Regulation 3.2 AUSTRALIA PATENTS ACT, 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT ORIGINAL Name of Applicant: ALBANY INTERNATIONAL CORP. Actual Inventors: H-AWES, John M; KORNETT, Glenn; RYDIN, Bjorn; QUIGLEY, Scott; ROYO, Michael A; DONOVAN, James G; YOOK, Steven Address for service in A J PARK, Level 11, 60 Marcus Clarke Street, Canberra ACT Australia: 2601, Australia Invention Title: Multiaxial Fabric Having Reduced Interference Pattern The following statement is a full description of this invention, including the best method of performing it known to us. 3416762.I WO 2006/116006 PCT/US2006/014959 MULTIAXIAL FABRIC HAVING REDUCED INTERFERENCE PATTERN 5 Field of the Inventiop The present invention relates to improvements in multilayer multiaxial fabrics for use in a papernaking machine. Description of the PriorArt 10 During the papermaking process, a cellulosic fibrous web is formed by depositing a fibrous slurry, that is, an aqueous dispersion of cellulose fibers, onto a moving forming fabric in the forming section of a paper machine. A large amount of water is drained from the slurry through the forming fabric, leaving the cellulosic fibrous web on the surface of the farming fabric. 15 The newly formed cellulosic fibrous web proceeds from the forming section to a press section, which includes a series of press nips. The cellulosic fibrous web passes through the press nips supported by a press fabric, or, as is often the case, between two such press fabrics. In the press nips, the cellulosic fibrous web is subjected to compressive forces which squeeze water therefrom, and which adhere 20 the cellulosic fibers in the web to one another to turn the cellulosic fibrous web into a paper sheet. The water is accepted by the press fabric or fabrics and, ideally, does not return to the paper sheet. The paper sheet finally proceeds to a dryer section, which includes at least one series of rotatable dryer drums or cylinders, which are internally heated by 25 steam. The newly formed paper sheet is directed in a serpentine path sequentially around each in the series of drums by a dryer fabric, which holds the paper sheet closely against the surfaces of the drums. The heated drums reduce the water content of the paper sheet to a desirable level through evaporation. It should be appreciated that the foring, press and dryer fabrics all take the 30 form of endless loops on the paper machine and function in the manner of conveyors. It should further be appreciated that paper manufacture is a continuous ia WO 2006/116006 PCT/US2006/014959 process which proceeds at considerable speeds.That is to say, the fibrou-s slurry is coontinfously deposited onto the fonning fabric in the forming section, while a newly manufactured paper sheet is-continuously wound onto rolls after it exits from the dryer section. 5 The present invention relates primarily to the fabrics used in:the press section, generally known as press fabrics, but it mhyalso find application in the fabrics used in the forming and dryer sections, as well as in those used as bases for polymer-coated paper industry process belts, such as, for example, long nip press belts: 10 Press fabrics play a critical role during the paper manufacturing process. One of their functions, as implied above, is to support and to carry the paper product being manufactured through the press nips. Press fabrics also participate in the fishing of the surface of the paper sheet That is, press fabrics are designed to have smooth surfaces and uniformly 15 resilient structures, so that, in the course of passing tbmugh the press nips, a smooth, mark-free surface is imparted to the paper. Perhaps most importantly, the press fabrics accept the large quantities of water extracted from the wet paper inthe press nip. In order to fulfill this function, There literally must be space, commonly referred to as void volume, within the 20 press fabric for the water to go, and the fabric must have adequate permeability to -water for its entire useful life. Finally, press fabrics must be able to prevent the . water accepted from the wet paper from returning to and rewetting the paper upon exit fomthepress nip. Contemporary press fabrics are used in a wide variety of styles designed to 25 meet the requirements of the paper machines on which they are installed for the -paper grades being manufactured. Generally, they comprise a woven base fabric into which has been needled a batting of fn6, non-woven fibrous material. The base fabrics may be woven from monofilament, plied monoflament, multifilament or plied multifilament yarns, and may be single-layered, multi-layered or 30 laminated. The yarns are typically extruded from any one of several synthetic 2 WO 2006/116006 PCT/US2006/014959 -polymeric resist such as polyamide and polyester resinsused for this purpose by those of ordinary skill in the paper machine clothing arts. Woven fabrics take many different forms. For example, they may be woven endless, or flat woven and subsequently rendered into endless form with a seam. 5 Alternatively, they may beproduced by a process commonly known as modified endless weaving, wherein the widthwise edges of the base fabric are provided with' seaming loops using the machine-direction (MD) yarns thereof In this process, the MD yams weave continuously back and forth between the widthwise edges of the fabric, at each edge turning back and forming a seaming loop. A base fabric 10 produced in this fashion is placed into endless form during installation on a paper machine, and for this reason is referred to as an on-machine-seamable fabric. To place such a fabric into endless form, the two widthwise edges are seamed together. To facilitate seaming, many current fabrics have seaming loops on the crosswise edges of the two ends of the fabric. The seaming loops themselves are often 15 formed by'the machine-direction (MD) yams of the fabric. The seam is typically formed by bringing the two ends of the fabric press together, by interdigitating the seaming loops at the two ends of the fabric, and by directing a so-called pin, or pintle, through the passage defined by the interdigitated seaming loops to lock the two ends of the fabric together. 