Fastener with tension indicator

Abstract

A fastener and a strap for mounting to a workpiece are provided. The fastener comprises a tension indicator which is used for indicating the condition that the belt reaches the required tension in the installation process. The tension indicator may be a visual indicator and may include two foldable flaps that are in a first position when untensioned and move to a second position when tensioned.

Description

[0001] This PCT patent application claims priority to U.S. Provisional Patent Application Serial No. 63 / 433,287, filed on December 16, 2022, the entire contents of which are incorporated herein by reference. Technical Field

[0002] Embodiments of the present invention generally relate to installing a strap using a fastener clamping assembly and, more particularly, to a fastener having a tension indicator for visually indicating when a desired tension has been achieved in the strap. Background Art

[0003] Users want to know that when they install a strap and fastener clamping assembly, the strap has the correct holding force and that the installation is consistent between different installers. Some installation tools, such as the model UL 4000-D sold by BANDIT-IDEX, Inc. of Denver, Colorado, are configured to monitor and set the tension applied to the strap during installation. Such automated tools tend to be more expensive than manual tools and are therefore less likely to be used in situations where multiple installers each have their own tool. Because manual tensioning tools are generally rugged and reliable, and were introduced earlier and are less expensive than automated tensioning tools, they are used far more frequently when installing strap clamps. Therefore, there is a need in the market for a way to circumvent the high cost of automated tools and develop a clamping technique that repeatedly and reliably achieves the target holding force using manual tools. This goal is achieved in accordance with embodiments of the present disclosure by incorporating a tension indicator into the design of the fastener rather than into the tool.

[0004] Manual installation tools and procedures using existing strap and fastener clamping devices do not assess or indicate to the user the strap application or retention force achieved as part of the installation. Current clamping device designs and manual installation procedures do not provide installers or users with confidence that the strap is correctly installed. Due to the nature of the tools and installation methods, the installer applies force to the tool, which in turn applies force to the strap and fastener to achieve the target retention (or clamping) force. However, after installation, the retention or clamping force can vary significantly between installers, especially among novice or inexperienced installers. In many cases, there are no obvious visual indicators, such as physical features on the strap or fastener, that clearly indicate whether the strap has been properly installed. Furthermore, current strap and fastener designs used with manual tensioning tools require an installation procedure, which introduces a high degree of variability between users and the potential for over- or under-tensioning. An under-tensioned clamping device may move, vibrate, or provide insufficient retention for the application, while an over-tightened strap may cause the strap or fastener to tear, leading to product failure.

[0005] Referring to FIG. 1 , a manual tensioning tool (Model COO 169) sold by BAND-IT-IDEX, Inc. of Denver, Colorado, is shown. Also shown is a Band-It 3 / 4-inch ear-lock fastener manufactured and sold by BAND-IT-IDEX, Inc., associated with a 3 / 4-inch strap and engaged with the tool. FIG. 3 shows an enlarged view of the fastener. As shown in FIG. 1 , the strap is ready for tensioning. The tool 10 includes a frame 12, a nose 20 attached to the frame, a strap slot 22 located in the nose 20, a clamp 24, a clamping lever 26, and a rotating tensioning handle 28 interconnected to the clamp 24 via a threaded rod 30. After the strap 32, fastener 34, and object to be clamped are positioned correctly, in a first step, the user or installer tensions the strap by rotating the tensioning handle 28 to pull the clamp 24 away from the nose 20. In the second step, as shown in Figures 2A and 2B, with the strap still secured in the tool 10, the tool is rotated away from the user or installer to flip the strap and tool over the buckle. The user also releases the tension handle 28 to release some of the tension in the strap. The excess strap length 32 is then cut off by activating the cutting lever 36. If the buckle includes retaining tabs 38 or "ears," the user then bends two retaining tabs 38 over the free ends of the strap to further secure the strap. If the installer under-tensions the strap in the first step, the target holding force will not be achieved, and the installation will fail. If the installer over-tensions the strap in the first step and fails to release the excess tension in the second step, the strap will typically yield and break when the tool is used to bend the strap around the buckle, resulting in a failed installation. Therefore, the installer must release the strap tension before or as part of the second step. When using a manual tool, the level of tension that should be applied in the first step and the amount of tension that should be released in the second step are not displayed or otherwise quantified to the installer. The correct amount of tension applied and released is learned through experience and repetition, and can vary between installers. Undertensioning is often more concerning than overtensioning because, in most cases, the strap will tear, split, or even break if it is over-tensioned. There is often no visual indication to the installer or inspector when the strap is under-tensioned.

