U.S. patent application number 11/248020 was filed with the patent office on 2007-04-12 for plastic heddle.
This patent application is currently assigned to GTP Greenville, Inc.. Invention is credited to Gene E. Faasse, Thomas A. Korbutt, Charles F. Kramer, Joseph Patrick Neel, John F. Perry.
Application Number | 20070079887 11/248020 |
Document ID | / |
Family ID | 37910130 |
Filed Date | 2007-04-12 |
United States Patent
Application |
20070079887 |
Kind Code |
A1 |
Korbutt; Thomas A. ; et
al. |
April 12, 2007 |
Plastic heddle
Abstract
Heddles for use within a harness frame of a weaving machine are
provided. Each of the heddles includes a body formed from a liquid
crystal polymer resin. The body forms at least one rod slot
enabling engagement with a harness frame. The body also has an
eyelet section with the eyelet section forming a yarn eye through
which a yarn is capable of passing.
Inventors: |
Korbutt; Thomas A.; (Greer,
SC) ; Faasse; Gene E.; (Easley, SC) ; Kramer;
Charles F.; (Greenville, SC) ; Perry; John F.;
(Alpharetta, GA) ; Neel; Joseph Patrick;
(Charlotte, NC) |
Correspondence
Address: |
DORITY & MANNING, P.A.
POST OFFICE BOX 1449
GREENVILLE
SC
29602-1449
US
|
Assignee: |
GTP Greenville, Inc.
|
Family ID: |
37910130 |
Appl. No.: |
11/248020 |
Filed: |
October 10, 2005 |
Current U.S.
Class: |
139/93 |
Current CPC
Class: |
D03C 9/02 20130101; D03C
9/024 20130101 |
Class at
Publication: |
139/093 |
International
Class: |
D03C 9/00 20060101
D03C009/00 |
Claims
1.) A heddle for use within a harness frame of a weaving machine,
said heddle comprising a body formed from a liquid crystal polymer
resin, said body forming at least one rod slot enabling engagement
with a harness frame and said body having an eyelet section with
said eyelet section forming a yarn eye through which a yarn is
capable of passing.
2.) A heddle as in claim 1, wherein said liquid crystal polymer
resin comprises an unfilled liquid crystal polymer.
3.) A heddle as in claim 1, wherein said eyelet section is turned
at an angle as compared to the rest of said body.
4.) A heddle as in claim 3, wherein said angle ranges between about
20 degrees and 30 degrees.
5.) A heddle as in claim 1, wherein said eyelet section comprises
thickened eyelet section walls that define the sides of the yarn
eye in a direction of yarn travel such that said yarn eye comprises
a tunnel eye, said tunnel eye providing an extended contact surface
on which the yarn may reside.
6.) A heddle as in claim 5, wherein the depth of said contact
surface is substantially larger than the width of the portion of
said body that is disposed between said eyelet section and said at
least one rod slot.
7.) A heddle as in claim 5, wherein said eyelet section defines a
gap through one of said eyelet section walls, said gap providing an
opening for insertion of the yarn into said tunnel eye.
8.) A heddle as in claim 7, wherein said gap is biased to prevent
said yarn from exiting said yarn eye during a weaving process.
9.) A heddle as in claim 5, wherein at least one of said eyelet
section walls defines an indention to facilitate insertion of the
yarn into said tunnel eye.
10.) A heddle as in claim 1, wherein said body includes
longitudinal walls defining said at least one rod slot.
11.) A heddle as in claim 10, wherein said at least one rod slot
comprises an O-shaped rod slot having a slit formed in one of said
longitudinal walls, said one longitudinal wall defining at least a
first edge of said slit being resiliently deformable to permit
insertion of a rod of a harness frame into said rod slot.
12.) A heddle as in claim 1, wherein said at least one rod slot
comprises at least one of an O-shaped rod slot, a C-shaped rod
slot, or a J-shaped rod slot.
13.) A heddle as in claim 1, wherein a first rod slot is disposed
at one end of said body and a second rod slot is disposed at an
opposite end of said body.
14.) A heddle as in claim 13, wherein at least one sharpened edge
is defined on said body proximal to at least one of said two slots,
said at least one sharpened edge being configured to aid in the
automatic draw-in of yarn through said yarn eye.
15.) A heddle as in claim 1, wherein said body includes gap-forming
protrusions thereon to aid in creating separation between heddles
when placed on a harness frame.
16.) A heddle as in claim 1, wherein a flow modifier is blended
with said liquid crystal polymer resin before molding of said
liquid crystal polymer resin into said body of said heddle.
