Multi-Component Plastic Heddle for Wear Resistance
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Solution Overview
Problem
Modern weaving machines experience excessive wear of the heald due to high-speed operations, leading to costly downtimes and the need for frequent replacement of the heald, which is exacerbated by the use of metallic materials that are heavy and prone to rust, while wear-resistant plastic or composite materials are expensive and inefficiently used.
Innovation Solution
The heald body is constructed from multiple longitudinal sections made of different plastic or composite materials, with the thread eye section being highly wear-resistant and end sections optimized for sliding properties, connected through multi-component injection molding to reduce production costs and enhance durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metallic stranded bodies are used for the thread eye, then wear resistance is improved, but weight increases and rusting occurs
Solution Approach 1:
The patent uses composite materials consisting of plastic matrix with embedded reinforcement elements (such as glass fibers, carbon fibers, or metallic strands) to create a thread eye that combines the light weight and corrosion resistance of plastic with the wear resistance of reinforcement materials. This resolves the contradiction by achieving wear resistance without the drawbacks of pure metallic constructions.
Solution Approach 2:
The patent applies different material compositions to different regions of the heddle - the thread eye area contains higher concentrations of wear-resistant reinforcement elements, while other parts use lighter plastic compositions. This localized material distribution achieves wear resistance where needed while minimizing overall weight.
2Reliability
If wear-resistant plastic or composite material is used for the entire heddle body, then wear resistance is improved, but production cost increases
Solution Approach 1:
The patent uses different plastic or composite materials for different longitudinal sections of the heddle body based on their specific functional requirements. The thread eye section uses wear-resistant materials, while end eyelet sections use materials with good sliding properties, and intermediate sections use cost-effective standard plastics. This targeted material selection achieves necessary wear resistance while minimizing production costs.
Solution Approach 2:
The heddle body is divided into multiple longitudinal sections that can be manufactured separately and then joined together. This segmentation allows each section to be optimized for its specific function and manufactured using the most cost-effective method, reducing overall production cost while maintaining wear resistance where required.
3Reliability
If multiple different materials are used for different longitudinal sections, then wear resistance and sliding properties are optimized, but manufacturing complexity increases
Solution Approach 1:
The patent integrates multiple material injection processes into a single multi-component injection molding operation. Different plastic or composite materials are injected in sequence or simultaneously into the same mold cavity to form different longitudinal sections, which are then bonded together in one manufacturing step. This merging of processes achieves functional optimization while minimizing manufacturing complexity compared to separate manufacturing and assembly operations.
Solution Approach 2:
The patent uses a mold design with intermediate bonding layers or surface treatments on the injection mold cavities that facilitate the bonding of different materials during the injection process. This intermediary mechanism enables the integration of multiple materials without requiring complex post-manufacturing joining operations.
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
This design results in a lightweight, wear-resistant, and cost-effective heald with improved durability and reduced maintenance needs, as specific materials are used where needed most, and the connection process simplifies production without requiring additional joining steps.
Implementation Method 1
The longitudinal sections are already connected to one another during the casting or injection molding of the heddle body in the mold
Implementation Method 2
A multi-component injection molding process is preferably used to produce the heald body
Data Source
Figure 1
Figure 2
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AI summary
The invention relates to a fly wire (10) comprising a stranded wire body (11) with a thread eyelet (13) and two end loops (12). The stranded wire body (11) is made of various plastic materials and/or composite materials, preferably by casting or multi-component injection molding. It has at least two longitudinal sections (14, 15, 16) that are consecutive in the longitudinal direction L of the stranded wire body (11). Two longitudinal sections (14, 15) or (15, 16) that are directly connected to each other are made of different plastic materials or different composite materials. The composite materials have a plastic matrix with additive elements (20). The stranded wire body (11) with its longitudinal sections (14, 15, 16) is manufactured in a single manufacturing step, wherein the adjacent longitudinal sections (14, 15, 16) are joined to each other. By using different plastics orFor composite materials for the individual longitudinal sections (14, 15, 16), the material can be adapted to the desired property of the respective longitudinal section (14, 15, 16) and at the same time a cost-effective production of the Weblitze (10) can be achieved.