11 ,  13 ,  15 ,  17  and  19  (listed from the bottom up on the left-hand side). The top and bottom weft yarns  1 - 50  are again listed right to left; 
           [0031]      FIG. 3  shows a photograph of a top side or paper facing side of an actual forming fabric utilizing the weave pattern shown in  FIGS. 1-2   b;    
           [0032]      FIG. 4  shows a photograph of a bottom side or machine side of the forming fabric shown in  FIG. 3 ; 
           [0033]      FIG. 5  shows a weave pattern repeat of a second embodiment of the present invention; 
           [0034]      FIG. 6   a  shows a cross-section view of the repeat shown in  FIG. 6  and illustrates binding warp yarns  1 ,  3 ,  5 ,  7  and  9  (listed from the top down on the left-hand side) and bottom warp yarns  2 ,  4 ,  6 ,  8  and  10  (listed from the top down on the left-hand side). The top and bottom weft yarns  1 - 45  are listed right to left; 
           [0035]      FIG. 6   b  shows a cross-section view of the repeat shown in  FIG. 6  and illustrates binding warp yarns  11 ,  13 ,  15 ,  17  and  19  (listed from the top down on the left-hand side) and bottom warp yarns  12 ,  14 ,  16 ,  18  and  20  (listed from the top down on the left-hand side). The top and bottom weft yarns  145  are again listed right to left; 
           [0036]      FIG. 7  shows a photograph of a top side or paper facing side of an actual forming fabric utilizing the weave pattern shown in  FIGS. 5-6   b ; and 
           [0037]      FIG. 8  shows a photograph of a bottom side or machine side of the forming fabric shown in  FIG. 7 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0038]    The particulars shown herein are by way of example and for purposes of illustrative discussion of the embodiments of the present invention only and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the present invention. In this regard, no attempt is made to show structural details of the present invention in more detail than is necessary for the fundamental understanding of the present invention, the description taken with the drawings making apparent to those skilled in the art how the several forms of the present invention may be embodied in practice. 
         [0039]      FIG. 1  shows a first non-limiting embodiment of the invention and depicts a top pattern view of the top fabric layer of the multilayer fabric (i.e., a view of the papermaking surface). The numbers  1 - 20  shown on the bottom of the pattern identify the upper and lower warp yarns while the right side numbers  1 - 50  show the upper or top and lower or bottom weft yarns. The bottom warp yarns shown on the bottom of the pattern are  1 ,  3 ,  5 ,  7 ,  9 ,  11 ,  13 ,  15 ,  17  and  19 . The upper warp yarns shown on the bottom of the pattern are  2 ,  4 ,  6 ,  8 ,  10 ,  12 ,  14 ,  16 ,  18  and  20 . The upper weft yarns shown on the right side of the pattern are  1 ,  3 ,  5 ,  6 ,  8 ,  10 ,  11 ,  13 ,: 15 ,  16 ,  18 ,  20 ,  21 ,  23 ,  25 ,  26 ,  28 ,  30 ,  31 ,  33 ,  35 ,  36 ,  38 ,  40 ,  41 ,  43 ,  45 ,  46 ,  48  and  50 . The lower weft yarns shown on the right side of the pattern are  2 ,  4 ,  7 ,  9 ,  12 ,  14 ,  17 ,  19 ,  22 ,  24 ,  27 ,  29 ,  32 ,  34 ,  37 ,  39 ,  42 ,  44 ,  47  and  49 . 
         [0040]    Also in  FIG. 1 , a blank cell is shown in locations where a binding warp yarn passes under a top weft yarn while a bottom warp yarn passes under a bottom weft yarn. Symbol X is shown in locations where a binding warp yarn passes over a top weft yarn while a bottom warp yarn passes under a bottom weft yarn. A shaded cell is shown in locations where a binding warp yarn passes over a bottom weft yarn while a bottom warp yarn passes over the same bottom weft yarn. As used herein, the term “over” in reference to a weave pattern of a warp yarn in the top layer means that the yarn passes vertically above a paper-side surface of the fabric and then over a top weft yarn. The term “over” in reference to a weave pattern of a warp yarn in the bottom layer means that the yarn passes vertically below a machine-side surface and then over a top weft yarn as opposed to passing between the top and bottom weft yarns. 
         [0041]      FIGS. 2   a  and  2   b  depict the paths of the upper and lower warp yarns  1 - 20  as they weave through the upper and lower weft yarns  1 - 50 . The fabric of  FIG. 1  thus shows a single repeat of the fabric that encompasses  50  weft yarns (yarns  1 - 50  represented horizontally in the figures) and  20  warp yarns (yarns  1 - 20  represented vertically in the figures). While  FIGS. 1-2   b  only show a single repeat unit of the fabric, those of skill in the art will appreciate that in commercial applications, the repeat unit shown in  FIGS. 1-2   b  would be repeated many times, in both the warp and weft directions, to form a large fabric suitable for use on a papermaking machine. 
         [0042]    As seen in  FIG. 2   a , bottom warp yarn  1  passes under bottom weft yarns  2 ,  4 ,  7 ,  9 ,  12  and  14 , then passes over bottom weft yarn  17 , then passes under bottom weft yarns  19  and  22 , then passes over bottom weft yarn  24 , then passes under bottom weft yarns  27 ,  29 ,  32 ,  34 ,  37  and  39 , then passes over bottom weft yarn  42 , then passes under bottom weft yarns  44  and  47 , and then passes over bottom weft yarn  49 . The bottom warp yarn  1  weaves only in the bottom layer and only with non-adjacent bottom weft yarns, e.g., four non-adjacent bottom weft yarns  17 ,  24 ,  42  and  49 . 
         [0043]    Also seen in  FIG. 2   a , binding warp yarn  2  passes from the bottom layer to the top layer by passing under top weft yarns  1  and  3 , then weaves with the top layer weft yarns  5 ,  6 ,  8 ,  10  and  11  to form a plain weave, then passes from the top layer to the bottom layer by passing under top weft yarns  13  and  15 , then passes over bottom weft yarn  17 , then passes under bottom weft yarns  19  and  22 , then passes over bottom weft yarn  24 , then passes from the bottom layer to the top layer by passing under top weft yarns  25 ,  26 , and  28 , then weaves with the top weft yarns  30 ,  31 ,  33 ,  35  and  36  to form a plain weave, then passes from the top layer to the bottom layer by passing under top weft yarns  38  and  40 , then passes over bottom weft yarn  42 , then passes under bottom weft yarns  44  and  47 , then passes over bottom weft yarn  49 , and then begins to pass back to the top layer. The binding warp yarn  2  binds to the bottom layer by weaving with the same non-adjacent bottom weft yarns that the bottom warp yarn  1  was woven with, e.g., by passing over the four non-adjacent bottom weft yarns  17 ,  24 ,  42  and  49 . 
         [0044]      FIG. 2   a  also illustrates bottom warp yarn  3  passing over bottom weft yarn  2 , then passes under bottom weft yarns  4  and  7 , then passes over bottom weft yarn  9 , then passes under bottom weft yarns  12 ,  14 ,  17 ,  19 ,  22  and  24 , then passes over bottom weft yarn  27 , then passes under bottom weft yarns  29  and  32 , then passes over bottom weft yarn  34 , and then passes under bottom weft yarns  37 ,  39 ,  42 ,  44 ,  47  and  49 . The bottom warp yarn  3  weaves only in the bottom layer and only with non-adjacent bottom weft yarns, e.g., four non-adjacent bottom weft yarns  2 ,  9 ,  27  and  34 . The pattern formed by bottom warp yarn  3  is the same as that of bottom warp yarn  1  except that it is shifted sideways by six bottom weft yarns. 