17.) A heddle molded from plastic for use within a harness frame of
a weaving machine, said heddle comprising, an eyelet section having
thickened eyelet section walls that define the sides of a tunnel
eye in a direction of yarn travel, said tunnel eye being configured
to receive a yarn therethrough and said tunnel eye being configured
to provide an extended contact surface on which the yarn may
reside; a first longitudinal section disposed on a first end of
said eyelet section, said first longitudinal section defining a
first rod slot distal from said eyelet section; and a second
longitudinal section disposed on an opposing second end of said
eyelet section, said second longitudinal section defining a second
rod slot distal from said eyelet section.
18.) A heddle as in claim 17, wherein said contact surface defines
a depth that is substantially larger than the width of at least one
of said first longitudinal section and said second longitudinal
section.
19.) A heddle as in claim 17, wherein said eyelet section defines a
gap through one of said eyelet section walls, said gap providing an
opening for insertion of the yarn into said yarn eye.
20.) A heddle as in claim 19, wherein said gap is biased to prevent
said yarn from exiting said yarn eye during a weaving process.
21.) A heddle as in claim 17, wherein one of said eyelet section
walls defines an indention to facilitate yarn entry into said
tunnel eye.
22.) A heddle as in claim 17, wherein each of said eyelet section
walls defines an indention to facilitate yarn entry into said
tunnel eye, whereby said indention on one eyelet section wall is on
a first end of said tunnel eye and said indention of said other
eyelet section wall is on a second end of said tunnel eye.
23.) A heddle as in claim 17, wherein each of said first and second
longitudinal sections include longitudinal walls defining each of
said rod slots.
24.) A heddle as in claim 23, wherein each of said first and second
rod slots comprises an O-shaped rod slot having a slit formed in
one of said longitudinal walls of each of said first and second rod
slots, each of said one of said longitudinal walls defining one of
said slits being resiliently deflectable to permit insertion of a
rod of a harness frame into said respective rod slot.
25.) A heddle molded from plastic for use within a harness frame of
a weaving machine, said heddle comprising: an eyelet section having
eyelet section walls that define the sides of a yarn eye in a
direction of yarn travel, said yarn eye being configured to receive
a yarn therethrough; a first longitudinal section disposed on a
first end of said eyelet section, said first longitudinal section
having longitudinal walls defining a first rod slot distal from
said eyelet section; a second longitudinal section disposed on an
opposing second end of said eyelet section, said second
longitudinal section having longitudinal walls defining a second
rod slot distal from said eyelet section; and each of said first
and second rod slots comprising an O-shaped rod slot having a slit
defined in one of said longitudinal walls of said first
longitudinal section and said second longitudinal section of each
of said first and second rod slots, said longitudinal walls of said
first longitudinal section and said second longitudinal section
that define said slits being resiliently deflectable to permit
insertion of a rod of a harness frame into said respective rod
slot.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] N/A
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] N/A
BACKGROUND
[0003] The invention relates to a plastic heddle and, in
particular, heddles molded from liquid crystal polymer resins.
[0004] Heddles used within harness frames serve the purpose of
controlling warp yarns in weaving machines. The warp yarns run
through yarn eyes that are positioned intermediate of the ends of
the respective heddles. As is commonly understood, a single warp
yarn passes through the yarn eye of the heddle. The raising and
lowering of different harness frames in which the heddles reside
form sheds within a weaving machine to allow insertion of filling
yarns to weave a fabric. The heddles are typically mounted on a
support bar of a harness frame within the weaving machine. In this
manner, the depth, or flat strip side, of the heddle is parallel to
the direction of travel of the warp yarn. The eye of the heddle is
typically rectangular with full rounded ends to minimize chafing of
the yarn passing through the eye. In an ideal configuration, the
eye of the heddle should not bind or shape the warp end passing
therethrough and should not crowd or contact the adjacent warp ends
controlled by heddles bound in adjacent harness frames during the
shed change.
[0005] Heddles may be formed by stamping and polishing of metal
strips. Most common heddles for use in weaving machines consist of
a relatively thin flat strip of metal, such as steel. These metal
heddles may be formed by soldered wire, or by stamping of strips of
metals. Metal heddles are more common within the industry because
of their durability and ease of use within the harness frame.
However, the metal heddles are limited by the fact that they are
usually stamped or soldered, thereby limiting the configurations
the heddles may possess. Further, the metal heddles require fine
machining such as polishing to ensure that the yarn eye is
internally smooth and will not cause any undue damage or chafing of
the warp yarn during the weaving process. The use of metal as
material and the handling involved in preparing the metal heddles
increases the cost of the heddles.