[0006] To address these issues, some current manual tensioning procedures rely on the installer to monitor the movement of a stamped or drawn mark on the strap. When the mark or marker stops moving during the tensioning process, the strap has reached its yield point and should not be tightened further. In practice, tensioning the strap until it stops moving can over-tension the strap and introduce subjectivity into the tensioning process, undermining the goals of consistency and repeatability. To prevent increasing the strap tension or tearing during the second step, installers typically loosen the tensioning handle 28 approximately half a turn while rotating the tool and strap over the fastener before cutting off the excess strap and locking it in place. If this loosening step is performed incorrectly, two consequences can occur. First, if sufficient tension is not removed, the strap may tear on the fastener's teeth, forcing the installer to repeat the entire procedure with a new strap and fastener. Second, the tensioning mechanism may be loosened too much, resulting in insufficient or too low a retention force, preventing the strap from securing the desired component to the target structure, pole, or object.

[0007] In summary, existing designs for strap and fastener clamps for manual tensioning tools do not provide an indicator that proper tension has been achieved and require an installation procedure that is inherently susceptible to user error and incorrect installation. Therefore, there is a need in the strap clamp art for an improved system, method, and apparatus for manually tensioning a strap relative to a fastener and an external object that provides consistency and repeatability among all installers, regardless of experience. Summary of the Invention

[0008] By adding a visual feature to the fastener that yields within a known tension range and provides a predetermined orientation, installers have a non-subjective indicator that the strap and fastener have been correctly installed, with the target retention force to keep the required components in place. With an indicator that proper tension has been achieved, the newly designed fastener eliminates the need for the user to release tension during the turning process, significantly reducing installation variability while improving strap retention. It also provides post-installation visual verification that the installer applied the target minimum force to the strap and fastener.

[0009] For installation, one end of the strap is bent back on itself, forming a loop of strap material. In one embodiment, this loop is wrapped around the front end of the buckle, while the free end of the strap passes through the buckle opening, around the object or objects being bound, and back through the buckle opening again. An automated or manual hand tool engages and pulls the free end of the strap through the buckle opening, adding tension to the strap. To address, or at least reduce, the subjectivity associated with properly tensioning the strap, according to one embodiment of the present disclosure, two metal strips or metal tabs, referred to as wings, are formed at the front end of the buckle and are integrally molded with the buckle. The wings can be coplanar with or slightly above the base of the buckle. The two wings can be asymmetrical, each having a different geometry or made of different materials. It is understood that in other embodiments, the tabs or metal wings can be in a different plane from the base of the buckle. The wings extend outward at an acute angle relative to the centerline of the buckle. In at least one embodiment, the tips of the wings extend outward beyond the side or lateral edges of the strap.

[0010] In one embodiment, a tab is formed at the front end of the fastener, and one or more strap loops are positioned around the tab and through the fastener. The tip of the tab is visible to the installer when the strap is in place. During tensioning, a hand tool pulls on the free end of the strap, moving the strap through the fastener while the one or more strap loops simultaneously move the fastener tab from a first position to a second position. The fastener tab flexes under the compressive force of the one or more strap loops caused by the tension of the hand tool. Increasing the tension in the strap redirects or repositions the tab to the predetermined second position, providing a visual indication that the correct tension has been achieved.

[0011] In another embodiment according to the present disclosure, a single tab or wing is provided near the front end of the fastener. The single tab or wing extends laterally outward from the body of the fastener in a first position at an acute angle relative to the centerline of the fastener. The tip or distal end of the tab or wing may extend beyond the side edge of the strap secured by the tensioning tool. Optionally, the fastener may further include a strap guide extending from the fastener body near the front end for engaging and aligning opposite side or lateral edges of the strap. The guide assists in properly aligning the strap relative to the fastener. The guide may include a chamfered front edge to assist in positioning the strap into the guide.

[0012] In yet another embodiment according to the present disclosure, one or more tension-indicating tabs or wings may include one or more cutouts, indentations, or surface configurations within the geometry of the tab and / or fastener that establish the locations at which the tab or wings will bend or deform when tensioned by the installation tool. The purpose of the specific surface configuration is to create one or more locations at which the tab or fastener deforms, thereby controlling the manner in which the tab bends or deforms. Such surface configurations also help predetermine the location and position of the tab that indicates when the target tension has been achieved.

