Polymeric Heddle Design With Cavities to Contain Overmolding Burrs
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Solution Overview
Problem
Existing heddles for Jacquard weaving looms suffer from burrs forming during overmolding, which can snag and damage adjacent warp threads, requiring time-consuming rework to remove these burrs.
Innovation Solution
The heddle design features a polymeric rod with cavities at its longitudinal extremity, recessing areas prone to burr formation, ensuring adjacent warp threads do not contact these burrs, and allowing overmolding without slides that reduce burr formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If overmolding is used to connect rod and link, then manufacturing efficiency is improved, but burrs form during the process which can damage warp threads
Solution Approach 1:
The patent extracts the harmful burrs from the functional surface by creating cavities that contain them internally. The cavities are positioned such that burrs formed during overmolding are recessed inside the rod structure, away from contact with warp threads, thus separating the harmful byproduct from the functional interaction zone.
Solution Approach 2:
The patent converts the harmful burr formation into a beneficial containment feature. By designing cavities that intentionally accommodate burrs, the harmful byproduct of overmolding is transformed into a contained element that cannot interfere with warp thread passage, effectively turning a manufacturing defect into a non-interfering internal feature.
2Object-generated harmful factors
If overmolding without slides is used, then burr formation is reduced, but the mold design becomes more complex
Solution Approach 1:
The patent introduces cavities as a third-dimensional feature within the rod structure to accommodate burrs. This dimensional addition allows the mold design to avoid complex slide mechanisms while still managing burr formation, as the cavities provide internal containment without requiring additional mold closing directions or sliding components.
3Reliability
If burrs are removed after overmolding, then warp thread damage is prevented, but rework time increases
Solution Approach 1:
The patent performs preliminary action by designing the rod with cavities that preemptively contain burrs before they can cause damage. The cavity structure is built into the mold design, so that when overmolding occurs, burrs are automatically recessed inside the rod during the primary manufacturing process, eliminating the need for subsequent burr removal operations.
Solution Approach 2:
The rod structure serves itself by containing its own manufacturing defects. The cavities are designed to automatically capture and contain burrs formed during overmolding, making the system self-correcting and eliminating the need for external rework operations to remove burrs that would otherwise damage warp threads.
Data Source
AI summary
This heddle includes a link and at least one rod made of polymeric material, one longitudinal extremity of which includes surfaces covering the transverse faces of the link. The rod and the link form at least one cavity, offset from the link parallel to a longitudinal axis and delimited by a first peripheral surface of the link, a second lateral surface, formed by the outer surface of the rod, and a third bottom surface, formed by the rod and extending one of the covering surfaces. An intersection line extends from the third bottom surface and delimits the first surface. The third bottom surface is arranged toward the outside of the rod relative to the second lateral surface. Each cavity is non-facing, according to a thickness axis in a direction away from the third bottom surface.