[0006] Heddles made out of plastics are also used within the
weaving industry. Plastic heddles can be formed by stamping or by
molding. Plastic heddles can be made more inexpensively as compared
to metal heddles. The plastics that are used are inexpensive
relative to steel and can be molded into heddles with relative
ease. Common plastics used to create such heddles include
polyester, vinyl chloride, and acetal. These plastics are used
because of their flow capabilities that facilitate successful
molding. However, due to the size and tolerance limitations needed
for the use of heddles in weaving machines, the heddles made from
such plastics are more flimsy than the metal heddles. Such heddles
also wear quickly where the warp yarns come in contact with the
walls of the yarn eye. Such wearing within the yarn eye can be
especially detrimental by creating a greater opportunity to damage
the yarn during the weaving process. Heretofore, the plastic
heddles have seen limited use, because the plastic heddles cannot
obtain enough rigidity, strength and durability to perform as well
as metal heddles.
SUMMARY OF THE INVENTION
[0007] It is therefore a principal object of the present invention
to provide a molded heddle which does not require extensive
machining or polishing while providing enough rigidity, strength,
and durability within the size limitations and tolerances needed
for the heddle's use within a weaving machine and with automatic
drawing-in machines.
[0008] It is another object of the present invention to provide a
heddle that reduces the wear within the rod slots as well as within
the yarn eye of the heddle over extended use as compared to
commonly used plastic heddles.
[0009] It is also an object of the present invention to provide a
heddle formed from liquid crystal polymer resins.
[0010] It is yet another object of the invention to provide a
heddle having an increased contact surface within the yarn eye that
supports the warp yarn passing therethrough to decrease damage
caused to warp yarn during the weaving operation.
[0011] It is a further object of the invention to provide a rod
slot for a plastic heddle that increases the ease of installation
of the heddle on a rod of a harness frame, while securely holding
the heddle to the rods of the harness frame.
[0012] Additional objects and advantages of the invention will be
set forth in part in the description that follows and in part will
be obvious from the description, or may be learned by the practice
of the invention. The objects and advantages of the invention may
be realized and attained by means of the instrumentalities and
combinations particularly pointed out in the appended claims.
[0013] To achieve the objects in accordance with the purpose of the
invention, as embodied and described herein, a heddle for use
within a harness frame of a weaving machine is provided that
includes a body formed from a liquid crystal polymer resin. The
body defines at least one rod slot enabling engagement with a
harness frame. The body has an eyelet section which defines a yarn
eye therein. The yarn eye permits a yarn to pass therethrough.
[0014] In another embodiment, a heddle molded from plastic for use
within a harness frame within a weaving machine is provided. The
heddle comprises an eyelet section having thickened eyelet section
walls that define the sides of a tunnel eye in a direction of yarn
travel through the tunnel eye. The tunnel eye is capable of
receiving a yarn therethrough and provides an extended contact
surface on which the yarn may reside. A first longitudinal section
is disposed on a first end of the eyelet section. The first
longitudinal section defines a first rod slot distal from the
eyelet section. Further, a second longitudinal section is disposed
on an opposing second end of the eyelet section with a second
longitudinal section defining a second rod slot distal from the
eyelet section.
[0015] In yet another embodiment that is configured as in the above
embodiment with the tunnel eye, at least one of the eyelet section
walls defines a gap providing an opening for insertion of the yarn
into the tunnel eye. The gap desirably is biased to prevent the
yarn from exiting the yarn eye during a weaving process.
[0016] In a further embodiment, a heddle molded from plastic for
use within the harness frame of the weaving machine is provided. An
eyelet section having eyelet section walls that define the sides of
a yarn eye in the direction of yarn travel through the yarn eye is
provided. The yarn eye is capable of receiving a yarn therethrough.
A first longitudinal section is disposed on a first end of the
eyelet section. The first longitudinal section has longitudinal
walls defining a first rod slot distal from the eyelet section. A
second longitudinal section is disposed on an opposing second end
of the eyelet section. The second longitudinal section has
longitudinal walls defining a second rod slot distal from the
eyelet section. The first and second rod slots defined within the
heddle comprise O-shaped rod slots having a slit defined in one of
the longitudinal walls of both the first longitudinal section and
the second longitudinal section. The longitudinal walls of the
first longitudinal section and the second longitudinal section that
define the slits are capable of being deflected to permit insertion
of a rod of a harness frame into the respective rod slots.
[0017] The accompanying drawings, which are incorporated in and
constitute a part of this specification, illustrate at least one
presently preferred embodiment of the invention as well as some
alternative embodiments. These drawings together with the
description serve to explain the principles of the invention but by
no means are intended to be exhaustive of all the possible
manifestations of the invention.