20 Further, the woven base fabrics may be laminated by placing onebase fabric within the endless loop formed by another, and by needling a staple fiber batting through both base fabrics to join then to one another. One or both woven base fabrics may be of the .on-machine-scamable type. In any event, the woven base fabrics are in the form of endless loops, or are 25 seamable into such forms, having a specific length, measured longitudinally therearound, and a specific width, measured transversely thereacross. Because paper machine configurations vary widely, paper machine clothing manufacturers are required to produce press fabrics, and other paper machine clothing, to the dimensions required to fit particular positions in the paper machines of their .3 - WO 20(6/116006 PCT/US2006/014959 customers. Needlessto say, this requirement makes it difficult to streamline the . manufacturing process, s each press fabric must typically be made to order. In response to this need to produce press fabrics in a variety of-lengths and *idtbs more quickly and efficiently, press fabrics have been produced in recent 5 years using a spiral winding technique disclosed in commonly -assigned U.S. Patent No; 5,360,656 to Rexfelt et al. (the '656 patent), the teachings of which are incorporated -herein by reference. The '656 patent shows a press fabric comprising a base fabric having one or more layers of staple fiber material needled thereinto. The base fabric comprises at 10 least one layer composed of a spirally wound strip of woven fabric having a width which is smaller than the width of the base fabric. The base fabric is endless in the' longitudinal, or machine, direction. Lengthwise threads of the -spirally wound strip make an angle with the longitudinal direction of the press fabric. The strip of woven fabric may be flat-woven on a loom which is narrower than those typically 15 used inthe production of paper machine clothing. The base fabric comprises apluralityof spirally wound and joined-tunis of the relatively narrow woven fabric strip. The fabric strip, if flat woven, is woven from lengthwise (warp) and crosswise (filling) yarns. Adjacent turns of the spirally wound fabric-strip may be abutted against one another, and the spirally continuous 20 seam so produced may be closed by sewing, stitching, melting, welding (e.g. ultrasonic) or gluing.. Alternatively, adjacent longitudinal edge portions of adjoining spiral turns may be arranged overlappingly, so:long as the edges have a reduced thickness, so es not to give rise to an increased thickness in the area of the overlap. Alternatively still, the spacing between lengthwise yarns may be increased 25 -at the edges of the strip, so that, when adjoining spiral tows are arranged overlappingly, there May be an unchanged spacing between lengthwise threads in the area of the overlap. A multiaxial press fabric may be made of two or more separate base fabrics with yarns running it atleast four different directions.'Whereas the standard press 30 fabrics of the prior art have three-axes: one in the machine direction (MD), one in 4 WO 2006/116006 PCT/US20061014959 -the crOss-machine direction (CD), and one -in the z-direction, which is through the thickness of the fabric, a multiaxial press fabric has not only these three axesbut also has at least two more axes defined by the directions of the yam systems in its spirally wound layer orlayers.Moreover, there are multiple flow paths inthe z 5 direction of a multiaxialpress fabric. As a consequence, a multiaxial press fabric. bas at leastfive axes. Because of its mutiaxial structure, anultiaxial press fabric having more than one layer exhibits superior resistance to nesting and/or to collapse in response to compression in a press nip during the papernaking process as compared to one having base fabric layers whose yarn systems are parallel to 10 onie another. The fact that there are two separate base fabrics, on top of the other, means that the fabrics are 'laminated" and each layer can be designed for a different functionality. In addition, the separate base fabrics or layers are typically joined together in a manner well known to the skilled artisan including, depending upon 15 the application, as aforesaid the needling of batt therethrough. As mentioned above, the topography of a press fabric contributes to the quality of-the paper sheet. A planar topography provides a uniform pressing surface for contacting the paper sheet and reducing press vibrations. Accordingly, efforts have been made to create a smoother contact surface on the press fabric. But 20 surface smoothness may be limited by the weave pattern forming the fabric. Cross over points of interwoven yarns form knuckles on the surface of the fabric. These knucides may be tbickei in the z-direction than the remaining areas of the fabric. Consequently, the surface of the fabric may have a non-planar topography . characterized with localized'areas -of varying thickness, or caliper variation, which 25 may cause sheet marking during a pressing operation. Caliper variation can even have an adverse effect an a batt layer resulting in non-uniform batt wear, compression and making. Laminated press fabrics, specifically multiaxial fabrics, may have such caliper variation. Specifically, in the special case of a multiaxial fabric-having two 30 layers with the same weave pattern, localized caliper variation may be intensified.