[0013] In other embodiments according to the present disclosure, the shape of the tab or wing can include an enhancement or extension that helps identify when the proper or desired tension has been achieved. The tab or wing can be shaped or contoured such that one edge of the tab or wing is designed and configured to abut an edge of the body of the fastener, forming a linear interface with parallel abutting edges. In another embodiment, a leg or flange can extend from the body of the fastener or the tab or wing, such that when deformed during tensioning, the leg or flange contacts the body of the fastener (if the leg is formed on the tab or wing) or the tab or wing (if the leg is formed on the body of the fastener), providing a visual indication to the installer that the strap is properly tensioned. If the leg or flange is sufficiently strong, it can also prevent or reduce the possibility of the operator over-tensioning the strap by resisting tension once contact is made between the leg or flange on one side and the fastener or tab / wing on the other side.

[0014] Because the desired tension in the strap can be predetermined by the material properties and geometry of the tab, the tension indicator can be designed to be below the strap's material yield strength. The force the installer applies to the tool to reposition the tension indicator (tab) is correlated to the desired, or target, retention force of the strap and fastener being installed. This allows the installer to skip the subjective step of loosening the tool's tensioning screw while folding the strap onto itself, reducing the likelihood of under-tensioning the strap during installation. Once the indicator is fully activated, the installer can simply fold the strap onto itself, cut it, and lock it into place by bending the fastener's lugs onto the strap. By eliminating the loosening step, retention forces have been shown to be higher and more consistently achieved on average, thereby reducing inter-installer variability. Furthermore, this target retention force is achieved with a lower maximum clamping force, which is beneficial for many potential reasons, including increased safety against strap / fastener damage and tool complexity / strength.

[0015] In yet another embodiment, the locking ears can be configured with an alignment feature that provides a visual indication to the installer that the tension indicator is fully moved to the second or installed position. For example, an extension or nose can be added to at least one of the locking ears to provide a visual line indicating that the tension indicator is in the desired second position. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The accompanying drawings are incorporated in and constitute a part of this specification, illustrate embodiments of the present invention, and together with the general description of the invention given above and the detailed description of the drawings given below, serve to explain the principles of the present invention. It should be understood, of course, that the present invention is not necessarily limited to the specific embodiments shown here.

[0017] FIG. 1 is an isometric view of a prior art manual tensioning tool, strap, and buckle.

[0018] 2A is a side view of the prior art tensioning tool, strap, and buckle of FIG. 1 .

[0019] 2B is an enlarged view of a portion of the tensioning tool, strap, and buckle of FIG. 1 , as labeled in FIG. 2A .

[0020] FIG. 3 is a side view of the fastener shown in FIG. 1 and FIG. 2 .

[0021] Figure 4 is an isometric view of the prior art manual tensioning tool and strap of Figures 1 and 2, with a first embodiment of a fastener according to the present disclosure.

[0022] Figure 5 yes Figure 4 Side view of the tensioning tool, strap, and fastener.

[0023] Figure 6 yes Figure 5 An enlarged view of a portion of the tensioning tool, strap, and fastener, such as Figure 5 Marked in the middle.

[0024] Figure 7 yes Figure 6 A bottom angled view of a fastener with the tension indicator in an untensioned or first state.

[0025] Figure 8 yes Figure 7 An angled bottom view of a fastener with the tension indicator in the second or fully tensioned state.

[0026] Figure 9A yes Figure 6 A top view of a fastener in which the tension indicator is in an untensioned or first state.

[0027] Figure 9B yes Figure 9A Front view of the fastener.

[0028] Figure 9C yes Figure 9A Bottom view of the fastener.

[0029] Figure 10A yes Figure 6 A top view of a fastener with the tension indicator in a second or fully tensioned state.

[0030] Figure 10B yes Figure 10A Front view of the fastener.

[0031] Figure 10C yes Figure 10A Bottom view of the fastener.

[0032] Figure 11A yes Figure 6A top view of a fastener with the tension indicator in an untensioned or first state and with the strap.

[0033] Figure 11B yes Figure 11A Front view of the buckle and strap.

[0034] Figure 11C yes Figure 11A Bottom view of the fastener and strap.