BRIEF DESCRPTION OF THE DRAWINGS
[0018] FIG. 1 illustrates a schematic perspective view of a heddle
according to one embodiment of the present invention;
[0019] FIG. 2 illustrates a partial cross-sectional view along the
line 2-2 of the heddle of FIG. 1;
[0020] FIG. 3 illustrates a schematic front view of another
embodiment of a heddle according to the present invention;
[0021] FIG. 4A illustrates a partial cross-sectional view of the
heddle along the line 4A-4A shown in FIG. 3;
[0022] FIG. 4B illustrates a partial cross-sectional view across
the eyelet section of an alternative embodiment of the heddle
according to the present invention;
[0023] FIG. 4C illustrates a partial cross-sectional view across
the eyelet section of a further embodiment of a heddle according to
the present invention taken along the line 4C-4C in FIG. 7;
[0024] FIG. 5 illustrates a perspective view of an end of a
longitudinal section of a heddle according to one embodiment of the
present invention;
[0025] FIG. 6 illustrates a perspective view of the yarn eye
section of a further embodiment of a heddle according to the
present invention;
[0026] FIG. 7 illustrates a perspective view of the embodiment of
the heddle illustrated in the partial cross-sectional view of FIG.
4C;
[0027] FIG. 8 illustrates a schematic of a harness frame having
heddles according to the present invention disposed therein;
[0028] FIG. 9A illustrates a side view of a rod slot section of an
embodiment of a heddle according to the present invention; and
[0029] FIG. 9B illustrates a side view of a rod slot section of a
further embodiment of a heddle according to the present
invention.
DETAILED DESCRIPTION
[0030] Reference will now be made in detail to the presently
preferred embodiments of the invention, one or more examples of
which are illustrated in the accompanying drawings. Each example is
provided by way of explanation of the invention, which is not
restricted to the specifics of the example. In fact, it will be
apparent to those skilled in the art that various modifications and
variations can be made in the present invention without departing
from the scope of spirit of the invention. For instance, features
illustrated or described as part of one embodiment, can be used in
another embodiment to yield a still further another embodiment.
Thus, it is intended that the present invention cover such
modifications and variations as come within the scope of the
appended claims and their equivalents. The same numerals are
assigned to the same components throughout the drawings and
description.
[0031] FIG. 8 illustrates a harness frame for use within a weaving
machine. In general, harness frame, generally 10, comprises two end
braces 12 connected to horizontal slat members 14. The harness
frame 10 includes support rods 20 supported lengthwise on the
harness frame 10 by attachments to slat members 14. As is commonly
understood in the art, heddles 16 are supported on support rods 20.
Rod slots 18 on the heddles 16 engage the support rods 20 to
support the heddles 16 within the harness frame 10. The heddles 16
further include yarn eyes 40 through which warp yarns to be woven
into a fabric pass.
[0032] FIG. 1 shows a schematic side view of a single heddle 16.
The body 22 of the heddle 16 is molded and includes an eyelet
section 28 which defines a yarn eye 40 through which a yarn 42
passes. The eyelet section 28 includes eyelet section walls 44
which extend longitudinally on either side of the yarn eye 40. A
first longitudinal section 24 of heddle 16 is disposed on a first
end of the eyelet section 28. The first longitudinal section 24
defines a first rod slot 30 that is distal from the eyelet section
28. The first longitudinal section 24 has longitudinal walls 32 at
one end that define the first rod slot 30 through which an upper
rod 20 of the harness frame 10 can be inserted.
[0033] A second longitudinal section 26 of heddle 16 is disposed on
the opposing second end of the eyelet section 28. The second
longitudinal section 26 also possesses longitudinal walls 36 at one
end that define a second rod slot 34 on an end of the second
longitudinal section 26 distal from the eyelet section 28.
[0034] In accordance with the present invention, the heddles 16 are
formed from a thermoplastic resin material such as a liquid crystal
polymer that can flow easily enough into the mold to create the
desired shape of the heddle 16. At the same time, the desired
liquid crystal polymer must be durable enough to add rigidity to
the heddle 16 as well as a strength and durability that other
plastics do not provide. The liquid crystal polymer provides more
rigid and durable heddles 16 than conventional plastic heddles. In
fact, the heddles 16 molded from the liquid crystal polymer exhibit
similar strength and rigidity characteristics as heddles stamped
out of steel. This added rigidity, strength, and durability
provides a longer lasting heddle that does not wear at the rod
slots 30, 34, or within the yarn eye 40 as easily as other plastic
heddles. Further, the rigidity of the heddles 16 molded from the
liquid crystal polymer prevent the bowing out of the heddles within
the harness frame to allow for more precise weaving and also to
permit the heddles 16 to be handled in a manner similar to steel
heddles, which conventional plastic heddles cannot do. An example
of a suitable liquid crystal polymer is Solvay's XYDAR liquid
crystal polymer grade SRT-900, available from Solvay Advanced
Polymers, LLC of Alpharetta, Ga. (website: solvay.com).