         [0045]    Also seen in  FIG. 2   a , binding warp yarn  4  passes over bottom weft yarn  2 , then passes under bottom weft yarns  4  and  7 , then passes over bottom weft yarn  9 , then passes from the bottom layer to the top layer by passing under top weft yarns  10 ,  11  and  13 , then weaves with the top layer weft yarns  15 ,  16 ,  18 ,  20  and  21  to form a plain weave, then passes from the top layer to the bottom layer by passing under top weft yarns  23  and  25 , then passes over bottom weft yarn  27 , then passes under bottom weft yarns  29  and  32 , then passes over bottom weft yarn  34 , then passes from the bottom layer to the top layer by passing under top weft yarns  35 ,  36 , and  38 , then weaves with the top weft yarns  40 ,  41 ,  43 ,  45  and  46  to form a plain weave, then passes from the top layer to the bottom layer by passing under top weft yarns  48  and  50 . The binding warp yarn  4  binds to the bottom layer by weaving with the same non-adjacent bottom weft yarns that the bottom warp yarn  3  was woven with, e.g., by passing over the four non-adjacent bottom weft yarns  2 ,  9 ,  27  and  34 . The pattern formed by binding warp yarn  4  is the same as that of binding warp yarn  2  except that it is shifted sideways by six top weft yarns. 
         [0046]      FIG. 2   a  additionally shows bottom warp yarn  5  passing under bottom weft yarns  2 ,  4 ,  7  and  9 , then passes over bottom weft yarn  12 , then passes under bottom weft yarns  14  and  17 , then passes over bottom weft yarn  19 , then passes under bottom weft yarns  22 ,  24 ,  27 ,  29 ,  32  and  34 , then passes over bottom weft yarn  37 , then passes under bottom weft yarns  39  and  42 , and then passes over bottom weft yarn  44 , then passes under bottom weft yarns  47  and  49 . The bottom warp yarn  5  weaves only in the bottom layer and only with non-adjacent bottom weft yarns, e.g., four non-adjacent bottom weft yarns  12 ,  19 ,  37  and  44 . The pattern formed by bottom warp yarn  5  is the same as that of bottom warp yarn  3  except that it is shifted sideways by four bottom weft yarns. 
         [0047]    Also seen in  FIG. 2   a , binding warp yarn  6  weaves with the top weft yarns  1 ,  3 ,  5  and  6  to form a plain weave, then passes from the top layer to the bottom layer by passing under top weft yarns  8  and  10 , then passes over bottom weft yarn  12 , then passes under bottom weft yarns  14  and  17 , then passes over bottom weft yarn  19 , then passes from the bottom layer to the top layer by passing under top weft yarns  20 ,  21  and  23 , then weaves with the top weft yarns  25 ,  26 ,  28 ,  30  and  31  to form a plain weave, then passes from the top layer to the bottom layer by passing under top weft yarns  33  and  35 , then passes over bottom weft yarn  37 , then passes under bottom weft yarns  39  and  42 , then passes over bottom weft yarn  44 , then passes from the bottom layer to the top layer by passing under top weft yarns  45 ,  46  and  48 , then passes over top weft yarn  50 . The binding warp yarn  6  binds to the bottom layer by weaving with the same non-adjacent bottom weft yarns that the bottom warp yarn  5  was woven with, e.g., by passing over the four non-adjacent bottom weft yarns  12 ,  19 ,  37  and  44 . The pattern formed by binding warp yarn  6  is the same as that of binding warp yarn  4  except that it is shifted sideways by six top weft yarns. 
         [0048]      FIG. 2   a  further shows bottom warp yarn  7  passing under bottom weft yarn  2 , then passes over bottom weft yarn  4 , then passes under bottom weft yarns  7 ,  9 ,  12 ,  14 ,  17  and  19 , then passes over bottom weft yarn  22 , then passes under bottom weft yarns  24  and  27 , then passes over bottom weft yarn  29 , then passes under bottom weft yarns  32 ,  34 ,  37 ,  39 ,  42  and  44 , and then passes over bottom weft yarn  44 , then passes under bottom weft yarn  49 . The bottom warp yarn  7  weaves only in the bottom layer and only with non-adjacent bottom weft yarns, e.g., four non-adjacent bottom weft yarns  4 ,  22 ,  29  and  47 . The pattern formed by bottom warp yarn  7  is the same as that of bottom warp yarn  5  except that it is shifted sideways by four bottom weft yarns. 
         [0049]    Also seen in  FIG. 2   a , binding warp yarn  8  passes under bottom weft yarn  2 , then passes over bottom weft yarn  4 , then passes from the bottom layer to the top layer by passing under top weft yarns  5 ,  6  and  8 , then weaves with the top weft yarns  10 ,  11 ,  13 ,  15  and  16  to form a plain weave, then passes from the top layer to the bottom layer by passing under top weft yarns  18  and  20 , then passes over bottom weft yarn  22 , then passes under bottom weft yarns  24  and  27 , then passes over bottom weft yarn  29 , then passes from the bottom layer to the top layer by passing under top weft yarns  30 ,  31  and  33 , then weaves with the top weft yarns  35 ,  36 ,  38 ,  40  and  41  to form a plain weave, then passes from the top layer to the bottom layer by passing under top weft yarns  43  and  45 , then passes over bottom weft yarn  47 , then passes under bottom weft yarn  49 . The binding warp yarn  8  binds to the bottom layer by weaving with the same non-adjacent bottom weft yarns that the bottom warp yarn  7  was woven with, e.g., by passing over the four non-adjacent bottom weft yarns  4 ,  22 ,  29  and  47 . The pattern formed by binding warp yarn  8  is the same as that of binding warp yarn  6  except that it is shifted sideways by six top weft yarns. 
         [0050]    Additionally,  FIG. 2   a  shows bottom warp yarn  9  passing under bottom weft yarns  2  and  4 , then passes over bottom weft yarn  7 , then passes under bottom weft yarns  9  and  12 , then passes over bottom weft yarn  14 , then passes under bottom weft yarns  17 ,  19 ,  22 ,  24 ,  27  and  29 , then passes over bottom weft yarn  32 , then passes under bottom weft yarns  34  and  37 , and then passes over bottom weft yarn  39 , then passes under bottom weft yarns  42 ,  44 ,  47  and  49 . The bottom warp yarn  9  weaves only in the bottom layer and only with non-adjacent bottom weft yarns, e.g., four non-adjacent bottom weft yarns  7 ,  14 ,  32  and  39 . The pattern formed by bottom warp yarn  9  is the same as that of bottom warp yarn  7  except that it is shifted sideways by four bottom weft yarns. 
         [0051]    Finally,  FIG. 2   a  shows binding warp yarn  10  passing over the top weft yarn  1 , then passes from the top layer to the bottom layer by passing under top weft yarns  3  and  5 , then passes over bottom weft yarn  7 , then passes under bottom weft yarns  9  and  12 , then passes over bottom weft yarn  14 , then passes from the bottom layer to the top layer by passing under top weft yarns  15 ,  16  and  18 , then weaves with the top weft yarns  20 ,  21 ,  23 ,  25  and  26  to form a plain weave, then passes from the top layer to the bottom layer by passing under top weft yarns  28  and  30 , then passes over bottom weft yarn  32 , then passes under bottom weft yarns  34  and  37 , then passes over bottom weft yarn  39 , then passes from the bottom layer to the top layer by passing under top weft yarns  40 ,  41  and  43 , then weaves with binding warp yarns  45 ,  46 ,  48  and  50  to form a plain weave. The binding warp yarn  10  binds to the bottom layer by weaving with the same non-adjacent bottom weft yarns that the bottom warp yarn  9  was woven with, e.g., by passing over the four non-adjacent bottom weft yarns  7 ,  14 ,  32  and  39 . The pattern formed by binding warp yarn  10  is the same as that of binding warp yarn  8  except that it is shifted sideways by six top weft yarns. 