WO 2006/116006 PCTIUS2006/014959 Therefore, a need exists'fore imultiaial press fabric with reduced caliper variation to improve pressure distribution and reduce sheet marking dining operation. SIMLJMARY OF THE INVENTION The present invention provides a-multilayer fabric for a paper machine 5 having improved pressing uniformity and reduced sheet marking. The invention in one embodiment provides a multilayer fabric formed from two or more base structures or layers, which may include a layer or layers formed from multiaxial sirips of material or layers of fabric in combination therewith for use on a paper machine. In the first embodiment, the fabric includes at least one 10 layerhaving a plurality of machine direction (MD) yarns and cross-machine . .direction (CD) yarns interwoven in a predetermined manner such that a distance between MD yarns varies and/or the distance between CD yams also varies such that there is a reduction of the interference pattern or the Moire Effect as between the layers making up the fabric. 15 In the second embodiment, the present invention provides for a multilayer fabric for use with a paper machine including an upper woven layer, a lower woven layer formed for example in a manner as described in U.S. Patent No. 5,939,176 to Yook (the '176 patent) with however a nonwoven layer disposed therebetween so -as to create void volume, maintain fabric openness and lessen or eliminate 20 interference patterns between the woven layers. In a third embodiment, the present invention provides for multilayer fabric for use with a paper machine which may be formed for example in -a manner described in the '656 or '176 patents including an upper woven layer and a lower woven layer with the inside of the upper'layer and the inside of the lower layer are 25 flattened or calendered to reduce the height of knuckles thereon, so as to minimize nesting therebetween and therebylessen or eliminate localized caliper variations md/or interference patterns between the woven layers. In a fourth embodiment, the present invention provides for amultilayer fabric for use with a paper machine. Two or more layers are woven -of MD and CD 30 yarns. A plurality of MD yams and a first plurality of CD yams form a first shed WO 20061116006 PCT/US2006/014959 ,pattern, and/or the plurality of MD.yanis and a second plurality of CD yarnstorma -second shed paftern within fabric layer, such that when two or more layers arc placed on top of each other so as to create the multilayered fabric, the interference ipatterntherebetwec is lessened. 5 - In a fifth embodiment, -thepresent -invention involves a laminate material which becomes part of a multilayer fabric with a multiaxial base. Note the numbering of the various embodiments is merly for clarity and readability purposes and should in no way indicate a particular order of preference or importance. 10 Note further that while only certain layers may be discussed, such layers may be part of a fabric having additional layers. For example, in a press fabric one or more layers of batt fiber would be added to either the paper contact side or machine side of the laminate by way of, for example, needling. The present invention will now be described in more complete detail with 15 reference being made to the figures wherein like reference numerals denote like elements and parts, which are identified below. BRIEF DESCRITON OF THE DRAWINGS For a more complete understanding of the -invention, reference is made to the following description and accompanying drawings, in which: 20 FIG. I is atop view of amultilayer multiaxialfabric in the form of an endless loop FIG. 2 is an interference pattern-formed from carbon impressions-of a -multilayermultiaxial fabric; FIG. 3 is an interfemnce pattern of aprior art multilayer fabric having an 25 ofiset of 0"; TIG. 4 is -an interferencepattern of a prior art multilayermnltiaxial fabric having an offset-of 3". FIG. 5 is a representation of the topography of the prior art muilayer multiaxial fabric depicted in FIG. 4; .7 WO 2006/116006 PCT/U1S2006/014959 FIG. 6 is a representation of the topography of aprior artinultilayer - multiaxial fabric having an offset of 6*; , FIG. 7 is a layer of a multilayer multiaxial fabric in accordance -withthe first embodiment of the present invention; 5 FIG. 8 is an interference pattern of a multilayer multiaxial fabric having two layers, each layer having the variable MD yarn spacing depicted in FIG.7.' FIG. 9 is a representation of the topography of the multilayer multiaxiai fabric depicted in FIG. 8; FIG. 10 is a layer of a multilayer multiaxial fabric having variable CD yarn 40 spacing in accordance with the first embodiment of the present invention; FIG. 10a