[0035] Preferably, the heddle 16 of the present invention can be
made from unfilled liquid crystal polymer. However, the use of
liquid crystal polymer also permits the insertion of additives
which can be useful within the heddle. For example, additives for
controlling static electricity may be added to the liquid crystal
polymer as it is molded into the heddle 16. Such an additive allows
for easier separation of heddles once they are packed onto a
harness frame. Other additives such as antimicrobial additives,
strengthening additives, or other commonly known additives may be
included or mixed in with the liquid crystal polymer. However, the
additives that are used within the liquid crystal polymer should
not be of a consistency or type which will damage the yarn 42
during use of the heddles 16 within a weaving process.
[0036] A flow modifier may be blended with the liquid crystal
polymer to enhance the material flow properties of the liquid
crystal polymer. The flow modifier helps to increase the ease of
flow of the liquid crystal polymer, thereby permitting an easier
fill of a mold cavity used to mold the heddles. An example of a
suitable flow modifier is Solvay's LCP-1000, available from Solvay
Advanced Polymers, LLC of Alpharetta, Ga. (website:
solvay.com).
[0037] The use of unfilled liquid crystal polymer resins creates a
plastic heddle that has outstanding strength at extreme
temperatures and excellent mechanical property retentions after
extended use and exposure to extreme conditions. Also, the liquid
crystal polymer resins can be easily processed and molded into the
desired shapes and configurations of the heddles. Further, the
liquid crystal polymer resins are exceptionally inert and resist
stress cracking in the presence of most chemicals even at elevated
temperatures. The easy processability of the liquid crystal polymer
resins provides a high melt flow and set up in molded parts. The
properties of the liquid crystal polymer resins are not affected by
minor variations in processing conditions and no post-curing is
necessarily required. The following are test results run on
commonly available samples of Solvay's XYDAR liquid crystal polymer
grade SRT-900 according to ASTM test methods. TABLE-US-00001
Mechanical Properties According to ASTM Tests (Specimen thickness
3.08 mm) Mechanical Property Results ASTM Test Method Tensile
Strength 20,300 psi D638 Tensile Modulus 1,740,000 psi D638
Elongation 2% D638 Flexural Strength 20,600 psi D790 Flexural
Modulus 1,590,000 psi D790 Izod Impact, notched 0.9 ft-lb/in.
D256A
[0038] TABLE-US-00002 Thermal Properties According to ASTM Tests
Thermal Property Results ASTM Test Method Heat deflection 232
degrees C. D648 temperature Processing 330 degrees C.-excellent
Temperature flow for 0.018'' (0.46 MM) wall width of a heddle
[0039] TABLE-US-00003 General Properties According to ASTM Tests
General Property Results ASTM Test Method Specific Gravity 1.38
D792 Water Absorption, 24 hours 0.05% D570
[0040] In the embodiment shown in FIG. 1, the plane in which the
eyelet section 28 resides is turned at an angle relative to the
plane in which the first and second longitudinal sections 24, 26
reside. This twisted eyelet section 28 permits the yarn eye 40 to
open toward the path of warp yarn 42 to allow for easy insertion of
the yarn and to prevent undue wear on the warp yarn 42 through
excessive chafing or other contact with the eyelet section walls
44. As the harness in which the heddle 16 is placed is moved upward
or downward as it rides along a cam, the yarn eye 40 in the heddle
16 will move the yarn 42. More specifically, as the harness frame
rides up the cam, a lower contact surface 27 of the yarn eye 40
contacts the yarn 42 and pushes the yarn 42 upward. Similarly, as
the harness frame rides the down the cam, the upper contact surface
29 of the yarn eye 40 pushes the yarn 42 downward.
[0041] FIG. 2 illustrates a cross-sectional view of the heddle 16
along the FIG. 1 line 2-2, which bisects the eyelet section 28. As
can be seen, the eyelet section 28 resides in a plane that is
turned at a twist angle .alpha. relative to the position of the
plane in which the second longitudinal section 26 resides. As
stated above, the eyelet section 28 is turned at a twist angle
.alpha. to increase the ease in which the yarn 42 may be inserted
therethrough and also to lessen the wear and tear on the yarn 42
during the weaving process. By turning the eyelet section 28 at a
twist angle .alpha., the yarn eye 40 creates a distance W.sub.E
through which the yarn 42 may pass.
[0042] As can be seen in the embodiment shown in FIG. 2, the
portion of the lower contact surface 27 that contacts the yarn 42
within the yarn eye 40 while the yarn 42 is being pushed upward by
the bottom of the heddle 16 is defined by a depth that is
designated D.sub.E. Similarly, the upper contact surface 29 (FIG.