         [0052]    With reference to  FIG. 2   b , bottom warp yarn  11  passes under bottom weft yarns  2 ,  4 ,  7 ,  9 ,  12  and  14 , then passes over bottom weft yarn  17 , then passes under bottom weft yarns  19  and  22 , then passes over bottom weft yarn  24 , then passes under bottom weft yarns  27 ,  29 ,  32 ,  34 ,  37  and  39 , then passes over bottom weft yarn  42 , then passes under bottom weft yarns  44  and  47 , and then passes over bottom weft yarn  49 . The bottom warp yarn  11  weaves only in the bottom layer and only with non-adjacent bottom weft yarns, e.g., four non-adjacent bottom weft yarns  17 ,  24 ,  42  and  49 . 
         [0053]    Also seen in  FIG. 2   b , binding warp yarn  12  passes from the bottom layer to the top layer by passing under top weft yarns  1  and  3 , then weaves with the top layer weft yarns  5 ,  6 ,  8 ,  10  and  11  to form a plain weave, then passes from the top layer to the bottom layer by passing under top weft yarns  13  and  15 , then passes over bottom weft yarn  17 , then passes under bottom weft yarns  19  and  22 , then passes over bottom weft yarn  24 , then passes from the bottom layer to the top layer after passing under top weft yarns  25 ,  26 , and  28 , then weaves with the top weft yarns  30 ,  31 ,  33 ,  35  and  36  to form a plain weave, then passes from the top layer to the bottom layer by passing under top weft yarns  38  and  40 , then passes over bottom weft yarn  42 , then passes under bottom weft yarns  44  and  47 , then passes over bottom weft yarn  49 , and then begins to pass back to the top layer. The binding warp yarn  12  binds to the bottom layer by weaving with the same non-adjacent bottom weft yarns that the bottom warp yarn  11  was woven with, e.g., by passing over the four non-adjacent bottom weft yarns  17 ,  24 ,  42  and  49 . 
         [0054]      FIG. 2   b  also illustrates bottom warp yarn  13  passing over bottom weft yarn  2 , then passes under bottom weft yarns  4  and  7 , then passes over bottom weft yarn  9 , then passes under bottom weft yarns  12 ,  14 ,  17 ,  19 ,  22  and  24 , then passes over bottom weft yarn  27 , then passes under bottom weft yarns  29  and  32 , then passes over bottom weft yarn  34 , and then passes under bottom weft yarns  37 ,  39 ,  42 ,  44 ,  47  and  49 . The bottom warp yarn  13  weaves only in the bottom layer and only with non-adjacent bottom weft yarns, e.g., four non-adjacent bottom weft yarns  2 ,  9 ,  27  and  34 . The pattern formed by bottom warp yarn  13  is the same as that of bottom warp yarn  11  except that it is shifted sideways by six bottom weft yarns. 
         [0055]    Also seen in  FIG. 2   b , binding warp yarn  14  passes over bottom weft yarn  2 , then passes under bottom weft yarns  4  and  7 , then passes over bottom weft yarn  9 , then passes from the bottom layer to the top layer by passing under top weft yarns  10 ,  11  and  13 , then weaves with the top layer weft yarns  15 ,  16 ,  18 ,  20  and  21  to form a plain weave, then passes from the top layer to the bottom layer by passing under top weft yarns  23  and  25 , then passes over bottom weft yarn  27 , then passes under bottom weft yarns  29  and  32 , then passes over bottom weft yarn  34 , then passes from the bottom layer to the top layer by passing under top weft yarns  35 ,  36 , and  38 , then weaves with the top weft yarns  40 ,  41 ,  43 ,  45  and  46  to form a plain weave, then passes from the top layer to the bottom layer by passing under top weft yarns  48  and  50 . The binding warp yarn  14  binds to the bottom layer by weaving with the same non-adjacent bottom weft yarns that the bottom warp yarn  13  was woven with, e.g., by passing over the four non-adjacent bottom weft yarns  2 ,  9 ,  27  and  34 . The pattern formed by binding warp yarn  14  is the same as that of binding warp yarn  12  except that it is shifted sideways by six top weft yarns. 
         [0056]      FIG. 2   b  also illustrates bottom warp yarn  15  passing under bottom weft yarns  2 ,  4 ,  7  and  9 , then passes over bottom weft yarn  12 , then passes under bottom weft yarns  14  and  17 , then passes over bottom weft yarn  19 , then passes under bottom weft yarns  22 ,  24 ,  27 ,  29 ,  32  and  34 , then passes over bottom weft yarn  37 , then passes under bottom weft yarns  39  and  42 , and then passes over bottom weft yarn  44 , then passes under bottom weft yarns  47  and  49 . The bottom warp yarn  15  weaves only in the bottom layer and only with non-adjacent bottom weft yarns, e.g., four non-adjacent bottom weft yarns  12 ,  19 ,  37  and  44 . The pattern formed by bottom warp yarn  15  is the same as that of bottom warp yarn  13  except that it is shifted sideways by four bottom weft yarns. 
         [0057]    Also seen in  FIG. 2   b , binding warp yarn  16  weaves with the top weft yarns  1 ,  3 ,  5  and  6  to form a plain weave, then passes from the top layer to the bottom layer by passing under top weft yarns  8  and  10 , then passes over bottom weft yarn  12 , then passes under bottom weft yarns  14  and  17 , then passes over bottom weft yarn  19 , then passes from the bottom layer to the top layer by passing under top weft yarns  20 ,  21  and  23 , then weaves with the top weft yarns  25 ,  26 ,  28 ,  30  and  31  to form a plain weave, then passes from the top layer to the bottom layer by passing under top weft yarns  33  and  35 , then passes over bottom weft yarn  37 , then passes under bottom weft yarns  39  and  42 , then passes over bottom weft yarn  44 , then passes from the bottom layer to the top layer by passing under top weft yarns  45 ,  46  and  48 , then passes over top weft yarn  50 . The binding warp yarn  16  binds to the bottom layer by weaving with the same non-adjacent bottom weft yarns that the bottom warp yarn  15  was woven with, e.g., by passing over the four non-adjacent bottom weft yarns  12 ,  19 ,  37  and  44 . The pattern formed by binding warp yarn  16  is the same as that of binding warp yarn  14  except that it is shifted sideways by six top weft yarns. 
         [0058]      FIG. 2   b  further illustrates bottom warp yarn  17  passing under bottom weft yarn  2 , then passes over bottom weft yarn  4 , then passes under bottom weft yarns  7 ,  9 ,  12 ,  14 ,  17  and  19 , then passes over bottom weft yarn  22 , then passes under bottom weft yarns  24  and  27 , then passes over bottom weft yarn  29 , then passes under bottom weft yarns  32 ,  34 ,  37 ,  39 ,  42  and  44 , and then passes over bottom weft yarn  44 , then passes under bottom weft yarn  49 . The bottom warp yarn  17  weaves only in the bottom layer and only with non-adjacent bottom weft yarns, e.g., four non-adjacent bottom weft yarns  4 ,  22 ,  29  and  47 . The pattern formed by bottom warp yarn  17  is the same as that of bottom warp yarn  15  except that it is shifted sideways by four bottom weft yarns. 
         [0059]      FIG. 2   b  further shows binding warp yarn  18  passing under bottom weft yarn  2 , then passes over bottom weft yarn  4 , then passes from the bottom layer to the top layer by passing under top weft yarns  5 ,  6  and  8 , then weaves with the top weft yarns  10 ,  11 ,  13 ,  15  and  16  to form a plain weave, then passes from the top layer to the bottom layer by passing under top weft yarns  18  and  20 , then passes over bottom weft yarn  22 , then passes under bottom weft yarns  24  and  27 , then passes over bottom weft yarn  29 , then passes from the bottom layer to the top layer by passing under top weft yarns  30 ,  31  and  33 , then weaves with the top weft yarns  35 ,  36 ,  38 ,  40  and  41  to form a plain weave, then passes from the top layer to the bottom layer by passing under top weft yarns  43  and  45 , then passes over bottom weft yarn  47 , then passes under bottom weft yarn  49 . The binding warp yarn  18  binds to the bottom layer by weaving with the same non-adjacent bottom weft yarns that the bottom warp yarn  17  was woven with, e.g., by passing over the four non-adjacent bottom weft yarns  4 ,  22 ,  29  and  47 . The pattern formed by binding warp yarn  18  is the same as that of binding warp yarn  16  except that it is shifted sideways by six top weft yarns. 