[0035] Figure 12A yes Figure 6 A top view of a fastener with the tension indicator in a second or fully tensioned state and with the strap.

[0036] Figure 12B yes Figure 12A Front view of the buckle and strap.

[0037] Figure 12C yes Figure 12A Bottom view of the fastener and strap.

[0038] Figure 13A yes Figure 6 An isometric top view of a fastener and strap with the tension indicator in an untensioned or first state.

[0039] Figure 13B is a bottom isometric view of the buckle and strap of FIG. 13 .

[0040] Figure 14A yes Figure 6 An isometric top view of a fastener and strap with the tension indicator in a second or tensioned state.

[0041] Figure 14B yes Figure 14A Bottom isometric view of the buckle and strap.

[0042] Figure 15 yes Figure 14A Side view of the fastener and strap.

[0043] Figure 16 yes Figure 4 and Figure 5 Isometric view of a prior art manual tensioning tool and strap with a second embodiment of a fastener according to the present disclosure.

[0044] Figure 17 yes Figure 16 Side view of the tensioning tool, strap, and fastener.

[0045] Figure 18 yes Figure 16 An enlarged view of a portion of the tensioning tool, strap, and fastener.

[0046] Figure 19 yes Figure 16 A bottom angled view of a fastener with the tension indicator in an untensioned or first state.

[0047] Figure 20A yes Figure 16 A top view of a fastener in which the tension indicator is in an untensioned or first state.

[0048] Figure 20B yes Figure 20A Front view of the fastener.

[0049] Figure 20C yes Figure 20A Bottom view of the fastener.

[0050] Figure 21A yes Figure 16 A top view of a fastener with the tension indicator in a second or fully tensioned state.

[0051] Figure 21B yes Figure 21A Front view of the fastener.

[0052] Figure 21C yes Figure 21A Bottom view of the fastener.

[0053] Figure 22A yes Figure 16 A top view of a fastener with the tension indicator in an untensioned or first state and with the strap.

[0054] Figure 22B yes Figure 22A Front view of the buckle and strap.

[0055] Figure 22C yes Figure 22A Bottom view of the fastener and strap.

[0056] Figure 23A yes Figure 16 A top view of a fastener with the tension indicator in a second or fully tensioned state and with the strap.

[0057] Figure 23B yes Figure 23A Front view of the buckle and strap.

[0058] Figure 23C yes Figure 23A Bottom view of the fastener and strap.

[0059] Figure 24A yes Figure 16 An isometric top view of a fastener and strap with the tension indicator in an untensioned or first state.

[0060] Figure 24B yes Figure 24A A bottom isometric view of the buckle and strap with the tension indicator in the second or tensioned state.

[0061] Figure 25A yes Figure 16 An isometric top view of a fastener and strap with the tension indicator in a second or tensioned state.

[0062] Figure 25B yes Figure 25A Bottom isometric view of the buckle and strap.

[0063] Figure 26 yes Figure 25A Side view of the fastener and strap.

[0064] Figure 27A is a top view of a third embodiment of a fastener according to the present disclosure.

[0065] Figure 27B yes Figure 27A Isometric view of the fastener.

[0066] Figure 28A is a top view of a fourth embodiment of a fastener according to the present disclosure.

[0067] Figure 28B yes Figure 28A Isometric view of the fastener. DETAILED DESCRIPTION

[0068] Figure 4-6 A tensioning tool 10 is shown for attaching a strap 102 and a fastener 104 to a workpiece. The tensioning tool 10 can be handheld. A hand tool is shown. In other embodiments, the tool 10 can be powered or automated, or mounted on a fixed structure. Figure 5 and Figure 6 Before or during installation, the installer forms a loop 106 of strap around one end of the strap. One portion 106a of the loop 106 is positioned below the buckle 104. A second portion 106b of the loop includes a bend that wraps around the front end 108 of the buckle 104. A third portion 106c of the loop extends through an opening 110 in the buckle 104, and the other or free end of the strap wraps around a workpiece (e.g., a rod, structure, or one or more objects) and returns again through the buckle opening 110.