is an interference pattern of a multilayer fabrichaving twolayers, each layer having the weave pattem depicted in FIG. 10. FIG. lOb is a representation of the topography of the multilayer multiaxial fabric depicted in FIG. I1a is FIG. 11 is another example of a layer of a multilayer multiaxial fabric having variable CD yarn spacing in accordance with the first embodiment of the present invention; FIG. 12 is a raultilayer multiaxial fabric in accordance with the second embodiment of the present invention; 20 FIG. 13 is a multilayer multiaxial fabric in accordance with the-third embodiment of the present invention; FIG. 14 is a regular plain weave strip ofmultiaxial material; FIG. 14a depicts alayer of strips ofmultiaxial material havingdesired shed patterns; 25 FIG 14b depicts an interferencepattem for a multilayer fabric -formed of two patterns offset from one another in accordance witha fourth embodiment of the - present invention; FIG. 14c depicts a -pattern for a multilayer prior art fabric formed of two layers of two standard weave patterns offset from one another at a typical desired 30 angle; WO 2006/116006 PCT/US2006/014959 FIG. 15A depicts a representativeinultiaxial base fabric; and FIGs. 15B-D depicts miultilayer multiaxial fabrics incorporating laminate material in accordance with the fifth embodiment 5 .DETAILED DESCRJPTION Multilayer fabrics may include two or more base substrates or layers. The present invention is, however,-particularly suited for multilayer, multiaxial fabrics. That being fabrics made of strips of material such as those described in the aforesaid '656 patent. While the present invention has particular application with 10 'regard to layers of woven strips of material, other construction of the strips as, for example, mesh and MD and-CD yarn arrays among others that may-exhibit the Moire Effect when layered may also be suitable for application as to one or more of the embodiments discussed herein. Also, it-should be further understood that the Layers of fabric maybe a -combination of layers such as layers of multiaxial layers 15 with a layer of traditional endless woven fabric or some combination thereof and Joined together by needling or in any other manner suitable for-that purpose. With that in mind, the invention will be described using as an example a multiaxial woven fabric having at least two layers which may be separate layers such as that described in the '656 patent. it also could be for example an endless 20 multiaxial fabric folded upon, itself along first and second fold lines such as that described in the '176 patent, or some combination thereof. In this -regard, the present invention provides for a multiaxial press fabric including a first (upper) woven layer and second (lower) woven layer, each layer having aplurality of interwoven MD yarns and CD yarns. Multiaxial fabrics may be further 25 characterized as having yarns running i at least two different directions. Due to the spiral orientation ofthe strips of material which fonn-the fabric, the MD yams are at a slight angle with the machine direction of the fabric. A relative angle or offset is also formed between the MD yarns of the first layer with the MD yarns of the second layer when laid thereon. Similarly, the CD yams of the first layer being 30 perpendicular to the MD yams of the first'layer, form the same angle with the CD 9 WO 2006/116006 PCT/US2006/014959 yarns of the second layer. in short, neither the i MD yarns nor the CD yams ofthe first layer align with the MD yarns or the CD yans-of the second layer when a spiral formed fabric are laid upon each other to create a multilayer fabric. Turning now specifically to FIG. 1. there is shown a typical multilayer 5 Maultiaxial fabric 100 having a first-(upper) layer 110 and a-second (lower) layer 120 in the form of an endless loop. As noted earlier, depending upon the ultimate fabric construction, additional layers may be added such as one or more layers of batt fiber attached by way of, for example, needling. First layer 110 has MD yams 130 and CD yams 140. Similarly, second layer 120 has MD yarns 150 and CD 10 yarns 160. Further, relative angle or offset 170 is formed between MD yarn 130 and MD yarn 150. Once multiaxial fabric 100 has been assembled, itmay be rendered into endless form with a. seam as shown, for example, in the '176 patent in .addition to U.S. PatentNos. 5,916,421 (the '421 patent) and 6,117,274 (the '274 patent). As maybe appreciated, other ways of forming multiaxial fabric 100 would 15 be readily apparent to those of skill inthe art. In-addition, all patents referred to 'herein are incorporated herein by reference as if fully set forth herein. It should be noted that in the case of most laminated multilayer fabrics whether or not multiaxial, some characteristic interference or the Moire Effect may occur since yarn alignment between layers is not often perfect. In laminated 20 multiaxial press fabrics (those consisting of two or more base structures or layers as .shown in FIG. 1) such fabrics the exhibit Moire Effect that is a function of the spacing and size of both MD and CD yams. This Effect is enhanced if the yarns -are single monofilament yams, especially as the diameter increases and count decreases. TheEffect exists inmultiaxial fabrics sincehe orthogonal yarn systems 25 of one layer is not parallel or perpendicular to those of the other layers. Multiaxial multilayer fabric structures have provided many papermaking pefonnance benefits because of their ability to resist base -fabriucompaction beller than conventional, endless woven laminate structures. The reason for this is that, in the case of for example, a two-layer multiaxial laminate, orthogonal yarn systems 30 of one layer are not parallel or perpendicular to those of the other laminated layer. 