         [0060]      FIG. 2   b  also shows bottom warp yarn  19  passing under bottom weft yarns  2  and  4 , then passes over bottom weft yarn  7 , then passes under bottom weft yarns  9  and  12 , then passes over bottom weft yarn  14 , then passes under bottom weft yarns  17 ,  19 ,  22 ,  24 ,  27  and  29 , then passes over bottom weft yarn  32 , then passes under bottom weft yarns  34  and  37 , and then passes over bottom weft yarn  39 , then passes under bottom weft yarns  42 ,  44 ,  47  and  49 . The bottom warp yarn  19  weaves only in the bottom layer and only with non-adjacent bottom weft yarns, e.g., four non-adjacent bottom weft yarns  7 ,  14 ,  32  and  39 . The pattern formed by bottom warp yarn  19  is the same as that of bottom warp yarn  17  except that it is shifted sideways by four bottom weft yarns. 
         [0061]    Finally, as seen in  FIG. 2   b , binding warp yarn  20  passes over the top weft yarn  1 , then passes from the top layer to the bottom layer by passing under top weft yarns  3  and  5 , then passes over bottom weft yarn  7 , then passes under bottom weft yarns  9  and  12 , then passes over bottom weft yarn  14 , then passes from the bottom layer to the top layer by passing under top weft yarns  15 ,  16  and  18 , then weaves with the top weft yarns  20 ,  21 ,  23 ,  25  and  26  to form a plain weave, then passes from the top layer to the bottom layer by passing under top weft yarns  28  and  30 , then passes over bottom weft yarn  32 , then passes under bottom weft yarns  34  and  37 , then passes over bottom weft yarn  39 , then passes from the bottom layer to the top layer by passing under top weft yarns  40 ,  41  and  43 , then weaves with binding warp yarns  45 ,  46 ,  48  and  50  to form a plain weave. The binding warp yarn  20  binds to the bottom layer by weaving with the same non-adjacent bottom weft yarns that the bottom warp yarn  19  was woven with, e.g., by passing over the four non-adjacent bottom weft yarns  7 ,  14 ,  32  and  39 . The pattern formed by binding warp yarn  20  is the same as that of binding warp yarn  18  except that it is shifted sideways by six top weft yarns. 
         [0062]    As is apparent from a comparison of  FIG. 2   a  and  2   b , the paths taken by the warp yarns  1 - 10  through the weft yarns  1 - 50  are respectively the same as paths taken by the warp yarns  11 - 20  through the weft yarns  1 - 50 , i.e., warp yarn  1  has the same path through the weft yarns  1 - 50  as warp yarn  11 , warp yarn  2  has the same path through the weft yarns  1 - 50  as warp yarn  12 , etc,. 
         [0063]      FIG. 3  shows a photograph of a top side or paper facing side of an actual forming fabric utilizing the weave pattern shown in  FIG. 1  and  FIG. 4  shows a photograph of a bottom side or machine side of the forming fabric shown in  FIG. 3 . 
         [0064]    By way of non-limiting example, the binding warp yarns  2 ,  4 ,  6 ,  8 ,  10 ,  12 ,  14 ,  16 ,  18  and  20  of the embodiment shown in  FIGS. 1-2   b  can have the following characteristics: acceptable size range of between approximately 0.10 mm and approximately 0.50 mm, preferable size ranges of between approximately 0.20 mm and approximately 0.80 mm, and most preferred size range of between approximately 0.12 mm and approximately 0.20 mm. The material for these yarns can be any natural or synthetic material, preferably a synthetic monofilament, and most preferably a polyester monofilament. 
         [0065]    By way of non-limiting example, the bottom warp yarns  1 ,  3 ,  5 ,  7 ,  9 ,  11 ,  13 ,  15 ,  17  and  19  of the embodiment shown in  FIGS. 1-2   b  can have the following characteristics: acceptable size range of between approximately 0.15 mm and approximately 0.60 mm, preferable size ranges of between approximately 0.20 mm and approximately 0.40 mm, and most preferred size range of between approximately 0.25 mm and approximately 0.35 mm. The material for these yarns can be any natural or synthetic material, preferably a synthetic monofilament, and most preferably a polyester monofilament. The bottom warp yarns can preferably be constructed using relatively large diameter yarns that are well suited to sustain the wear caused by the friction between the machine side surface of the fabric and the papermaking machine during use of the fabric. 
         [0066]    By way of non-limiting example, the top weft yarns  1 ,  3 ,  5 ,  6 ,  8 ,  10 ,  11 ,  13 ,  15 ,  16 ,  18 ,  20 ,  21 ,  23 ,  25 ,  26 ,  28 ,  30 ,  31 ,  33 ,  35 ,  36 ,  38 ,  40 ,  41 ,  43 ,  45 ,  46 ,  48  and  50  of the embodiment shown in  FIGS. 1-2   b  can have the following characteristics: acceptable size range of between approximately 0.10 mm and approximately 0.50 mm, preferable size ranges of between approximately 0.20 mm and approximately 0.80 mm, and most preferred size range of between approximately 0.12 mm and approximately 0.80 mm. The material for these yarns can be any natural or synthetic material, preferably a synthetic monofilament, and most preferably a polyester monofilament. 
         [0067]    By way of non-limiting example, the bottom weft yarns  2 ,  4 ,  7 ,  9 ,  12 ,  14 ,  17 ,  19 ,  22 ,  24 ,  27 ,  29 ,  32 ,  34 ,  37 ,  39 ,  42 ,  44 ,  47  and  49  of the embodiment shown in  FIGS. 1-2   b  can have the following characteristics: acceptable size range of between approximately 0.15 mm and approximately 0.60 mm, preferable size ranges of between approximately 0.20 mm and approximately 0.40 mm, and most preferred size range of between approximately 0.25 mm and approximately 0.35 mm. The material for these yarns can be any natural or synthetic material, preferably a synthetic monofilament, and most preferably a polyester monofilament. These bottom weft yarns may also be constructed using larger diameter yarns than the upper warp yarns. 
         [0068]    In the embodiment shown in  FIGS. 1-2   b  all of the binding warp yarns form a plain weave in the top layer by weaving with five top weft yarns and bind to the bottom layer by weaving with four bottom weft yarns with a non-plain weave in two spaced apart locations, i.e., spaced apart by ten top weft yarns and/or sic bottom weft yarns in each repeat of the fabric. Furthermore, all of the bottom warp yarns weave only in the bottom layer. Additionally, when a binding warp yarn passes from the bottom layer to the top layer, it passes under three adjacent top weft yarns before weaving with a plain weave in the top layer. When a binding warp yarn passes from the top layer to the bottom layer, it passes under two adjacent top weft yarns before weaving with a non-plain weave in the bottom layer. Thus, the area of the plain weave (between a binding warp yarn and top weft yarns) is off-center with respect to an area or spacing between the two areas where the same binding warp yarn weaves to the bottom layer. Also, in the area or spacing between two the plain weave areas (between a binding warp yarn and top weft yarns), the area where the binding warp weaves with the bottom layer is off-center. These features are also desirable in numerous papermaking applications. 