[0069] refer to Figure 7-10C The clasp has a base 112 having an upper surface 114, a lower surface 116, and a rear end 118. The opening 110 is formed by the underside of a bridge 122 extending from the upper surface 114 of the clasp 104 (see FIG. Figure 9B 、 10B, 11B and 12B). When tensioning is complete, the bridge portion 122 provides a surface onto which the free end of the strap 102 can be bent or flipped and secured in place by the buckle ears 124. Teeth 126 formed on the front end of the bridge portion 122 help to secure the strap relative to the buckle. Thus, when the strap 102 is installed on the workpiece, the strap 102 is secured to the buckle 104 at both the strap loop 106 and the opposite end. Figure 4 As best shown, the strap loop 106 also includes a tail 106d or free end that is engaged by the tool for tensioning the strap. The clamp 24 of the tensioning tool 10 pulls the free end 106d of the strap 102 through the buckle opening, increasing the tension on the strap 102. Figure 6 As shown, during the tensioning process, the nose 20 of the tool 10 presses against the buckle 104, while the bend 106b in the strap loop 106 pulls on the front end 108 of the buckle 104. To complete the installation process, the tool 10 is rotated away from the installer to bend the free end 106d of the strap onto the bridge 122. FIG2B illustrates the rotation of the tool 10. The lever 36 is activated to sever the free end or tail 106d from the strap 102.

[0070] Figure 7 and Figure 8 The tension indicator 130 of the fastener 104 is shown in an untensioned or first state and a tensioned or second state, respectively. The tension indicator is formed at an acute angle α relative to the fastener centerline c / 1. As shown, the fastener 104 includes a base 112. Figures 9A-9C Also shown is the tension indicator 130 of the fastener 104 in an untensioned or first state. Figures 10A-10C The tension indicator 130 of the fastener 104 is shown in a tensioned or second state. The fastener 104 includes a tension indicator 130 formed from two metal strips or tabs (also referred to as flaps) that are coplanar with or slightly above the fastener base 114. As shown, it will be appreciated that the two strips are symmetrical, but they could also be asymmetrical, have a different number of flaps, or have different geometries, materials, etc. Tension indicator 130 could also include any number of flaps.

[0071] Figures 9A-9C , 11A-11C and 13A-13B illustrate a first embodiment of a buckle 104 according to the present disclosure, wherein the strap 102 and the tension indicator 130 are in an untensioned or first state. In contrast, Figures 10A-10C , 12A-12C and 14A-14B show the strap 102 of the buckle 104 and the tension indicator 130 in the tensioned or second state. Figure 11A 、 11C, 12A, 12C and 13A-14B, the strap loop 106b surrounds the tension indicator 130 and passes through the buckle 104. The bend 106b in the strap loop 106 surrounds the tension indicator 130. During tensioning, the tensioning tool 10 pulls the free end 106d of the strap 102 through the buckle 104 while the nose 20 of the tool 10 abuts or rests against the bridge 122 or the rear end 118 of the buckle 104, or both, as shown. Figure 4-6 As shown. The nose 20 abutting the fastener 104 stabilizes the position of the fastener and enables the tool 10 to tension the strap 102 while remaining in the same or similar position adjacent the workpiece. Thus, as tension increases, the bend 106b of the strap loop 106 is pulled toward the tension indicator 130, and the tension indicator 130 begins to bend or deform under the compressive force of the strap loop 106 caused by the tension of the tensioning tool 10. More specifically, the tension indicator 130 is deformed from a first position (e.g., an untensioned state) to a second position (e.g., a second position) of the strap loop 106. Figure 9A and 11A ) moves to a second position (eg, Figure 10A and 12A In other words, increasing the tension in strap 102 forces tension indicator or tab 130 to transition or move to a predetermined second position, visually indicating that the correct tension has been achieved. In some embodiments, tension indicator or tab 130 is crushed or deformed when moving between the first position and the second position.

[0072] Because the desired tension in strap 102 can be predetermined by the material properties and geometry of tension indicator 108, tension indicator 108 can be designed or configured to change state at a desired tension below the yield strength of strap 102's material. This eliminates the need for initially over-tensioning the strap and the subjective step of loosening or relaxing the tool's tensioning lever when folding or rotating strap 102 onto itself. Once tension indicator 130 is fully activated, the installer can simply fold strap 102 onto itself and flip it over onto bridge 122, cut free end 106d, and lock the strap and fastener in place by repositioning one or more fastener ears 124 onto strap 102. By removing the loosening or tensioning step, retention has been shown to be closer to the target retention force and more consistently achieved, thereby eliminating variability between installers.

