Self stitching multilayer papermaking fabric

Abstract

A multi-layer self-stitched papermakers' fabric including a top fabric layer of relatively fine machine direction and cross machine direction yarns and a bottom fabric layer of relatively coarse machine direction and cross machine direction yarns, interwoven to produce seating and self-stitching conditions for optimal drainage. In a preferred embodiment, the top fabric layer has a right to left twill on its upper papermaking surface and the bottom fabric layer has a left to right twill on its upper interlacing surface. The questions raised in reexamination request No. 90/003,352, filed Mar. 7, 1994, have been considered and the results thereof are reflected in this reissue which constitutes the reexamination certificate required by 35 U.S.C. 307 as provided in 37 CFR 1.570(e).

What is claimed is: 
     
       1. An endless .Iadd.layer .Iaddend.papermaking fabric comprising: a top fabric layer including relatively fine machine direction yarns interwoven with relatively fine cross machine direction yarns in a repeating pattern to form an upper surface and a lower surface, the top fabric layer cross machine direction yarns including alternately stitching and non-stitching cross machine direction yarns;   a bottom fabric layer including relatively coarse machine direction yarns interwoven with relatively coarse cross machine direction yarns in a repeating pattern to form an upper surface and a lower surface;   the number of the relatively fine top fabric layer cross machine direction yarns being approximately twice that of the relatively coarse bottom fabric layer cross machine direction yarns;   wherein said top fabric layer cross machine direction yarns travel singly and engage selected machine direction yarns of the bottom fabric layer at a highest elevation relative to the elevation of the machine direction yarns of the bottom fabric layer other than said selected machine direction yarns to bind the fabric layers together.   
     
     
       2. The papermaking fabric of claim 1 wherein the top fabric layer is a 2×2 twill weave. 
     
     
       3. The papermaking fabric of claim 2 wherein the bottom fabric layer is a 2×2 twill weave. 
     
     
       4. The papermaking fabric of claim 3 wherein the top fabric layer machine direction yarns are approximately 0.16 millimeter, the top fabric layer cross machine direction yarns are approximately 0.18 millimeter, the bottom fabric layer machine direction yarns are approximately 0.34 millimeter and the bottom fabric cross machine direction yarns are approximately 0.36 millimeter in diameter. 
     
     
       5. The papermaking fabric of claim 3 wherein the upper surface of the top fabric layer is a right to left twill and the upper surface of the bottom fabric layer is a left to right twill. 
     
     
       6. The papermaking fabric of claim 3 wherein the twill of the upper surface of the top fabric layer is opposite to the twill of the upper surface of bottom fabric layer. 
     
     
       7. The papermaking fabric of claim 1 wherein every other cross machine direction yarn of the top fabric layer engages every eighth machine direction yarn in the bottom fabric layer and every machine direction yarn in the bottom fabric layer is interlaced with every other cross machine direction yarn of the top fabric layer within one weave repeat. 
     
     
       8. An endless papermaking fabric comprising: a top fabric layer including relative fine machine direction yarns interwoven with relatively fine cross machine direction yarns in a repeating pattern to form an upper surface and a lower surface, the top fabric layer cross machine direction yarns including alternating stitching and non-stitching cross machine direction yarns the upper surface including machine direction and cross machine direction floats and the lower surface including machine direction and cross machine direction floats;   a bottom fabric layer including relatively coarse machine direction yarns interwoven with relatively coarse cross machine direction yarns in a repeating pattern to form an upper surface and a lower surface, the upper surface including machine direction and cross machine direction floats and the lower surface including machine direction and cross machine direction floats;   the number of relatively fine top fabric layer cross machine direction yarns being approximately twice that of the relatively coarse bottom fabric layer cross machine direction yarns;   wherein said top fabric layer cross machine direction yarns engage selected machine direction yarns of the bottom fabric layer at a highest elevation relative to the elevation of the machine direction yarns of the bottom fabric layer other than said selected machine direction yarns to bind the fabric layers together; and   wherein the lower surface machine direction floats of the upper fabric layer contact the upper surface cross machine direction floats of the bottom fabric layer in a maximum contact same plane configuration.   
     
     
       9. The papermaking fabric of claim 8 wherein the maximum contact same plane configuration is a 90 degree cross-shaped orientation mode. 
     
     
       10. The papermaking fabric of claim 9 wherein the top fabric layer is a 2×2 twill weave. 
     
     
       11. The papermaking fabric of claim 10 wherein the bottom fabric layer is a 2×2 twill weave. 
     
     
       12. The papermaking fabric of claim 11 wherein the top fabric layer machine direction yarns are approximately 0.16 millimeter, the top fabric layer cross machine direction yarns are approximately 0.18 millimeter, the bottom fabric layer machine direction yarns are approximately 0.34 millimeter and the bottom fabric cross machine direction yarns are approximately 0.36 millimeter in diameter. 
     
     
       13. The papermaking fabric of claim 11 wherein the upper surface of the top fabric layer is a right to left twill and the upper surface of the bottom fabric layer is a left to, right twill. 
     
     
       14. The papermaking fabric of claim 11 wherein the twill of the upper surface of the top fabric layer is opposite to the twill of the upper surface of bottom fabric layer. 
     