         [0069]      FIG. 5  shows a second non-limiting embodiment of the invention and depicts a top pattern view of the top fabric layer of the multilayer fabric (i.e., a view of the papermaking surface). The numbers  1 - 20  shown on the bottom of the pattern identify the upper and lower warp yarns while the right side numbers  1 - 45  show the upper and lower weft yarns. The upper warp yarns shown on the bottom of the pattern are  1 ,  3 ,  5 ,  7 ,  9 ,  11 ,  13 ,  15 ,  17  and  19 . The lower warp yarns shown on the bottom of the pattern are  2 ,  4 ,  6 ,  8 ,  10 ,  12 ,  14 ,  16 ,  18  and  20 . The top weft yarns shown on the right side of the pattern are  1 ,  3 ,  4 ,  6 ,  7 ,  9 ,  10 ,  12 ,  13 ,  15 ,  16 ,  18 ,  19 ,  21 ,  22 ,  24 ,  25 ,  27 ,  28 ,  30 ,  31 ,  33 ,  34 ,  36 ,  37 ,  39 ,  40 ,  42 ,  43  and  45 . The bottom weft yarns shown on the right side of the pattern are  2 ,  5 ,  8 ,  11 ,  14 ,  17 ,  20 ,  23 ,  26 ,  29 ,  32 ,  35 ,  38 ,  41  and  44 . 
         [0070]    Also in  FIG. 5 , a blank cell is shown in locations where a binding warp yarn passes under a top weft yarn while a bottom warp yarn passes under a bottom weft yarn. Symbol X is shown in locations where a binding warp yarn passes over a top weft yarn while a bottom warp yarn passes under a bottom weft yarn. A shaded cell is shown in locations where a binding warp yarn passes over a bottom weft yarn while a bottom warp yarn passes over the same bottom weft yarn. As used herein, the term “over” in reference to a weave pattern of a warp yarn in the top layer means that the yarn passes vertically above a paper-side surface of the fabric and then over a top weft yarn. The term “over” in reference to a weave pattern of a warp yarn in the bottom layer means that the yarn passes vertically below a machine-side surface and then over a top weft yarn as opposed to passing between the top and bottom weft yarns. 
         [0071]      FIGS. 6   a  and  6   b  depict the paths of the upper and lower warp yarns  1 - 20  as they weave through the upper and lower weft yarns  1 - 45 . The fabric of  FIG. 5  thus shows a single repeat of the fabric that encompasses  45  weft yarns (yarns  1 - 45  represented horizontally in the figures) and  20  warp yarns (yarns  1 - 20  represented vertically in the figures). While  FIGS. 5-6   b  only show a single repeat unit of the fabric, those of skill in the art will appreciate that in commercial applications, the repeat unit shown in  FIGS. 5-6   b  would be repeated many times, in both the warp and weft directions, to form a large fabric suitable for use on a papermaking machine. 
         [0072]    As seen in  FIG. 6   a , binding warp yarn  1  passes from the bottom layer to the top layer by passing under top weft yarns  1  and  3 , then weaves with the top layer weft yarns  4 ,  6 ,  7 ,  9  and  10  to form a plain weave, then passes from the top layer to the bottom layer by passing under top weft yarns  12 ,  13  and  15 , then passes over bottom weft yarn  17 , then passes under bottom weft yarn  20 , then passes over bottom weft yarn  23 , then passes from the bottom layer to the top layer by passing under top weft yarns  24  and  25 , then weaves with the top weft yarns  27 ,  28 ,  30 ,  31  and  33  to form a plain weave, then passes from the top layer to the bottom layer by passing under top weft yarns  34  and  36 , then passes over bottom weft yarn  38 , then passes back to the top layer by passing under top weft yarns  39 ,  40 ,  42 ,  43  and  45 . The binding warp yarn  1  binds to the bottom layer by weaving with the same adjacent bottom weft yarns that the bottom warp yarn  2  was woven with, e.g., by passing over the three non-adjacent bottom weft yarns  17 ,  23  and  38 . 
         [0073]    Also seen in  FIG. 6   a , bottom warp yarn  2  passes under bottom weft yarns  2 ,  5 ,  8 ,  11  and  14 , then passes over bottom weft yarn  17 , then passes under bottom weft yarn  20 , then passes over bottom weft yarn  23 , then passes under bottom weft yarns  26 ,  29 ,  32  and  35 , then passes over bottom weft yarn  38 , then passes under bottom weft yarns  41  and  44 . The bottom warp yarn  2  weaves only in the bottom layer, weaves first with three adjacent bottom weft yarns, e.g., bottom weft yarns  17 ,  20  and  23 , and then binds with only one bottom weft yarn, e.g., bottom weft yarn  38 . 
         [0074]      FIG. 6   a  also illustrates binding warp yarn  3  passing over bottom weft yarn  2 , then passes under bottom weft yarns  3 ,  4 ,  6 ,  7 ,  9 ,  10  and  12 , then weaves with the top layer weft yarns  13 ,  15 ,  16 ,  18  and  19  to form a plain weave, then passes from the top layer to the bottom layer by passing under top weft yarns  21 ,  22  and  24 , then passes over bottom weft yarn  26 , then passes under bottom weft yarn  29 , then passes over bottom weft yarn  32 , then passes from the bottom layer to the top layer by passing under top weft yarns  33  and  34 , then weaves with the top weft yarns  36 ,  37 ,  39 ,  40  and  42  to form a plain weave, then passes from the top layer to the bottom layer by passing under top weft yarns  43  and  45 . The binding warp yarn  3  binds to the bottom layer by weaving with the same bottom weft yarns that the bottom warp yarn  4  was woven with, e.g., by passing over the three non-adjacent bottom weft yarns  2 ,  26  and  32 . The pattern formed by binding warp yarn  3  is different from that of binding warp yarn  1  in both position and weaving path. 
         [0075]    Also seen in  FIG. 6   a , bottom warp yarn  4  passes over bottom weft yarn  2 , then passes under bottom weft yarns  5 ,  8 ,  11 ,  14 ,  17 ,  20  and  23 , then passes over bottom weft yarn  26 , then passes under bottom weft yarn  29 , then passes over bottom weft yarn  32 , then passes under bottom weft yarns  35 ,  38 ,  41  and  44 . The bottom warp yarn  4  weaves only in the bottom layer, weaves first with one bottom weft yarn, e.g., bottom weft yarn  2 , and then weaves with three bottom weft yarns, e.g., bottom, weft yarns  26 ,  29  and  32 . The pattern formed by bottom warp yarn  4  is the same as that of bottom warp yarn  2  except that it is shifted sideways by three bottom weft yarns. 
         [0076]      FIG. 6   a  also shows binding warp yarn  5  weaving with the top weft yarns  1 ,  3 ,  4  and  6  to form a plain weave, then passes from the top layer to the bottom layer by passing under top weft yarns  7  and  9 , then passes over bottom weft yarn  11 , then passes from the bottom layer to the top layer by passing under top weft yarns  12 , 13 ,  15 ,  16 ,  18 ,  19  and  21 , then weaves with the top weft yarns  22 ,  24 ,  25 ,  27  and  28  to form a plain weave, then passes from the top layer to the bottom layer by passing under top weft yarns  30 ,  31  and  33 , then passes over bottom weft yarn  35 , then passes under bottom weft yarn  38 , then passes over bottom weft yarn  41 , then passes from the bottom layer to the top layer by passing under top weft yarns  42  and  43 , then passes over top weft yarn  45 . The binding warp yarn  5  binds to the bottom layer by weaving with the same bottom weft yarns that the bottom warp yarn  6  weaves with, e.g., by passing over the three non-adjacent bottom weft yarns  11 ,  35  and  41 . The pattern formed by binding warp yarn  5  is the same as that of binding warp yarn  3  except that it is shifted sideways by nine top weft yarns. 
