Narrow Cropped Heald with Offset Shaft for Thread Passage
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Solution Overview
Problem
Existing methods for producing healds result in significant material waste and limited material optimization due to the need for strong material deformation to achieve the required shape and functionality, restricting the choice of materials and the possibilities for efficient production.
Innovation Solution
A flat ribbon heald made from a metal ribbon section where material is removed along the shank to form a transition section between the end eyelet and the shaft, allowing for a subsequent offset of the shaft relative to the end eyelets through plastic deformation, enabling a larger thread passage space without increasing material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If healds are cranked to create offset between thread eyes of adjacent healds, then thread passage space is improved, but material consumption increases due to removal of parts from metal strip blank
Solution Approach 1:
The heald is divided into distinct functional sections: a shaft portion for mounting, a transition section with varying width, and an end eyelet portion. This segmentation allows each section to be optimized independently - the transition section tapers to reduce material while maintaining structural integrity, and the end eyelet is positioned to maximize thread passage space without requiring additional material removal from adjacent healds.
Solution Approach 2:
Instead of creating offset between adjacent healds through lateral cranking that consumes material, the invention positions the end eyelet offset from the longitudinal centerline of the shaft in the longitudinal direction. This dimensional repositioning achieves the same thread passage space improvement without requiring material removal, as the offset is achieved through the transition section geometry rather than lateral displacement.
2Loss of substance
If strong material deformation is applied to produce elongate openings by slitting and widening, then material usage is reduced, but choice of material and possibilities for material optimization are restricted
Solution Approach 1:
The transition section is designed with a predetermined tapered geometry that gradually reduces width from the shaft to the end eyelet. This preliminary shaping allows the end eyelet to be formed with minimal additional deformation, as the material is already positioned and oriented correctly. The taper acts as a built-in guide that prepares the material for the final eyelet formation, reducing the intensity of deformation required.
Solution Approach 2:
The transition section features a gradual width reduction rather than abrupt changes, creating local variations in material thickness and density that facilitate easier deformation. The tapered geometry distributes stress more evenly during forming operations, allowing a broader range of materials to be used without risk of cracking or failure, thus expanding material choice while still achieving material efficiency.
3Ease of operation
If paired healds with differently offset shafts are used, then thread passage space is improved, but the space between shafts of adjacent healds is limited
Solution Approach 1:
The invention achieves offset in the longitudinal direction (along the shaft axis) rather than laterally (perpendicular to shaft axis). The end eyelet is positioned at a distance X from the longitudinal centerline of the shaft, creating the necessary thread passage space while keeping the shafts of adjacent healds close together. This longitudinal positioning allows greater flexibility in arranging multiple healds on the heddle shaft.
Solution Approach 2:
The offset is achieved locally at the end eyelet position rather than through overall shaft cranking. The transition section creates a localized geometric variation that positions the end eyelet offset from the shaft centerline, while the shaft itself remains straight and can be positioned close to adjacent shafts. This localized approach maximizes thread passage space without compromising shaft spacing.
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 approach allows for the production of high-performance healds with reduced material consumption and fewer local material deformations, optimizing the choice of materials and achieving a larger offset between thread and end eyelets, thus enhancing the functionality and efficiency of the healds.
Implementation Method 1
The shaft is subsequently offset in relation to the end eyelets. This offset of the shank relative to the end eyelets, which does not yet exist after the heddle has been cut out or punched out, but is subsequently produced, is achieved by plastic deformation of the transition area or a part of the shank within the said plane.
Data Source
Figure 1~3
Figure 4~6
Figure 7~9
AI summary
The flashing lights according to the invention consist of a metal strip section of width (B) that is narrower than the total width (B+X) required for the flat strip wire (20). The flat strip wire (20) has a substantially unprocessed, or at least untrimmed, edge (9) originating from the metal strip section and an edge (10, 11, 12, 13, 14) that has been produced in the area of the shaft (4) and the transition sections (5, 6) by trimming the metal strip section. An outwardly directed offset of the shaft (4) creates an increased distance (R) between two corresponding oppositely offset flat strip flashing lights of a flashing light pair (23), to which two oppositely offset flat strip flashing lights (20, 21) belong.