Needling Device with Movable Needle Looms for Pattern Flexibility

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Solution Overview

Problem

Existing needling devices for nonwoven webs require replacement of needle boards to produce different stitch patterns, limiting flexibility and efficiency.

Innovation Solution

A device with multiple needle looms arranged in series, where the distance between looms can be adjusted and locked, using cams with synchronous movement and a resilient connecting element to allow horizontal movement, enabling precise control and easy pattern changes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If needle boards are replaced to produce different stitch patterns, then pattern versatility is improved, but device complexity and production time increase

Engineering Contradiction:

Improvestitch pattern varietyVSAvoidneedle board replacement time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The needle looms are made movable along the guide instead of being fixed, allowing dynamic repositioning to change stitch patterns. The distance between needle looms can be adjusted and locked at desired positions, enabling pattern variation without replacing needle boards.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The needling device is divided into multiple independent needle looms that can be individually positioned and adjusted along the guide. Each needle loom operates independently, allowing flexible configuration for different stitch patterns.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If needle looms are made movable for pattern adjustment, then adaptability is improved, but positioning precision and stability may worsen

Engineering Contradiction:

Improvedistance adjustment flexibilityVSAvoidneedle loom positioning accuracy

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The needle looms are designed to be movable during setup but lockable during operation. The locking mechanism ensures precise positioning is maintained throughout the needling process, preventing unwanted movement while allowing repositioning when pattern changes are needed.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system allows for adjustment and locking of needle loom positions, implying a feedback mechanism where the position can be set, locked, and maintained with precision throughout the needling operation.

Inventive Principle:

Principle #23Feedback

3Stability of the object's composition

If camshafts are connected for synchronous movement, then coordination is improved, but risk of jamming increases

Engineering Contradiction:

Improvesynchronous movement coordinationVSAvoidcamshaft jamming resistance

Core Design Contradiction:

Stability of the object's compositionVSReliability

Solution Approach 1:

A flexible connecting element is used to connect the camshafts, allowing for slight movements and misalignments without causing jamming. The flexibility accommodates manufacturing tolerances and operational variations while maintaining synchronous movement.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The resilient connecting element acts as a cushioning mechanism that prevents jamming by absorbing misalignments and movements before they can cause the camshafts to lock up or jam during operation.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

4Reliability

If connecting element is resilient horizontally but rigid vertically, then jamming prevention is improved, but structural complexity increases

Engineering Contradiction:

Improvecamshaft jamming resistanceVSAvoidconnecting element design complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The connecting element is designed with anisotropic properties - flexible in the horizontal direction to prevent jamming, but rigid in the vertical direction to maintain structural integrity. This directional flexibility is achieved through the specific geometry and material properties of the connecting element.

Inventive Principle:

Principle #30Flexible shells and thin films

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enables flexible and efficient production of various needle patterns with high accuracy and low maintenance, reducing costs and simplifying the process of producing different stitch patterns.

Implementation Method 1

the connecting element between the cam followers is resilient only in the direction perpendicular to the axes of the camshafts in the plane extending between the axes of the camshafts, but is rigid in the direction transverse to that plane

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS7975353B2Device and method for needling a nonwoven web

Publication Date: 2011.07.12 DILO MASCHINENFABRIK KG

AI summary

A device for needling a nonwoven web includes several needle looms arranged in series, each with at least one needle bar, a pair of infeed rollers, and a pair of outfeed rollers. The needle looms can move along a guide in the transport direction of the nonwoven web and can be locked in place at any desired distance from each other.