     
       15. The papermaking fabric of claim 9 wherein every other cross machine direction yarn of the top fabric layer engages every eighth machine direction yarn in the bottom fabric layer and every machine direction yarn in the bottom fabric layer is interlaced with every other cross machine direction yarn of the top fabric layer within one weave repeat. .Iadd. 
     
     
       16.  An endless papermaking fabric comprising: a top fabric layer including relatively fine machine direction yarns interwoven with relatively fine cross machine direction yarns in a repeating pattern to form a 2×2 twill with an upper surface and a lower surface, the top fabric layer cross machine direction yarns including stitching and non-stitching cross machine direction yarns;   a bottom fabric layer including relatively coarse machine direction yarns interwoven with relatively coarse cross machine direction yarns in a repeating pattern to form an upper surface and a lower surface;   the number of the relatively fine top fabric layer cross machine direction yarns being approximately twice that of the relatively coarse bottom fabric layer cross machine direction yarns;   wherein said top fabric layer cross machine direction yarns travel singly in said 2×2 twill pattern to engage the top fabric layer machine direction yarns and engage selected machine direction yarns of the bottom fabric layer at a highest elevation relative to the elevation of the machine direction yarns of the bottom fabric layer other than said selected machine direction yarns to bind the fabric layers together. .Iaddend..Iadd.   
     
     
       17.  The papermaking fabric of claim 16 wherein the bottom fabric layer is a 2×2 twill weave. .Iaddend..Iadd.18. The papermaking fabric of claim 17 wherein the top fabric layer machine direction yarns are approximately 0.16 millimeter, the top fabric layer cross machine direction yarns are approximately 0.18 millimeter, the bottom fabric layer machine direction yarns are approximately 0.34 millimeter and the bottom fabric cross machine direction yarns are approximately 0.36 millimeter in diameter. .Iaddend..Iadd.19. The papermaking fabric of claim 17 wherein the upper surface of the top fabric layer is a right to left twill and the upper surface of the bottom fabric layer is a left to right twill. 
     
     
        .Iaddend..Iadd.20.  The papermaking fabric of claim 17 wherein the twill of the upper surface of the top fabric layer is opposite to the twill of the upper surface of the bottom fabric layer. .Iaddend..Iadd.21. The papermaking fabric of claim 16 wherein every other cross machine direction yarn of the top fabric layer engages every eighth machine direction yarn in the bottom fabric layer and every machine direction yarn in the bottom fabric layer is interlaced with every other cross machine direction yarn of the top fabric layer within one weave repeat. .Iaddend..Iadd.22. An endless papermaking fabric comprising: a top fabric layer including relative fine machine direction yarns interwoven with relatively fine cross machine direction yarns in a repeating pattern to form an upper surface and a lower surface, the top fabric layer cross machine direction yarns including stitching and non-stitching cross machine direction yarns, the upper surface including machine direction and cross machine direction floats and the lower surface including machine direction and cross machine direction floats;   a bottom fabric layer including relatively coarse machine direction yarns interwoven with relatively coarse cross machine direction yarns in a repeating pattern to form an upper surface and a lower surface, the upper surface including machine direction and cross machine direction floats, and the lower surface including machine direction and cross machine direction floats;   the number of relatively fine top fabric layer cross machine direction yarns being approximately twice that of the relatively coarse bottom fabric layer cross machine direction yarns;   wherein said top fabric layer cross machine direction yarns engage selected machine direction yarns of the bottom fabric layer at a highest elevation relative to the elevation of the machine direction yarns of the bottom fabric layer other than said selected machine direction yarns to bind the fabric layers together; and   wherein the lower surface machine direction floats of the upper fabric layer contact the upper surface cross machine direction floats of the bottom fabric layer in a maximum contact same plane configuration. .Iaddend..Iadd.23. The papermaking fabric of claim 22 wherein the maximum contact same plane configuration is a 90 degree cross-shaped orientation mode. .Iaddend..Iadd.24. The papermaking fabric of claim 23 wherein the   
     
     
        top fabric layer is a 2×2 twill weave. .Iaddend..Iadd.25.  The papermaking fabric of claim 24 wherein the bottom fabric layer is a 2×2 twill weave. .Iaddend..Iadd.26. The papermaking fabric of claim 25 wherein the top fabric layer machine direction yarns are approximately 0.16 millimeter, the top fabric layer cross machine direction yarns are approximately 0.18 millimeter, the bottom fabric layer machine direction yarns are approximately 0.34 millimeter and the bottom fabric cross machine direction yarns are approximately 0.36 millimeter in diameter. .Iaddend..Iadd.27. The papermaking fabric of claim 26 wherein the upper surface of the top fabric layer is a right to left twill and the upper surface of the bottom fabric layer is a left to right twill. .Iaddend..Iadd.28. The papermaking fabric of claim 25 wherein the twill of the upper surface of the top fabric layer is opposite to the twill of the upper surface of bottom fabric layer. .Iaddend..Iadd.29. The papermaking fabric of claim 23 wherein every other cross machine direction yarn of the top fabric layer engages every eighth machine direction yarn in the bottom fabric layer and every machine direction yarn in the bottom fabric layer is interlaced with every other cross machine direction yarn of the top fabric layer within one weave repeat. .Iaddend.