1) has a similar depth D.sub.E (not shown) on the upper portion of
the yarn eye 40 to contact the yarn and push it downward when the
harness frame within which the heddle resides moves downward to
form a bottom portion of a shed during the weaving process. The
depth D.sub.E is slightly greater than the width W.sub.b of the
longitudinal sections 24, 26. The surface area created by the depth
D.sub.E on which the yarn resides during its positioning within a
shed is greater than the width W.sub.b of the longitudinal sections
24, 26 because of the twist imposed by the twist angle .alpha.. In
heddles lacking a twist, the lower contact surface area is
determined by the thickness of the heddle and is more prone to wear
during extended use of heddles made out of other types of plastics.
Such wear creates grooves in the eyelet section of other types of
plastic heddles that lead to greater opportunity to damage the yarn
during weaving. However, the heddle 16 made from a liquid crystal
polymer resin better resists wear on the upper and lower contact
surfaces 29, 27 of the yarn eye 40 within the eyelet section 28,
thereby decreasing the chance of damaging the yarn 42 after
extended periods of use of the heddle 16.
[0043] Depending on the type of fabric to be woven, weavers want to
have the flexibility to include as many ends per inch in a fabric
as possible. To maximize the number of ends per inch, heddles are
often packed tightly together within the harness frame. For this
reason, the twist angle .alpha. at which the eyelet section 28 is
turned should be great enough to create a yarn eye 40 with a width
W.sub.E great enough allow easy insertion of the yarn 42, while at
the same time not causing damage to the yarn during the weaving
process. Further, the width of the heddle W.sub.s should be
minimized to allow as many heddles to be placed on a harness frame
as possible to increase the number of ends per inch that may be
woven. Thus, the twist angle .alpha. should be great enough to
increase the efficiency of the threading of the heddle and to
reduce the wear on the yarn while at the same time minimizing the
increased width of the heddle. The twist angle .alpha. may range
from between about five degrees to about forty-five degrees. A
twist angle .alpha. from about 20 degrees to about 30 degrees is
desirable.
[0044] The eye section can also be formed in a manner consistent
with the heddle eyelet structure disclosed in U.S. Pat. No.
5,348,055, which is hereby incorporated herein by this reference in
its entirety. For example, the eyelet section 28 may also be formed
in a manner so that the heddle includes a substantially flat width
section which is substantially parallel to the warp ends passing
through the yarn eye. The eye may be disposed through the width
section and may be defined by a first side segment and a second
side segment. The side segments are oppositely laterally disposed a
predetermined distance relative to the width section so that a
plane through the eye forms a predetermined angle with the plane of
the width section. The side segments are also formed so that a
plane through each of the side segments also forms a predetermined
angle with the plane of the eye. The side segments can be formed
parallel to the width section.
[0045] As shown in FIG. 5, the heddles 16 that are formed from the
desired liquid crystal polymer may include a sharpened edge 49 that
permits an automatic draw-in machine to select the heddle on the
harness frame during the draw-in of yarn ends through the yarn eye
40 of the respective heddle 16. The sharpened edge 49 permits a
fork-like mechanism on the automatic draw-in machine to engage the
sharpened edge 49, and thereby the heddle 16, to position the
heddle relative to a needle that inserts a yarn 42 through the yarn
eye 40 of the eyelet section 28. While such a mechanism may be
employed on steel heddles, conventional plastic heddles are too
flimsy to allow automatic draw-in machines to engage the heddle in
the same manner. The rigid heddle 16 formed by the liquid crystal
polymer also allows for desorting slots 38 to be molded in both the
first longitudinal section 24 and the second longitudinal section
26 to facilitate the separation of two rows of heddle eyes (duplex
heddles) in preparation for automatic draw-in. Further, the
rigidity of the liquid crystal polymer also allows for the
formation of a porter hole in both the first longitudinal section
24 and the second longitudinal section 26 for insertion of a
handling pin to facilitate handling and shipping of heddles in
stacked relationship.
[0046] The width W.sub.b of the heddle in each of the longitudinal
sections 24, 26 should be relatively thin in order to increase the
number of heddles that will fit side-by-side on a harness. For
example, the width of the heddle may be somewhere around 0.012
inches (0.3 mm) in many commonly used heddles. Such a small
tolerance of the width still allows for a heddle 16 formed of the
liquid crystal polymer to perform many of the same functions as a
steel heddle, which other plastic heddles cannot do. Other larger
widths for the heddles may also be produced using liquid crystal
polymer to form the body of the heddle.
[0047] To prevent the sticking together of the heddles 16 formed of
the liquid crystal polymer once they are placed on a harness frame,
protrusions 48 may be molded at different points along the heddle,
for example at an end near a rod slot 34. As shown in FIG. 5, the
protrusions 48 extend outward from the surface 45 of the heddle 16.