[0073] Steering Figure 16-26 , shows a second embodiment of a fastener with a tension indicator according to the present disclosure. More specifically, Figure 16-18The same manual tensioning tool as in Figures 1-6 is shown, but a different fastener is used. As with the previous embodiment, the installer forms a strap loop 106 at one end of the strap before or during installation. One portion 106a of the loop 106 is positioned beneath the fastener 204. A second portion 106b, comprising a bend in the loop, wraps around the front end 208 of the fastener 204. A third portion 106c of the loop extends through an opening 210 in the fastener 204, with the opposite or free end 106d wrapping around a workpiece (e.g., a rod or one or more objects) and returning through the fastener opening 210.

[0074] The details of fastener 204 are Figure 19-26 2. The fastener 204 has a base 212 having an upper surface 214, a lower surface 216, and a rear end 218. The opening 210 is formed by the underside of a bridge portion 222 extending from the upper surface 214 of the fastener 204. When tensioning is complete, the bridge portion 222 provides a surface onto which the free end of the strap can be bent or flipped and secured by the fastener ears 224. Teeth 226 formed on the front end of the bridge portion 222 help to secure the strap relative to the fastener. Thus, when the strap 102 is installed on the workpiece, the strap 102 is secured to the fastener 204 at both the strap loop 106 and the opposite end. Figure 16 As best shown, the strap 102 also includes a tail 106d or free end that is engaged by the tool for tensioning the strap. The clamp 24 of the tensioning tool 10 pulls the free end 106d of the strap 102 through the buckle opening 210, increasing the tension in the strap 102. Figure 18 As shown, during the tensioning process, the nose 20 of the tool 10 rests against the buckle 204, while the bend 106b in the strap loop 106 pulls on the front end 108 of the buckle 204. To complete the installation process, the tool 10 is rotated away from the installer to bend the free end 106d of the strap onto the bridge 222 (see FIG. 2B , which illustrates the rotation of the tool 10 relative to the buckle). The lever 36 is activated to sever the free end or tail 106d from the strap 102.

[0075] and Figure 4-15 The embodiments are different, Figure 16-26 The fastener 204 has a single tension indicator 230. Figure 19 As shown, for example, tension indicator 230 is a single tab or wing extending laterally outward from the buckle, near the front end 218 of the buckle 204. The tension indicator is formed at an acute angle α relative to the centerline of the buckle. Opposite tension indicator 230, and also extending from the buckle near the front end 218, is a guide arm 240. Guide arm 240 includes a guide surface 242 for contacting the side edge 106e of strap 102, as shown in FIG. Figures 22A-23C Compare Figure 24A and 25AWhen the strap 102 is initially tensioned, the side edge 106e of the strap 102 may abut the chamfer 244. Upon further tensioning, the side edge 106e abuts the guide surface 242, which helps maintain the position of the strap 102 relative to the buckle 204 for proper tensioning and proper operation of the tension indicator 230. The guide surface 242 of the guide arm 240 may also include a chamfer 244 to further help properly position the strap relative to the guide surface when the installer initially begins to tension the strap 102 with the tensioning tool.

[0076] about Figure 16-26 In certain embodiments, at least one of the fastener ears 224 may be configured with a nose or extension 250 including a front edge 252 ( Figure 18 、 24A and 25A). Reference Figure 23A When the tension indicator 230 is moved to the second position, the side edge 232 of the tension indicator 230 will be aligned with the front edge 252 of the extension 250 of the ear lock 224 when viewed directly from above. Visual confirmation can be performed before or after the ear lock 224 is bent. The edges 232 and 252 will be visually aligned in a common plane.

[0077] According to a third embodiment of the fastener 304 of the present disclosure, Figure 27A (first untensioned state) and Figure 27B (Second tensioned state). Here, the side edge 350 of the base 312 of the tension indicator 330 includes two contours or notches 352a and 352b, which are used to locate the area or point where the tension indicator 330 will bend when the strap 102 is tensioned. The notches reduce the lateral width of the tension indicator 330 from w1 to w2, thereby defining the location where the tension indicator 330 will bend. In a preferred embodiment, the notches are located where the indicator is expected to deform. The indicator is a moment arm that originates from the center of the top notch or notch. The length of the moment arm can be adjusted to reduce or increase the force required to fold the indicator. By pre-positioning or pre-determining the location where the tension indicator will bend or deform when tensioned, consistent and repeatable tension is achieved from one fastener to the next. Furthermore, the minimum thickness from the top notch to the bottom notch is the effective width of the indicator and also affects the force required to fold the indicator. In the illustrated embodiment, the notch is rounded or has a fixed radius. In the embodiment shown, the diameter is approximately 0.140 inches, which is twice (2X) the thickness of the fastener metal.