         [0077]    As seen in  FIG. 6   a , bottom warp yarn  6  passes under bottom weft yarns  2 ,  5  and  8 , then passes over bottom weft yarn  11 , then passes under bottom weft yarns  14 ,  17 ,  20 ,  23 ,  26 ,  29  and  32 , then passes over bottom weft yarn  35 , then passes under bottom weft yarn  38 , then passes over bottom weft yarn  41 , then passes under bottom weft yarn  44 . The bottom warp yarn  6  weaves only in the bottom layer, weaves first with one bottom weft yarn, e.g., bottom weft yarn  11 , and then weaves with three bottom weft yarns, e.g., bottom weft yarns  35 ,  38  and  41 . The pattern formed by bottom warp yarn  6  is the same as that of bottom warp yarn  4  except that it is shifted sideways by three bottom weft yarns. 
         [0078]    Additionally,  FIG. 6   a  shows binding warp yarn  7  passing from the top layer to the bottom layer by passing under top weft yarns  1  and  3 , then under bottom weft yarn  5 , then passes from the bottom layer to the top layer by passing under top weft yarns  6  and  7 , then weaves with the top weft yarns  9 ,  10 ,  12 ,  13  and  15  to form a plain weave, then passes from the top layer to the bottom layer by passing under top weft yarns  16  and  18 , then passes over bottom weft yarn  20 , then passes from the bottom layer to the top layer by passing under top weft yarns  21 ,  22 ,  24 ,  25 ,  27 ,  28  and  30 , then weaves with the top weft yarns  31 ,  33 ,  34 ,  36  and  37  to form a plain weave, then passes from the top layer to the bottom layer by passing under top weft yarns  39 ,  40  and  42 , then passes over bottom weft yarn  44 , then begins to pass back to the top layer from the bottom layer by passing under top weft yarn  45 . The binding warp yarn  7  binds to the bottom layer by weaving with the same non-adjacent bottom weft yarns that the bottom warp yarn  8  weaves with, e.g., by passing over the three non-adjacent bottom weft yarns  5 ,  20  and  44 . The pattern formed by binding warp yarn  7  is different from that of the binding warp yarns  1 ,  3 ,  5  and  9 . 
         [0079]    As seen in  FIG. 6   a , bottom warp yarn  8  passes under bottom weft yarn  2 , then passes over bottom weft yarn  5 , then passes under bottom weft yarns  8 ,  11 ,  14  and  17 , then passes over bottom weft yarn  20 , then passes under bottom weft yarns  23 ,  26 ,  29 ,  32 ,  35 ,  38  and  41 , then passes over bottom weft yarn  44 . The bottom warp yarn  8  weaves only in the bottom layer and only with non-adjacent bottom weft yarns, e.g., three non-adjacent bottom weft yarns  5 ,  20  and  44 . The pattern formed by bottom warp yarn  8  is different from that of the bottom warp yarns  2 ,  4 ,  6  and  10 . 
         [0080]    Furthermore,  FIG. 6   a  shows binding warp yarn  9  passing over the top weft yarn  1 , then passes from the top layer to the bottom layer by passing under top weft yarns  3 ,  4  and  6 , then passes over bottom weft yarn  8 , then passes under bottom weft yarn  11 , then passes over bottom weft yarn  14 , then passes from the bottom layer to the top layer by passing under top weft yarns  15  and  16 , then weaves with the top weft yarns  18 ,  19 ,  21 ,  22  and  24  to form a plain weave, then passes from the top layer to the bottom layer by passing under top weft yarns  25  and  27 , then passes over bottom weft yarn  29 , then passes from the bottom layer to the top layer by passing under top weft yarns  30 ,  31 ,  33 ,  34 ,  36 ,  37  and  39 , then weaves with top weft yarns  40 ,  42 ,  43  and  45  to form a plain weave. The binding warp yarn  9  binds to the bottom layer by weaving with the same bottom weft yarns that the bottom warp yarn  10  weaves with, e.g., by passing over the three non-adjacent bottom weft yarns  8 ,  14  and  29 . The pattern formed by binding warp yarn  9  is the same as that of binding warp yarn  1  except that it is shifted sideways by six top weft yarns. 
         [0081]    Finally, as seen in  FIG. 6   a , bottom warp yarn  10  passes under bottom weft yarns  2  and  5 , then passes over bottom weft yarn  8 , then passes under bottom weft yarn  11 , then passes over bottom weft yarn  14 , then passes under bottom weft yarns  17 ,  20 ,  23  and  26 , then passes over bottom weft yarn  29 , then passes under bottom weft yarns  32 ,  35 ,  38 ,  41  and  44 . The bottom warp yarn  10  weaves only in the bottom layer and only with non-adjacent bottom weft yarns, e.g., three bottom weft yarns  8 ,  14  and  29 . The pattern formed by bottom warp yarn  10  is the same as that of bottom warp yarn  2  except that it is shifted sideways by three bottom weft yarns. 
         [0082]    With reference to  FIG. 6   b , binding warp yarn  11  passes from the bottom layer to the top layer by passing under top weft yarns  1  and  3 , then weaves with the top layer weft yarns  4 ,  6 ,  7 ,  9  and  10  to form a plain weave, then passes from the top layer to the bottom layer by passing under top weft yarns  12 ,  13  and  15 , then passes over bottom weft yarn  17 , then passes under bottom weft yarn  20 , then passes over bottom weft yarn  23 , then passes from the bottom layer to the top layer by passing under top weft yarns  24  and  25 , then weaves with the top weft yarns  27 ,  28 ,  30 ,  31  and  33  to form a plain weave, then passes from the top layer to the bottom layer by passing under top weft yarns  34  and  36 , then passes over bottom weft yarn  38 , then passes back to the top layer by passing under top weft yarns  39 ,  40 ,  42 ,  43  and  45 . The binding warp yarn  11  binds to the bottom layer by weaving with the same adjacent bottom weft yarns that the bottom warp yarn  12  was woven with, e.g., by passing over the three non-adjacent bottom weft yarns  17 ,  23  and  38 . 
         [0083]    Also seen in  FIG. 6   b , bottom warp yarn  12  passes under bottom weft yarns  2 ,  5 ,  8 ,  11  and  14 , then passes over bottom weft yarn  17 , then passes under bottom weft yarn  20 , then passes over bottom weft yarn  23 , then passes under bottom weft yarns  26 ,  29 ,  32  and  35 , then passes over bottom weft yarn  38 , then passes under bottom weft yarns  41  and  44 . The bottom warp yarn  12  weaves only in the bottom layer, weaves first with three adjacent bottom weft yarns, e.g., bottom weft yarns  17 ,  20  and  23 , and then binds with only one bottom weft yarn, e.g., bottom weft yarn  38 . 
         [0084]      FIG. 6   b  also illustrates binding warp yarn  13  passing over bottom weft yarn  2 , then passes under bottom weft yarns  3 ,  4 ,  6 ,  7 ,  9 ,  10  and  12 , then weaves with the top layer weft yarns  13 ,  15 , 16 ,  18  and  19  to form a plain weave, then passes from the top layer to the bottom layer by passing under top weft yarns  21 ,  22  and  24 , then passes over bottom weft yarn  26 , then passes under bottom weft yarn  29 , then passes over bottom weft yarn  32 , then passes from the bottom layer to the top layer by passing under top weft yarns  33  and  34 , then weaves with the top weft yarns  36 ,  37 ,  39 ,  40  and  42  to form a plain weave, then passes from the top layer to the bottom layer by passing under top weft yarns  43  and  45 . The binding warp yarn  13  binds to the bottom layer by weaving with the same bottom weft yarns that the bottom warp yarn  14  was woven with, e.g., by passing over the three non-adjacent bottom weft yarns  2 ,  26  and  32 . The pattern formed by binding warp yarn  13  is different from that of binding warp yarn  11  in both position and weaving path. 