10 WO 2006/116006 PCT/US2006/014959 - loweverbecause of this, the relative anglebetween the respective MD and CD yarn systems of each layer (i.e. layers 110 and 120) ranges in practicality from I to 10 offset. The effect of this angle is that it greatly intensifies the Moire Effect and could cause the planaity of the interfacial topography to deteriorate., 5 The Effectin this regard is shown in FIG. 2 where an interference pattern 200 is formed in a prior art multilayer multiaxial press fabric illustrated. Interference patterns are characteristic of the yarn arrangement forming a multilayer multiaxial fabric and illustrate the pressure distribution of the press fabric during operation. Here, interference pattern 200 is formed from carbon 10 impression of a multilayermultiaxial fabric having monofilament yarns in both directions. Contact points 210 indicate areas of pressure concentration exerted.on the sheet during a-pressing operation. Specifically, dark contact point 220 is an area of highest pressure which may indicate a high caliper area. The high caliper -area may result from knucdes formed from overlapping yarns in the first and 15 second layers. In contrast, light contact point 230 is an area of lower pressure which may indicate alow caliper area. Further, open area 240 maybe an area where no yams intersect. The pattern of light contact points 230 and dark contact points 220 indicates a non-planar topography and a non-uniform pressure distribution. Specifically, 20 MD bands 250 and CD bands 260 form areas of high caliper and exemplify caliper variation. This visual representation is known as a Moire Effect. Caliper variation may be a function of the spacing and size of the intersecting yats in each layer of the fabric. Therefore, as the diameter of yarns Increase and the number of yams in a specified area, -or count decreases, the 25 localized caliper variation is more prominent and objectional sheet marking may occur. An interference pattern for a multilayermultiaxial fabric is generated by superposing a first woven layer onto tie plane of the second woven layer. Using a modeling program you can generate interference patterns and topography for any 30 combination of types of layers -inmultiaxial fabrics. 11 WO 2006/116006 PCT/IUS2006/014959 FIG. 3 is an-interference pattern 300 of a fabric formed by superposinga first woven Iayer onto the plane of a second woven layer. The fabric is formed from two layers having a plain weave of monofilament yams having an offset of 0*. In other words, there is no multiaxial-effect provided by:each layer. As shown, the 5 yarns ofthe first layer entirely overlap the yams of the second layer. FIG. 4 is an interference pattern 400 of a multiaxial multilayer fabric formed from the same woven fabric layers 110 and 120 as in FIG. 3, but having an offset of 30 from each other. MD bands 410 and CD bands 420 are clearly visible, which may indicate caliper, mass and/or pressure variation. Such a fabric when in 10 use may result in non-uniform drainage of water from the paper sheet which -obviously would be undesirable. FIG. 5 is a representation of the topography 500 of the miltiaxial multilayer fabric depicted in FIG.4 having points or regions 510, 520, 530, 540 and 550. Blackpoint or region 510 represents an area where 4 yarns cross, dark grey 520 15 represents a point of region where 3 yarns cross, medium gray 530 represents a. point or region where 2 yams cross, and white 550 is open area. As shown, the topography may be non-planer with MD bands 560 and CD bands 570. FIG. 6 is a representation of the topography 600 of the multiaxial multilayer fabric depicted in FIG. 4, with an offset of 6" between layers. As shown, the 20 topography is non-planer. In this close-up representation, the caliper, mass and pressure variation of the fabric is clearly shown. More specifically, region 610 indicates an'area where four yarns overlap. Thepattern of the points may resultin DIi bands and CD bands as aforenoted well. Tuningnow to FIG. 7there is shown layer 700 in accordance with the first 25 enibodiment of the present invention. Layer 700 includes a plurality of MD yarns 710 and CD yams 720 interwoven in a predetermined manner. The distance or spacing 730 between one pair'of adjacent MUD yams 710 is different than the distance or spacing 740 between another pair of adjacent-MD yarns 710. Further, the distance 750 between one pair of adjacent -CD yarns 720 is different than the 30 distance 760 between another pair of adjacent CD yards 720. That is, layer'700 has 12 WO 2006/116006 PCT/US2006/014959 variable distances or spacing between pairs of adjacent MD yarns 710 -and variable; distances or spacing between pairs of adjacent CD yams 720. This purposeful introduction of what might be considered "non-uniformity" into each layer is such that fhe net'non-uniformity effect is less. S Although the variable distances are shown between adjacentpairs of adjacent MD yarns and between adjacent pairs of adjacent CD yarns, the invention is not so limited. A variable distance or spacing between pairs of adjacent