[0078] Steering Figure 28A and 28B , showing a fourth embodiment of a fastener 404 according to the present disclosure. Figure 28A A first or untensioned state is shown. Figure 28B The second or tensioned state is shown. Here, Figure 27ABy extending the width w1 by a dimension “x”, the width “w3” of the tension indicator 430 is compared to the tension indicator 330 of FIG. Figure 27A In this embodiment, when the tension indicator moves to the second position ( Figure 28B ), an abutment interface 454 is formed by the two edges 450a and 450b, creating a hard stop that the operator can tactilely detect. This promotes repeatability and consistency between fasteners. Ideally, the tension indicator 430 will move to a second state or position in which edge surface 450a abuts edge surface 450b and forms an interface 454, with the two surfaces being substantially parallel and abutting, as shown in FIG. Figure 28B shown.

[0079] In one embodiment, the fastener material is annealed 201 stainless steel having a thickness of 0.070 inches plus or minus 0.0030 inches. It will be appreciated by those skilled in the art upon review of this disclosure that other metals and alloys having different thicknesses may also be used.

[0080] In one example, assume the target holding force is approximately 400 lbs. Using prior art straps, buckles, and manual tensioning methods, such as those shown in Figures 1-3, the holding force of the strap and buckle combination after installation may vary from 100 lbs (significantly under-tensioned) to 700 lbs. Figure 4-28B For fasteners manufactured with the embodiments of the present invention, the variability in holding force will be improved. For example, the variability in under-tensioning will be reduced and increased to approximately 250 pounds on average, and the upper end tension will be maintained at approximately 700 pounds. Therefore, the average holding force will be increased. For the embodiments of Figures 27 and 28, it is believed that the range of variability in holding force is further narrowed and can be between 300 lbs and 400 lbs using optimized notches or cuts. In other words, the target holding force is more consistently achieved, which is beneficial in increasing the safety factor of the strap and / or fastener and / or reducing the variability in the target holding force. These embodiments demonstrate that appropriate tension has been achieved, allowing the flipping process to be completed without retracting the tension applied by the tool, eliminating a significant source of user-to-user variability.

[0081] By adding a tension indicator 130, 230, 330, and 430 in the form of a visual indicator to fasteners 104, 204, 304, and 404, respectively, which yields within a known tension range and in a predetermined direction, the installer has a non-subjective indicator that the strap and fastener combination has been properly installed with the target retention force to hold the desired component in place. By providing an indication that proper tension has been achieved, fasteners 104, 204, 304, and 404 enable the installation process to eliminate the need for the user to release tension during the flipping process, thereby significantly reducing installation variability. The tension indicator of each embodiment is configured to move from a first position to a second position to indicate that proper tension has been achieved. Optionally, a hard stop may be included as part of the fastener design to provide additional tactile feedback to the installer. Optionally, the tension indicator may be configured to deform or change its shape, i.e., be crushed, when moving from the first position to the second position.

[0082] Although various embodiments of the present invention have been described in detail, it is apparent that modifications and variations of these embodiments will occur to those skilled in the art. However, it is expressly understood that such modifications and variations are within the scope and spirit of the present invention, as described in the following claims.

Claims

1. A fastener configured to interact with a strap to clamp one or more objects, the fastener comprising: a. a base having front and rear ends and upper and lower surfaces; b at least one tab formed at the front end of the base and extending from the base at a certain angle, at least one tab is coplanar with the base; as well as c. a bridge portion extending from the upper surface of the base and forming an opening between the lower side of the bridge portion and the upper surface of the base, d. wherein at least one tab is configured to move between a first position and a second position.

2. The fastener of claim 1 wherein at least one tab lies in a plane different from the plane of the base.

3. The fastener of claim 1 wherein at least one tab is deformable.

4. The fastener of claim 3, wherein the at least one tab is crushed when the at least one tab is deformed.

5. The fastener of claim 1 , wherein the at least one tab comprises two tabs, and the two tabs extend in opposite directions from the front end of the base at an angle relative to a centerline of the fastener.

