Multi-Layer Heald Structure for Lightweight Wear Resistance
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Solution Overview
Problem
Weaving machine healds face challenges in achieving a balance between stability, long service life, and low weight due to high acceleration demands, requiring innovative designs that are both durable and lightweight.
Innovation Solution
A heald body constructed from multiple foil layers, connected via material bonding, with reinforcement sections to enhance tensile strength and wear resistance, potentially incorporating electrically conductive materials to prevent static charging, and featuring a multi-layer design for optimized weight distribution and production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the heald body is made from a single flat strip or simple material, then the manufacturing process is simple, but the tensile strength and resistance to cutting by warp threads are insufficient
Solution Approach 1:
The heald body is constructed from multiple foil layers (at least two) that are connected to one another, forming a composite structure. This multi-layer construction provides enhanced tensile strength and resistance to cutting by warp threads while maintaining a relatively simple overall design. The foil layers can be made from the same or different materials, allowing optimization of specific properties.
Solution Approach 2:
The heald body is divided into multiple discrete foil layers that are connected together. This segmentation allows each layer to contribute to the overall strength while enabling flexible manufacturing processes. The layered structure can be produced by stacking and connecting individual foils or by forming a multi-layer web in one process.
2Strength
If the heald body is made from thick or heavy material, then the strength and durability are improved, but the total weight of the heddle shaft increases, requiring greater acceleration forces
Solution Approach 1:
The heald body is constructed from thin foil layers rather than thick solid material. The multiple thin layers provide the necessary strength and wear resistance through their composite structure, while keeping the overall weight low. This approach allows the heddle to be both durable and lightweight, reducing the acceleration forces required for the heddle shaft.
Solution Approach 2:
By using multiple foil layers connected together, the structure achieves high strength-to-weight ratio. The composite construction provides durability and wear resistance equivalent to or better than solid thick material, but with significantly reduced weight, thereby lowering the inertial forces during acceleration.
3Strength
If the thread eye area is reinforced with additional material, then the resistance to being cut by warp threads is improved, but the overall weight and material usage increase
Solution Approach 1:
The multi-layer construction can be applied selectively to specific areas of the heald body, particularly reinforcing the thread eye area where cutting resistance is most critical. The foil layers can be arranged or connected with varying density in different regions, providing enhanced protection where needed while minimizing material usage in less critical areas.
Solution Approach 2:
The use of multiple foil layers creates a composite structure that concentrates material where strength is most needed. The layered construction at the thread eye area provides superior resistance to cutting by warp threads compared to single-layer designs, while the overall material quantity remains controlled through efficient layer arrangement.
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
The solution results in a lightweight, durable heald with improved resistance to wear and cutting, capable of withstanding high accelerations while maintaining low weight, ensuring extended service life and efficient production processes.
Implementation Method 1
The foil layers are connected in particular by means of a material connection, for example by gluing
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The heddle (10) has a heddle body (11) extending in a longitudinal direction (L) and a thread eye (12) is provided for receiving a wrap thread. The heddle body has two foil layers (16) in a reinforcing portion (15), where the foil layers are laid flat against each other and are interconnected. Three foil layers are provided in the reinforcing portion, where multiple reinforcing portions are provided in the heddle body. The reinforcing portion of the heddle body with two foil layers (16a,16b), is connected to a connecting portion (21) of the heddle body. An independent claim is provided for a method for manufacturing a heddle with heddle body.