         [0085]    Also seen in  FIG. 6   b , bottom warp yarn  14  passes over bottom weft yarn  2 , then passes under bottom weft yarns  5 ,  8 ,  11 ,  14 ,  17 ,  20  and  23 , then passes over bottom weft yarn  26 , then passes under bottom weft yarn  29 , then passes over bottom weft yarn  32 , then passes under bottom weft yarns  35 ,  38 ,  41  and  44 . The bottom warp yarn  14  weaves only in the bottom layer, weaves first with one bottom weft yarn, e.g., bottom weft yarn  2 , and then weaves with three bottom weft yarns, e.g., bottom weft yarns  26 ,  29  and  32 . The pattern formed by bottom warp yarn  14  is the same as that of bottom warp yarn  12  except that it is shifted sideways by three bottom weft yarns. 
         [0086]      FIG. 6   b  also illustrates binding warp yarn  15  weaving with the top weft yarns  1 ,  3 ,  4  and  6  to form a plain weave, then passes from the top layer to the bottom layer by passing under top weft yarns  7  and  9 , then passes over bottom weft yarn  11 , then passes from the bottom layer to the top layer by passing under top weft yarns  12 ,  13 ,  15 ,  16 ,  18 ,  19  and  21 , then weaves with the top weft yarns  22 ,  24 ,  25 ,  27  and  28  to form a plain weave, then passes from the top layer to the bottom layer by passing under top weft yarns  30 ,  31  and  33 , then passes over bottom weft yarn  35 , then passes under bottom weft yarn  38 , then passes over bottom weft yarn  41 , then passes from the bottom layer to the top layer by passing under top weft yarns  42  and  43 , then passes over top weft yarn  45 . The binding warp yarn  15  binds to the bottom layer by weaving with the same bottom weft yarns that the bottom warp yarn  16  weaves with, e.g., by passing over the three non-adjacent bottom weft yarns  11 ,  35  and  41 . The pattern formed by binding warp yarn  15  is the same as that of binding warp yarn  13  except that it is shifted sideways by nine top weft yarns. 
         [0087]    Additionally,  FIG. 6   b  shows bottom warp yarn  16  passing under bottom weft yarns  2 ,  5  and  8 , then passes over bottom weft yarn  11 , then passes under bottom weft yarns  14 ,  17 ,  20 ,  23 ,  26 ,  29  and  32 , then passes over bottom weft yarn  35 , then passes under bottom weft yarn  38 , then passes over bottom weft yarn  41 , then passes under bottom weft yarn  44 . The bottom warp yarn  16  weaves only in the bottom layer, weaves first with one bottom weft yarn, e.g., bottom weft yarn  11 , and then weaves with three bottom weft yarns, e.g., bottom weft yarns  35 ,  38  and  41 . The pattern formed by bottom warp yarn  16  is the same as that of bottom warp yarn  14  except that it is shifted sideways by three bottom weft yarns. 
         [0088]    Also seen in  FIG. 6   b , binding warp yarn  17  passes from the top layer to the bottom layer by passing under top weft yarns  1  and  3 , then under bottom weft yarn  5 , then passes from the bottom layer to the top layer by passing under top weft yarns  6  and  7 , then weaves with the top weft yarns  9 ,  10 ,  12 ,  13  and  15  to form a plain weave, then passes from the top layer to the bottom layer by passing under top weft yarns  16  and  18 , then passes over bottom weft yarn  20 , then passes from the bottom layer to the top layer by passing under top weft yarns  21 ,  22 ,  24 ,  25 ,  27 ,  28  and  30 , then weaves with the top weft yarns  31 ,  33 ,  34 ,  36  and  37  to form a plain weave, then passes from the top layer to the bottom layer by passing under top weft yarns  39 ,  40  and  42 , then passes over bottom weft yarn  44 , then begins to pass back to the top layer from the bottom layer by passing under top weft yarn  45 . The binding warp yarn  17  binds to the bottom layer by weaving with the same non-adjacent bottom weft yarns that the bottom warp yarn  18  weaves with, e.g., by passing over the three non-adjacent bottom weft yarns  5 ,  20  and  44 . The pattern formed by binding warp yarn  17  is different from that of the binding warp yarns  11 ,  13 ,  15  and  19 . 
         [0089]      FIG. 6   b  also illustrates bottom warp yarn  18  passing under bottom weft yarn  2 , then passes over bottom weft yarn  5 , then passes under bottom weft yarns  8 ,  11 ,  14  and  17 , then passes over bottom weft yarn  20 , then passes under bottom weft yarns  23 ,  26 ,  29 ,  32 ,  35 ,  38  and  41 , then passes over bottom weft yarn  44 . The bottom warp yarn  18  weaves only in the bottom layer and only with non-adjacent bottom weft yarns, e.g., three non-adjacent bottom weft yarns  5 ,  20  and  44 . The pattern formed by bottom warp yarn  18  is different from that of the bottom warp yarns  12 ,  14 ,  16  and  20 . 
         [0090]    Also shown in  FIG. 6   b , binding warp yarn  19  passes over the top weft yarn  1 , then passes from the top layer to the bottom layer by passing under top weft yarns  3 ,  4  and  6 , then passes over bottom weft yarn  8 , then passes under bottom weft yarn  11 , then passes over bottom weft yarn  14 , then passes from the bottom layer to the top layer by passing under top weft yarns  15  and  16 , then weaves with the top weft yarns  18 ,  19 ,  21 ,  22  and  24  to form a plain weave, then passes from the top layer to the bottom layer by passing under top weft yarns  25  and  27 , then passes over bottom weft yarn  29 , then passes from the bottom layer to the top layer by passing under top weft yarns  30 ,  31 ,  33 ,  34 ,  36 ,  37  and  39 , then weaves with top weft yarns  40 ,  42 ,  43  and  45  to form a plain weave. The binding warp yarn  19  binds to the bottom layer by weaving with the same bottom weft yarns that the bottom warp yarn  20  weaves with, e.g., by passing over the three non-adjacent bottom weft yarns  8 ,  14  and  29 . The pattern formed by binding warp yarn  19  is the same as that of binding warp yarn  11  except that it is shifted sideways by six top weft yarns. 
         [0091]    Finally, as seen in  FIG. 6   b , bottom warp yarn  20  passes under bottom weft yarns  2  and  5 , then passes over bottom weft yarn  8 , then passes under bottom weft yarn  11 , then passes over bottom weft yarn  14 , then passes under bottom weft yarns  17 ,  20 ,  23  and  26 , then passes over bottom weft yarn  29 , then passes under bottom weft yarns  32 ,  35 ,  38 ,  41  and  44 . The bottom warp yarn  20  weaves only in the bottom layer and only with non-adjacent bottom weft yarns, e.g., three bottom weft yarns  8 ,  14  and  29 . The pattern formed by bottom warp yarn  20  is the same as that of bottom warp yarn  12  except that it is shifted sideways by three bottom weft yarns. 
         [0092]    As is apparent from a comparison of  FIG. 6   a  and  6   b , the paths taken by the warp yarns  1 - 10  through the weft yarns  1 - 45  are respectively the same as paths taken by the warp yarns  11 - 20  through the weft yarns  1 - 45 , i.e., warp yarn  1  has the same path through the weft yarns  1 - 45  as warp yarn  11 , warp yarn  2  has the same path through the weft yarns  1 - 45  as warp yarn  12 , etc,. 
         [0093]      FIG. 7  shows a photograph of a top side or paper facing side of an actual forming fabric utilizing the weave pattern shown in  FIG. 5  and  FIG. 8  shows a photograph of a bottom side or machine side of the forming fabric shown in  FIG. 7 . 