6. The fastener of claim 5, wherein the angle is the same for each tab.

7. The fastener of claim 1, further comprising a guide arm extending from the front end of the base and laterally spaced from the at least one tab, the guide arm including a guide surface configured to engage a side edge of the strap.

8. The fastener of claim 7, wherein the guide arm has a side edge configured to engage a side edge of the strap.

9. The fastening of claim 8, wherein the side edge includes a first portion and a second portion angled relative to the first portion.

10. The fastening of claim 1 , wherein the at least one tab comprises a body having a first side edge and a second side edge opposite the first side edge, and further comprising at least one notch located along one of the first side edge and the second side edge of the at least one tab.

11. The fastener of claim 10, wherein the at least one notch comprises two notches, the second notch being located along the other of the first side edge and the second side edge of the at least one tab.

12. The fastener of claim 1, wherein the at least one tab contacts the base of the fastener when the at least one tab is moved to the second position.

13. The fastener of claim 1 , further comprising at least one ear lock extending from the fastener, the ear lock having a first portion and a second portion extending from the first portion, the second portion having a front edge, the at least one tab having a side edge, and wherein when the at least one tab is in the second position and the ear lock is unfolded, the front edge of the second portion of the ear lock is coplanar with the side edge of the at least one tab.

14. A combination, a. A fastener having a base having front and rear ends and upper and lower surfaces, at least one tab formed at the front end of the base and extending from the base at an angle, and a bridge extending from the upper surface of the base and forming an opening between a lower side of the bridge and the upper surface of the base; and b. an elongated strap having a first end and a second end, the strap forming a loop at the first end, the loop having a first portion positioned proximate a lower surface of the base of the buckle, a second portion forming a bend in the strap proximate the at least one tab, and a third portion extending along the upper surface of the base and through an opening between the bridge portion and the base of the buckle, wherein the bend surrounds the at least one tab.

15. The combination of claim 14, wherein at least one tab is coplanar with the base.

16. The combination of claim 14, wherein at least one tab lies in a plane different from the plane of the base.

17. The fastener of claim 14, wherein the at least one tab comprises two tabs, and wherein the two tabs extend in opposite directions from the front end of the base at an angle relative to a centerline of the fastener.

18. The fastener of claim 17, wherein the angle is the same for each tab.

19. The fastener of claim 14, further comprising a guide arm extending from the front end of the base and laterally spaced from the at least one tab, the guide arm including a guide surface configured to engage a side edge of the strap.

20. The fastener of claim 17, wherein the guide arm has a side edge configured to engage a side edge of the strap.

21. The fastening of claim 20, wherein the side edge includes a first portion and a second portion oriented at an angle relative to the first portion.

22. The fastener of claim 14, wherein the at least one tab comprises a body having a first side edge and a second side edge opposite the first side edge, and further comprising at least one notch located along one of the first side edge and the second side edge of the at least one tab.

23. The fastener of claim 14, wherein the at least one notch comprises two notches, the second notch being located along the other of the first side edge and the second side edge of the at least one tab.

24. The fastener of claim 1, wherein the at least one tab contacts the base of the fastener when the at least one tab is moved to the second position.

25. A method comprising: a. Providing a first length of strip material having a first end and a second end; b. providing a buckle, the buckle having a base, the base having a front end and a rear end and an upper surface and a lower surface, the buckle further having at least one tab formed at the front end of the base and extending from the base at a certain angle, the buckle further having a bridge portion extending from the upper surface of the base and forming an opening between a lower side of the bridge portion and the upper surface of the base, wherein the at least one tab is configured to move from a first position to a second position; c. positioning the first end of the strap and the first portion of the strap material near the lower surface of the base of the fastener; d. Wrapping the second portion of the tape material around the front end of the fastener to form a loop of tape material, the second portion of the tape material being a continuation of the first portion of the tape material; e. positioning a third portion of the tape material near the upper surface of the base of the fastener, the tape material extending through the opening in the fastener; f. The second end of the strap is wrapped around at least one object and passed through the opening; as well as g. The strap is tensioned using a tensioning tool wherein the tabs deform when the desired tension is reached.

26. The method of claim 25, further comprising providing a second length of strap material and a second fastener, repeating steps a through g with the second length of strap material and the second fastener, and wherein the retention force of the first and second straps tensioned using the first and second fasteners is substantially the same.

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