Patent ID: 8701255

Claim:
A method for producing a multi-layer fabric, said method comprising the steps of: providing a first set of yarns with a first and second amount of yarns; coating separate yarns of the first amount of yarns with a removable coating with a first thickness such that a coating diameter of each of the separate yarns is at least two times a diameter of each of the separate yarns; controlling tension in each yarn of the first amount of yarns; weaving a first fabric layer in a plain weave architecture of balanced crimp contents with the first amount of yarns; applying a first measured crimp by said weaving step in each yarn of the first amount of yarns wherein the thickness of the removable coating alters a crimp content of each yarn of the first amount of yarns when woven; coating separate yarns of the second amount of yarns with a removable coating with a second thickness such that a coating diameter of each of the separate yarns is at least two times a diameter of each of the separate yarns of the second amount of yarns; controlling tension in each yarn of the second amount of yarns; weaving a second fabric layer with the second amount of yarns in a plain weave architecture with balanced crimp contents; applying a second measured crimp in each yarn of the second amount of yarns by said step of weaving the second fabric layer wherein the thickness of the removable coating alters a crimp content of each yarn of the second amount of yarns when woven; and combining the first fabric layer and the second fabric layer such that a face of each layer contacts the face of another layer in a planer contact.