Such protrusions 48 help to prevent the heddle 16 from becoming too
close to a neighboring heddle. The protrusions 48 can be figures,
letters, waves, bends or the like molded within the heddle 16. For
example, the protrusions 48 can be formed as the likeness of a
manufacturer's logo or brand. These protrusions 48 create a
separation between the heddles to allow for easier drawing in of
the yarns through the respective yarn eyes 40 of the eyelet
sections 28.
[0048] Heddles 16 may have different types of rod slots at either
end of the body 22. As illustrated in FIG. 1, the rod slots 34 may
be closed and oblong-shaped, which are commonly referred to as
O-shaped rod slots. The rod slots may also be C-shaped or J-shaped
as illustrated in FIGS. 9A and 9B, respectively. Such C-shaped and
J-shaped rod slots can be easily molded in the heddle using liquid
crystal polymer while still having the rigidity and strength to
engage the rods of the harness frame during extended use within a
weaving machine. FIG. 9A shows an end section of a body 22 of a
heddle 16 comprising molded liquid crystal polymer. A C-shaped rod
slot 134 is defined in an end of a body 22 between first
longitudinal wall 136 and second longitudinal wall 36. The first
longitudinal wall 136 is interrupted to define an opening 135
through which a rod may enter into the rod slot 134. FIG. 9B shows
an end section of a body 22 of a liquid crystal polymer heddle 16
defining a J-shaped rod slot 234 between first longitudinal wall
236 and second longitudinal wall 36. The first longitudinal wall
236 is interrupted to define an opening 235 through which a rod may
enter into the J-shaped rod slot 234. Since the heddles 16
illustrated in FIGS. 9A and 9B are molded from liquid crystal
polymer, the first longitudinal walls 136, 236 of the respective
C-shaped rod slot 134 and J-shaped rod slot 136 may be deflected to
one side to allow the respective heddles to engage the rod. The
respective longitudinal walls 136, 236 should be resilient enough
to resume a position to engage the rod if any portion is deflected.
For the C-Shaped rod slot 134, one or both portions of the
longitudinal wall 136 may be deflectable.
[0049] In accordance with one aspect of the present invention, FIG.
5 shows a further embodiment for the rod slots 34 of the heddles 16
that are molded from liquid crystal polymer. FIG. 5 shows a portion
of a second longitudinal section 26 wherein the second longitudinal
section 26 forms a first longitudinal wall 36 and a second
longitudinal wall 36 that is opposed to the first wall 36. An
O-shaped rod slot 34 is defined between the first and second
longitudinal walls 36, 36'. The second longitudinal wall 36' is
interrupted to define a slit 46 that is configured to allow for
easier installation of the heddle onto the rods of the harness
frame. The slit 46 is defined by opposed free edges of the second
longitudinal wall 36' where wall 36' is interrupted. In the
embodiment shown in FIG. 5, the slit 46 effectively divides the
second wall 36' into a relatively longer leg and a relatively
shorter leg. Since the heddle 16 is made from a liquid crystal
polymer, the second longitudinal wall 36' may be deflected to one
side to allow the heddle to engage the rods of the harness frame in
a similar manner as the C-shaped rod slot or the J-shaped rod slot.
At least the longer leg of the deflected longitudinal wall 36' can
be deflected one way, and the shorter leg can be deflected the
opposite way or remain fixed and undeflected. Once the rod slot 34
is inserted onto the rod, at least the longer leg of the deflected
longitudinal wall 36' is sufficiently resilient so that it
generally resumes its original position, thereby permitting the
heddle 16 to have longitudinal walls 36 and 36' on either side of
the rod that resides in the rod slot 34. In some embodiments, the
legs of the deflecting wall 36' are about equal in length. In some
embodiments, both legs of the deflected longitudinal wall 36' are
resiliently deflectable.
[0050] The use of a thermoplastic polymer to mold the heddles in
accordance with the present invention allows the heddles to be
created in different embodiments. For example, FIGS. 3, 4A, 4B, 4C,
6 and 7 illustrate a portion of a heddle having an eyelet section
50 which has an extended depth D.sub.t as compared to the heddle
illustrated in FIGS. 1 and 2. As seen in FIG. 3 in a plane front
view, a middle portion of the heddle 16 is shown. The heddle 16 has
a first longitudinal section 24 and a second longitudinal section
26 on either side of an eyelet section 50. The first and second
longitudinal sections 24, 26 have a width W.sub.L. The eyelet
section 50 has thickened eyelet section walls 52, 54 as shown in
cross-sectional view of FIG. 4A.
[0051] The cross section in FIG. 4A illustrates that the eyelet
section 50 and the eyelet section walls 52, 54 are thickened in its
depth D.sub.t, while the width W.sub.t of the eyelet section 50 is
no greater than the width W.sub.s of the turned eyelet section 28
of FIG. 2. Such an eyelet section 50 creates a tunnel eye 56 having
a width W.sub.e and a depth equal to the depth D.sub.t thereby
creating an extended contact surface 60. The contact surface 60 may
be substantially larger than the width W.sub.L of the first and
second longitudinal sections 24, 26. For example, the depth D.sub.t
may be one and a half to more than three times larger than the
width W.sub.L of the first and second longitudinal sections 24, 26.