         [0094]    By way of non-limiting example, the binding warp yarns  1 ,  3 ,  5 ,  7 ,  9 ,  11 ,  13 ,  15 ,  17  and  19  of the embodiment shown in  FIGS. 5-6   b  can have the following characteristics: acceptable size range of between approximately 0.10 mm and approximately 0.50 mm, preferable size ranges of between approximately 0.20 mm and approximately 0.80 mm, and most preferred size range of between approximately 0.12 mm and approximately 0.20 mm. The material for these yarns can be any natural or synthetic material, preferably a synthetic monofilament, and most preferably a polyester monofilament. 
         [0095]    By way of non-limiting example, the bottom warp yarns  2 ,  4 ,  6 ,  8 ,  10 ,  12 ,  14 ,  16 ,  18  and  20  of the embodiment shown in  FIGS. 5-6   b  can have the following characteristics:,acceptable size range of between approximately 0.15 mm and approximately 0.60 mm, preferable size ranges of between approximately 0.20 mm and approximately 0.40 mm, and most preferred size range of between approximately 0.25 mm and approximately 0.35 mm. The material for these yarns can be any natural or synthetic material, preferably a synthetic monofilament, and most preferably a polyester monofilament. The bottom warp yarns can preferably be constructed using relatively large diameter yarns that are well suited to sustain the wear caused by the friction between the machine side surface of the fabric and the papermaking machine during use of the fabric. 
         [0096]    By way of non-limiting example, the top weft yarns  1 ,  3 ,  4 ,  6 ,  7 ,  9 ,  10 ,  12 ,  13 ,  15 ,  16 ,  18 ,  19 ,  21 ,  22 ,  24 ,  25 ,  27 ,  28 ,  30 ,  31 ,  33 ,  34 ,  36 ,  37 ,  39 ,  40 ,  42 ,  43  and  45  of the embodiment shown in  FIGS. 5-6   b  can have the following characteristics: acceptable size range of between approximately 0.10 mm and approximately 0.50 mm, preferable size ranges of between approximately 0.20 mm and approximately 0.80 mm, and most preferred size range of between approximately 0.12 mm and approximately 0.80 mm. The material for these yarns can be any natural or synthetic material, preferably a synthetic monofilament, and most preferably a polyester monofilament. 
         [0097]    By way of non-limiting example, the bottom weft yarns  2 ,  5 ,  8 ,  11 ,  14 ,  17 ,  20 ,  23 ,  26 ,  29 ,  32 ,  35 ,  38 ,  41  and  44  of the embodiment shown in  FIGS. 5-6   b  can have the following characteristics: acceptable size range of between approximately 0.15 mm and approximately 0.60 mm, preferable size ranges of between approximately 0.20 mm and approximately 0.40 mm, and most preferred size range of between approximately 0.25 mm and approximately 0.35 mm. The material for these yarns can be any natural or synthetic material, preferably a synthetic monofilament, and most preferably a polyester monofilament. These bottom weft yarns may also be constructed using larger diameter yarns than the upper warp yarns. 
         [0098]    In the embodiment shown in  FIGS. 5-6   b  all of the binding warp yarns form a plain weave in the top layer by weaving with five top weft yarns and bind to the bottom layer by weaving With at least one bottom weft yarns in two or more spaced apart locations. Furthermore, all of the bottom warp yarns weave only in the bottom layer. Additionally, when a binding warp yarn passes from the bottom layer to the top layer, it passes under at least two adjacent top weft yarns before weaving with a plain weave in the top layer. When a binding warp yarn passes from the top layer to the bottom layer, it passes under at least two adjacent top weft yarns before weaving with the bottom layer. The area of the plain weave (between a binding warp yarn and top weft yarns) is off-center with respect to an area or spacing between the two areas where the same binding warp yarn weaves to the bottom layer. Also, in the area or spacing between two the plain weave areas (between a binding warp yarn and top weft yarns), the area where the binding warp weaves with the bottom layer is off-center. These features are also desirable in numerous papermaking applications. 
         [0099]    The invention encompasses a variety of different types of fabrics. For instance, the invention noted herein encompasses fabrics woven with different repeat than that pictured and described above. The fabric can have various top to bottom warp yarn ratios. The invention further contemplates other multilayer fabrics and not just the multilayer fabrics depicted in the figures. 
         [0100]    The fabrics pictured and otherwise described and claimed herein may be employed in a variety, of applications, including board and packaging grades. 
         [0101]    The configurations of the individual yarns utilized in the fabrics of the present invention can vary, depending upon the desired properties of the final papermakers&#39; fabric. For example, the yarns may be multifilament yarns, monofilament yarns, twisted multifilament or monofilament yarns, spun yarns, or any combination thereof. Also, the materials comprising yarns employed in the fabric of the present invention may be those commonly used in papermakers&#39; fabric. For example, the yarns may be formed of polypropylene, polyester, nylon, or the like. The skilled artisan should select a yarn material according to the particular application of the final fabric. Those of skill in the art will appreciate that yarns having diameters outside the herein disclosed ranges may be used in certain applications. In one embodiment of the present invention, one or more of the weft and warp yarns can have a diameter of about 0.13 mm, or about 0.17 mm, or about 0.33, or about 0.36 mm. Fabrics employing these yarn sizes may be implemented with polyester yarns or with a combination of polyester and nylon yarns. 
         [0102]    The fabrics of the present invention have been described herein are flat woven fabrics and hence the warp yarns for these fabrics run in the machine direction (a direction aligned with the direction of travel of the papermakers&#39; fabric on the papermaking machine) when the fabric is used on a papermaking machine and the weft yarns for these fabrics run in the cross machine direction (a direction parallel to the fabric surface and traverse to the direction of travel) when the fabric is used on a papermaking machine. However, those of skill in the art will appreciate that the fabrics of the present invention could also be woven using an endless weaving process. If such endless weaving were used, the warp yarns would run in the cross machine direction and the weft yarns would run in the machine direction when the fabric was used on a papermaking machine. 
         [0103]    Pursuant to another aspect of the present invention, methods of making the papermaker&#39;s fabrics are provided. Pursuant to these methods, the fabrics can be woven using separate warp and weft beams. 
         [0104]    Pursuant to another aspect of the present invention, methods of making paper are provided. Pursuant to these methods, one of the exemplary papermaker&#39;s forming fabrics described herein is provided, and paper is then made by applying paper stock to the forming fabric and by then removing moisture from the paper stock. As the details of how the paper stock is applied to the forming fabric and how moisture is removed from the paperstock is well understood by those of skill in the art, additional details regarding this aspect of the present invention will not be provided herein. 
         [0105]    To the extent that the pattern repeat symbols shown in  FIGS. 1 and 5  are inconsistent with the respective weave patterns shown in  FIGS. 2   a - 2   b  and  6   a - 6   b , the paths shown in  FIGS. 2   a - 2   b  and  6   a - 6   b  shall serve as a basis for correcting the symbols shown in  FIGS. 1 and 5 . Applicant also reserves the right to submit any additional drawings showing weave patterns of the type shown in  FIGS. 2   a - 2   b  and  6   a - 6   b  for any pattern repeat shown in  FIGS. 1 and 5  which are not deemed to be consistent with the weave patterns shown in  FIGS. 2   a - 2   b  and  6   a - 6   b.    
         [0106]    It is noted that the: foregoing examples have been provided merely for the purpose of explanation and are in no way to be construed as limiting of the present invention. While,the present invention has been described with reference to exemplary embodiments, it is understood that the words which have been used herein are words of description and illustration, rather than words of limitation. Changes may be made, within the purview of the appended claims, as presently stated and as amended, without departing from the scope and spirit of the present invention in its aspects. Although the present invention has been described herein with reference to particular means, materials and embodiments, the present invention is not intended to be limited to the particulars disclosed herein; rather, the present invention extends to all functionally equivalent structures, methods and uses, such as are within the scope of the appended claims.

Technology Classification (CPC): 3