Needle Board Asymmetric Angles Prevent Pattern Formation
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Solution Overview
Problem
Existing needle boards for needling machines often result in pattern formation in flat textile materials, especially at high feed-per-stroke ratios, which is undesirable for achieving uniform needling.
Innovation Solution
The needle board features first and second needle rows arranged at different angles relative to the longitudinal direction of the board, with specific angle ranges and spacing configurations to prevent pattern formation and ensure uniform stitching, even at high conveying speeds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If needle rows are arranged in simple rows and columns in longitudinal and transverse directions, then the device complexity is low and ease of manufacture is high, but pattern formation occurs in the needled flat textile material especially at high feed-per-stroke ratios
Solution Approach 1:
The patent applies asymmetry by arranging needle rows at different angles (first angle α and second angle β) relative to the longitudinal direction, where the absolute values of these angles are different. This asymmetric angular arrangement breaks the symmetry that causes pattern formation, while maintaining a relatively simple manufacturing process. The first needle rows are arranged at angle α and the second needle rows at angle β, creating an asymmetric needle distribution that prevents regular pattern formation in the needled material.
Solution Approach 2:
The patent introduces angular dimensionality by arranging needle rows at different angles to the longitudinal direction rather than simply in parallel rows. The first needle rows are inclined at a first angle α and the second needle rows at a second angle β, adding an angular dimension to the needle arrangement. This dimensional change transforms the simple rectangular grid into a more complex angular pattern that eliminates pattern formation while remaining manufacturable.
2Manufacturing precision
If needle rows are arranged in a herringbone pattern to prevent pattern formation, then the uniformity of needling is improved, but the device complexity increases
Solution Approach 1:
The patent segments the needle board into distinct groups: first needle rows arranged at a first angle α and second needle rows arranged at a second angle β. This segmentation divides the complex herringbone pattern into manageable sections with different angular orientations. Each segment can be independently configured and manufactured, reducing the overall device complexity while maintaining the uniformity benefits of the herringbone pattern through the combination of different angular segments.
Data Source
AI summary
The needle board for use in a needling machine for needling a flat textile material comprises first needle rows and second needle rows, wherein the first needle rows and the second needle rows are arranged inclined with respect to a longitudinal direction of the needle board, which longitudinal direction corresponds to a direction in which the flat textile material to be needled is conveyed in the needling machine. The first needle rows are arranged at a first angle to the longitudinal direction, and the second needle rows are arranged at a second angle to the longitudinal direction. An absolute value of the second angle is different from an absolute value of the first angle.