MD yarns and/or between pairs of adjacent CD yarns inay be arranged in any manner. For example, distance 750 between one pair of adjacent CD yarns 720 may be 0 followed by a distance 76 between another pair of adjacent CD yams 720 followed by a distance 770 between another pair of adjacent CD yams 720 and so forth, or a number of distances 750 between pairs of adjacent of CD yarns 720 followed by a number of distances 760 between adjacent pairs of CD yams followed by a number of distances 770 and so forth. Further, there may be only 15 one distance between pairs of adjacent CD yarns Throughout the length of the fabric that may be different than the remaining distances between pairs of adjacent CD yarns. Alternatively, all the distances between pairs of adjacent CD yams may be different. The variable distances described between pairs of adjacent CD yarns may be applied to the distances between pairs of adjacent Ml) yarns. Such 20 -arrangement of variable distances between pairs of adjacent M) yarnsand between pairs of adjacent CD yarns may improve pressing uniformity and reduce sheet marking. Any combination of distances between MD yarns and/or CD yarns is envisioned.in the present invention. FIGS. :8 and 9 are the interference patten and topography of the multilayer 25 multiaxial -fabric having a first -layer and a second layer in the staggered arrangement of varying MD and CD yam spacing as shown in Figure 7. Each layer is offset of3* from-each other. As shown in FIGS. 8 and 9, the well defined Moire Effect MD and CD bands that are characteristic of prior art multilayer multiaxial fabrics (compare FIGS. 2,4, and 5) has been reduced or.eliminated. Accordingly, 13 WO 2006/116006 PCT/US20061014959 the topography of the fabric is morejuniform and should rest in improved pressing uniformity with reduced sheet marking. Note that implementation of the desired spacing of for example;the MD and/or CD yarns is readily acconpiished by the skilled artisan. In this regard, 5 predetermined distances between pairs of adjacent CD yams may-be achieved bya . -programmed servo control of length factor in weaving or selective weave patterns to Ibrce non-unifonn or variable grouping, and/or use of randomly or non randomly inserted dissolving yarns. For example, in FIG. 10 layer 1000 is a pattern, for example, which has a plurality of interwoven MD yarns 1010 and CD yams 10 1020, with variable CD spacing. That is, a first spacing 1030 is different than a second spacing 1040. While the CD spacing varies in this illustration, the MD spacing 1050 does not. Accordingly, the variations and combinations are infinite. FIGS. lOa and lOb are the interference pattern and topography of the multiaxial fabric having a first layer and a second layer formed from the weave 15 pattern and yam spacing depicted in FIG. 10. As shown in FIGS. 10a and 10b, the higher CD yarn count and the variable spaced CD yanis depicted in the weave pattern of FIG 10 result in minimizing well defined MD and CD bands, compared to that of FIGS. 4 and 5. Accordingly, the topography of a multiaxial multilayer fabric can be rendered more uniform, which should result in improved pressing 20 uniformly and reduced sheet marking. FIG. 11 is another example of a layer with a weave pattern having variable CD spacing. FIG 11 is a layer 1100 having a plurality ofMD yams 1110 and-CD yarns 1120 with non-uniform CD spacing. That is, the distance-between pairs of adjacent CD yams is different. For example, a fist distimce I130,; second 25 distance 1140 and a-third distance 1150 are different and so on. Note that while the MD yarns 1110 are shown tobe at anniformly-spaced distance from each-other, variation of such spacing is envisaged as part of the present invention. In this regard, the predetermined spaced distances'between pails .of adjacent MD yars may be achieved by, for example, non-uniform reed dent 30 spacing, multiple diameter MD strands, or non-uniform reed dent insertion of yans 14 WO 2006/116006 PCTIUS2006/014959 :among others. Other ways of producing variable predetermined distances between pairs of adjacent MD yarns would be readily apparent to those so skilled in the art. In addition as to all ofthe embodiments discussed herein, additional layers can be added such as fiber batt attached by needling. 5 Turning now to the second embodiment nfthe present invention, it involves the use of the nonwoven layer 1230 between the multiaxial layers 1210 and 1220 which serves to create void volume and preserve fabric openness. Also the interference pattern that commonly occurs between multiaxial layers is reduced or eliminated by disposing a nonwoven layer between a first (upper) woven layer and 10 a second (lower) woven layer of a miltiaxial fabric.-The nonwoven layer may include materials such as knitted, extruded mesh, MD or CD yarn arrays, and full width or spiral wound strips of nonwoven fiberous material. This is illustrated in FIG. 12 which is an on-machine seanable multilayer. multiaxial fabric 1200. Ths fabric 1200 is created by creating a double length 15 seamed multiaxial fabric that is flattened. Upper layer 1210 and lower layer 1220 are made into -the form of an endless fabric as provided in patent '176 to Yook with a nonwoven layer 1230 is disposed between upper woven layer 1210 and lower woven layer 1220 prior to folding over. Nonwoven layer 1230 may be that as aforesaid and typically comprises a sheet or web structure bonded together by 20 entangling fiber or filaments mechanically, thermally or chemically. It may be made of any suitable material, such as polyamide and polyester resins, used for this purpose by those of ordinary skill in the paper machine clothing arts. Nonwoven layer 1230 may be disposed between upper woven layer. 