Bi-Level Metal Locking Cleat for Tool-Free High-Force Cable Bundling
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Solution Overview
Problem
Existing metal locking cleats, such as bi-level metal locking ties and stainless steel strap cable cleats, face challenges in installation complexity and require tools for assembly, while also struggling to withstand strong impulse forces.
Innovation Solution
A bi-level metal locking cleat design with a multi-level housing and a metal locking head, allowing easy assembly without tools and featuring a deformable tie body that enhances strength to withstand impulse forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a bi-level head design is used to increase loop tensile strength, then strength is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The housing is divided into two distinct levels: an upper level that receives the locking head and a lower level that receives the tie body. This segmentation allows each level to be optimized independently for its specific function while simplifying the overall manufacturing process compared to a single complex bi-level head.
Solution Approach 2:
The invention transitions from a two-dimensional bi-level head design to a three-dimensional multi-level housing structure. The housing extends vertically with distinct upper and lower levels, providing spatial separation of functions while maintaining structural strength without requiring complex progressive die stamping.
2Strength
If a progressive die with multiple stamping stations is used to manufacture the bi-level head, then strength is improved, but manufacturing complexity and equipment requirements increase
Solution Approach 1:
The manufacturing process is segmented into separate steps for the housing and the locking mechanism components. The housing can be formed using simpler stamping or casting processes, while the locking head and tie body are manufactured independently and assembled, eliminating the need for complex multi-station progressive dies.
Solution Approach 2:
The invention combines the functional benefits of a bi-level head with a modular assembly approach. Rather than forming the entire complex structure in one progressive die, the design merges simpler manufacturing processes for individual components that are then assembled, reducing equipment requirements while maintaining strength.
3Strength
If threading is required to secure the locking head, then strength is improved, but ease of operation decreases
Solution Approach 1:
The tie body serves a dual function: it provides the locking mechanism and simultaneously acts as its own installation tool. The free end of the tie body is used to thread through the locking head and secure it in place, eliminating the need for separate threading tools or complex threading operations.
Solution Approach 2:
The tie body is designed to perform multiple functions: it wraps around the load, provides the locking engagement, and serves as the installation tool for securing the locking head. This multi-functionality simplifies the installation process while maintaining strong locking engagement.
4Strength
If stainless steel strap cable cleats are used to withstand impulse forces, then strength is improved, but ease of operation decreases due to tool requirements
Solution Approach 1:
The tie body is designed to be self-installing without requiring external tools. The free end of the tie body is used to manually thread through the locking head and secure it, enabling installation in confined spaces while maintaining the strength to withstand impulse forces such as short circuit events.
Data Source
Figure 1A~1B
Figure 2
Figure 3
AI summary
A metal locking cleat (50) secures cable bundles while withstanding impulse forces and short circuit events. The metal locking cleat has a housing (60), a tie body (130), and a metal locking head (100). The housing has a top, a bottom, sides, a front, a back, an upper level, and a lower level. The tie body is positioned in the lower level of the housing and the metal locking head is positioned in the upper level of the housing. The tie body wraps around a cable bundle, through the lower level of the housing for multiple loops, through the upper level of the housing, and through the metal locking head to secure the metal locking cleat.