Also, the contact surface 60 is larger than the depth D.sub.e of
the turned eyelet section 28 of FIG. 2. Such a tunnel eye 56 with
its larger contact surface 60 gives more support to the warp yarn
extending through the tunnel eye 56 during weaving and does not
create as large a pressure point in the yarn as the contact
surfaces 27, 29 of the yarn eye 40 shown in FIGS. 1 and 2. The
tunnel eye 56 thereby can further reduce wear and tear on the yarn
passing therethrough as well as wear and tear on the heddle 16
during extended use within a weaving machine. The edges 58 of the
eyelet section walls may be round and smooth to further reduce wear
and tear on the yarn passing through the tunnel eye 56.
[0052] The eyelet section 50 can have different configurations to
improve the insertion of a yarn through the tunnel eye 56. As shown
in FIG. 6, a thickened eyelet wall 53 may be interrupted to form a
gap 62. Each opposed edge of the gap 62 is defined by one of the
opposed, free edges of the eyelet wall 53. The gap 62 may extend
through the thickened eyelet wall 53 and create an opening within
the thickened eyelet section wall 53 that is wide enough to accept
a yarn therethrough so that the yarn may reside in the tunnel eye
56 between the eyelet walls 53, 54. The gap 62 may be biased at an
angle .beta. so as to prevent an inadvertent removal of the yarn
from the tunnel eye 56 during movement of the heddle 16. By having
the gap 62 biased at angle .beta., then during normal operations of
the weaving machine, the yarn would not enter a position that would
permit the yarn to exit through the gap 62. The angle .beta. may
range from about five degrees to about sixty degrees.
[0053] FIG. 7 shows a further embodiment of an eyelet section 50 of
a portion of a heddle 16. The eyelet section 50 has a first
thickened eyelet section wall 52' and a second eyelet section wall
54 with the tunnel eye 56 defined therebetween. The first eyelet
section wall 52' has an indention 64 formed therein to permit
easier insertion of the yarn through the tunnel eye 56. Further,
the indention 64 has a smooth rounded surface which slopes down to
the contact surfaces 60, 60' of the tunnel eye 56. The smooth
surfaces and the curved slopes remove sharp edges that can damage
the yarn during operation of the weaving machine.
[0054] FIG. 4C illustrates a cross-sectional view through the
eyelet section 50 and the tunnel eye 56 shown in FIG. 7. By having
the indention 64 within the first eyelet section wall 52', the
depth D.sub.i which the yarn must pass between both eyelet section
wall 54 and eyelet section wall 52' is greatly reduced as compared
to the cross-section shown in FIG. 4A. By reducing the distance in
which the warp end must pass between the two eyelet section walls,
the efficiency and ability to draw the warp end through the tunnel
eye 56 of the heddle 16 can be increased. Further, by having a
sloping rounded surface 66 forming the ends of the indentions 64,
the yarn is less likely to be damaged during operation of the
weaving machine. Further, by having softened rounded edges 58 at
the ends of the eyelet section walls 52', 54, the warp yarns are
further protected from damage.
[0055] FIG. 4B shows a cross-sectional view of a further embodiment
of an eyelet section 50 forming a tunnel eye 56. In this
embodiment, however, both first eyelet section wall 52' and second
eyelet section wall 54' form indention 64 and indention 68,
respectively, on opposite sides of the eyelet section 50. Such an
embodiment further increases the opportunity for increased
efficiency and drawing in of warp ends through the tunnel eye 56 of
the heddle 16 while still providing an extended contact surface 60
to help support the warp end passing through the tunnel eye 56
during operation. The eyelet section walls 52', 54' should be large
enough to prevent any compromise of the integrity of the heddle 16.
By employing eyelet section walls 52', 54', the depth of the
distance of which the warp end must pass through the first eyelet
section wall 52' and the second eyelet section wall 54' can be
minimized or even possibly eliminated. Such a configuration can
again increase the speed and efficiency of the draw-in of the warp
yarns through the tunnel eyes of the heddles 16. The eyelet section
walls 52', 54' may be sloped in a manner similar to the first
eyelet section wall 52' shown in FIGS. 4C and 7. Again, the edges
58 of the eyelet section walls 52', 54' can be rounded and smooth
to protect the yarn.
[0056] While at least one presently preferred embodiment of the
invention has been described using specific terms, such description
is for illustrative purposes only, and is to be understood that
changes and variations may be made without departing from the
spirit and scope of the following claims.
* * * * *