1210 -and lower woven layer 1220 by any means so known by those skilled in the art. After nonwoven 25 layer 1230 is disposed between upper layer 1210 and lower layer 1220, the fabric 1200 may be rendered into endless form with a seam as taught by the '176 patent. The resulting fabric is a three-layer laminate, i.e., woven mutiaxial layer, nonwoven layer and woven multiaxial layer. Again, additional layers may be added such as fiberous batt in the case of press fabrics. 15 WO 20061116006 PCT/US2006/014959 In yet the third embodientdn accordance with the present invention, the topography of a multilayer multiaxial fabric may be made more planar by flattening the inside of the fabric, which is ultimately one side of each layer that fonns the multilayer multiaxial fabric. Specifically, the multiaxial fabric when flattened -upon 5 itself along a first and second fold line and made on-machine-seamable as taught in.: the '176 patent canbe considered to have an upper layer having aplurality of interwoven MD and CD yams having an inner side and an outer side; and a lower layer having a plurality of interwoven MD and CD yarns having an inner side and an outer side. The knuckles or yarn crossovers of the inner side of the upper layer 10 and the inner side of the lower layer may be flattened by a predetermined technique such as calendering. The predetermined technique. as aforesaid may be any process that flattens knuckles on each of the layers so as to improve pressing uniformity and reduce sheet marking. For example, one predetermined technique may be calendering one side of each layer at the appropriate pressure, speed and 15 temperature to flatten knuckles. The multilayer multiaxial fabric is then assembled so that the smooth sides ofthe two layers, after flattening, are in contact with each other (smooth side on the smooth side). The calendered fabric with two smooth inner surfaces should have reduced caliper variation because the layers of the fabric will less likely nest in a given area. Nesting occurs whenever the yams or knuckles 20 of one fabric layer shift or nest into the openings between yams or knuckles of the other layer. The interference pattern may still be visible to a certain extent but the potentially harmful caliper variation may be significantly reduced thus improving pressure distribution. Note that a similar approach may be taken to the.individual layers making up a fabric taught in the 66 patent. 25 FIG. 13 illustrates a multilayer multiaxial fabric 1300 which is formed by an endless single layer multiaxial fabric folded upon itself to create a double layer: fabric and rendered on-nachine-seamable in a manner discussed, for example, in the aforenoted '176 patent. After folding, the multiaxial fabric 1300 has alternatively a firstlayer1310 and a second layer 1320. First layer 1310 includes 30 inner side 1330 and outer side 1340. Similarly, second layer 1320 includes inner 16 WO 2006/116006 PCT/US2006/014959 -side 1350 and outer sid& 1360.' One or both of tb inner side or -outer 'side of.each layer, for example, inner sides 1330 and 1350, may be, for-example, calendered to flatten the knuckles of the woven layer so that the caliper variation-is reduced. In yet a fourth embodiment in accordance with the present invention,:the 5 layers of a militiaxial fabric may each be formed by.mixing different weave repeats or shed patterns. The number of yarns intersected before a weave pattern repeats is known as a shed. For example, a plain weave can therefore be termed a two shed weave. By mixing the shed patterns in a fabric, for example, a 2-shed pattem with a 3-shed pattern, a shute in the 3-shed weave may zigzag or interlace between ends of 10 the 2-shed weave. The interlacing yarn between the 2-shed ends may reduce -caliper variation and improve pressing urifonnity. The interlacing yarn may be in the machine direction and/or the cross--macline direction. Fig. 14 is a representation of a layer 1405 of regular plain weave strip of multiaxial material. Fig. 14a is a representation of a layer 1410 of a multiaxial 15 fabric 1400. Fig. 14b showslayer 1410 folded upon itself to create a multilayer multiax:ial fabric 1400. Multiaxial fabric 1400 includes a first layer 1410 and a second layer 1420. First layer 1410 includes a plurality of interwoven MD yams 1412 and CD yams 1414. Similarly, second layer 1420 includes a plurality of MD yams 1412 and CD yarns 1414, which are obviously for the MD yarns the 20 continuation of the same yarns with interwoven CD yarns.. The arrangement of the MD and CD yams in first layer 1410 and second layer 1420 which, due to spiraling are at an angle to one another, improves the pressure distribution of the fabric during operation as well as the Moire Effect. Tirst layer 1410 and secondjlayer N420 are formed frommixing weave repeats, for example, a 2-shedpattern with a: 25 3-shed patten. Specifically, in first layer 1410, as shown in Fig. 14a,.CD yarn 1426 interlaces between the 2-shed ends 1430 and 1432. Similarly, in second layer 1420 CD yam 1428 interlaces between the 2-shed ends 1434 and 1436. As a result caliper variation is reduced and pressing uniformity is improved. Notably, as shown in FIG. 14(b), there are no continuous orwell defined MD or'CDbands. 