Multi-layer warp bound papermaker's forming fabrics

Abstract

The present invention is directed to forming fabrics. The forming fabrics may include a series of repeat units. Each of the repeat units may include a set of binding warp yarns including a first set of binding warp yarns and a second set of binding warp yarns, wherein a binding warp yarn from the first set is paired with a binding warp yarn from the second set; a set of spring warp yarns, wherein each spring warp yarn is between a first pair of binding warp yarns and a second pair of binding warp yarns; a set of top weft yarns including odd and even top weft yarns, wherein the top weft yarns interweave with the binding warp yarns and the spring warp yarns to form a top fabric layer, wherein the spring warp yarns interweave only with the top weft yarns; a set of bottom weft yarns; and a set of bottom warp yarns, the bottom warp yarns interwoven with the bottom weft yarns to form a bottom fabric layer. The binding warp yarns from the first and second set and the spring warp yarns interweave with the top weft yarns to relatively form a plain weave pattern in defined zones such that (a) the first set of binding warp yarns only pass over even top weft yarns; (b) the second set of binding warp yarns only pass over odd top weft yarns; (c) the first binding warp yarn in the pair is offset from the second binding warp yarn in the pair by at least three top weft yarns to create an overlap in the warp path of the pair of binding warp yarns; and (d) each spring warp yarn passes over even and odd top weft yarns. The binding warp yarns from the first and second set and the bottom warp yarn interweave with the bottom weft yarns.