17 WO 2006/116006 PCT/US20061014959 In contrast, FIG. 14c illustrates layer 1405 folded upon itself to create a typical multilayermultiaxial fabric 1450 including first woven layer 1460 and second woven layer 1470. As shown, the plain weave multiaxial fabric 1450 upon being folded-results in-noticeable MD bands 1480. MD -bands- 1480 may-be areas 5 -of different caliper, mass or pressure uniformity which may mark the paper sheet -during a pressing operation. Note further that while itis illustrated inFigs. 14b and 14c that the multiaxial fabric is being folded on itself-to create a multilayer fabric, in the situation ofa multilayer fabric as taught by the '656 patentthe same principal would apply. J0 Interlacing between shed patterns may be in the MD and/or CD directions. Further, the interlacing yarn may-be in the first layer and/or second layer if two . separate fabric layers are involved. Also, any shed combination that produces an interlacing yam is envisioned in the present invention. For example, -an interlacing -yarn may be present by mixing a 2-shed pattern with a 5-shed pattern, a 3-shed 15 pattern and a 4-shed patten and so forth..Furthermore, even if only one.of the two layers of the multilayer fabric includes this multi-shed weave, an appreciable improvement in the interference pattern should be realized. Also, the invention is not limited to a specific number of fabric layers, i.e. two, rather it -is applicable to -nore than two. Also a fiberous batt layer or layers may also be attached by 20 needling. Turning now to the fifth embodiment in Fig. ISA, an endless single layer multiaxial base fabric 1500 is shown. This fabric 1500 -can be created in any -manner heretofore discussed. Note that in the-to be eam.area,'.the-cross-machine direction yarns are removed for seaming purposes in accordance-with the teachings 25 of the '176 patent. Figs. 15B-D show further multilayer variations -that are envisioned by the present invention. In this regard a multilayer fabric 1510 is *showninfig. 15B. It is created by adding a laminate material 1512 to tlie outside of base fabric 1500 and needling the fabric with laminate -to attach-the same. Note the laminate may be any material suitable for the purpose, such as-that described -18 WO 2006/116006 PCT/US2006/014959 - with regard to the second embodiment or even batt. This applies to all Versions of the fith embodiment. The fabric would then be removed from the needle loom-with the laminate -material cut away inthe loop area 1514. The fabric 1516 is folded-on itself as 5 -shown and then seamed-in a manner as taughtin the '176 patent. Theresulting . fabric 1510-would have twolayefs funed from base fabric 1500 and alayer of laminate material 1512 on the top and one on the bottom. . Turning now to Fig. 1SC another mutilayer fabric 1520 is shown utilizing base fabric 1500. In this embodiment the laminate material 1522 is attached'to the 10 inside of base fabric 1500 by needling. The fabric is then removed from the. needling loom and the laminate cut away in the loop areas 1524. The fabric 1520 is then folded upon itself and seamed in a manuer as taught in the '176 patent. The Resulting fabric 1520 would have two layers of laminate material 1522 inside two layers of base fabric 1500. 15 With regard now to Fig. 15D, there is shown fabric 1530 which is a - mnltilayer fabric. In this version it too utilizes the base fabric 1500. A laminate material 1532 is placed on the top outside of the base fabric 1500 and needled thereto for one-half the length ofthe fabric between the loop areas 1534. The remaining laminate material not needled is removed by cutting The fabric 1530 is 20 removed from the needle loom and turned inside out and folded upon itself and again seamed in a manner taught by the '176 patent The resulting fabric would have two layers of base fabric 1500 with a layer of laminate 1532 inside. A variation of thiswould be to place a laminate material on the inside of a base fabric 1500 and needle the fabric between the loop areas, remove the excess 25 laminate material not needled, fold it'upon itself and seam as aforesaid, The fabric. -will have the same construction as fabric 1530. -odifications to the above would be obvious to those of ordinary skill in the art, but would not bring the invention so modified beyond the-scope of the present invention. The claims to follow should be construed ID cover-such 0 situations. 19 The term 'comprising' as used in this specification and claims means 'consisting at least in part of. When interpreting statements in this specification and claims which include the term 'comprising', other features besides the features prefaced by this term in each statement can also be present. Related terms such as 'comprise' and 'comprised' are to be 5 interpreted in similar manner. In this specification where reference has been made to patent specifications, other external documents, or other sources of information, this is generally for the purpose of providing a context for discussing the features of the invention. Unless specifically stated otherwise, reference to such external documents is not to be construed as an admission that 10 such documents, or such sources of information, in any jurisdiction, arc prior art, or form any part of the common general knowledge in the art. 20 3419036-1