Button Head Tie Radial Truss and Wedge Design

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Solution Overview

Problem

Current button head ties are prone to breakage due to bending shear stresses, high stress concentrations from sharp serrations, and limited tensile strength, and they often fail to securely engage the strap due to improper insertion angles and inadequate wedging action, leading to unexpected bundle release.

Innovation Solution

A new button head tie design featuring a thinner, more flexible strap with wider rails and rounded serrations, a straight internal aperture to prevent angled insertion, increased wedge angle, collapsible standoff tabs for easy insertion, and a radial truss structure for enhanced strength, ensuring proper engagement and higher tensile strength.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the tie strap is made thicker to increase strength, then the tensile strength improves, but the strap becomes more susceptible to bending shear stresses and breakage

Engineering Contradiction:

Improvetensile strengthVSAvoidbreakage resistance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent changes the geometric parameters of the tie strap by making it thinner while compensating for strength through the truss work structure in the button head and the engagement geometry between wedge and strap, resolving the contradiction between thickness and breakage resistance

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The button head incorporates a truss work structure that creates a composite-like configuration, combining multiple structural elements (ribs, webbing, hub) to achieve high strength-to-weight ratio and resistance to both tensile and bending loads

Inventive Principle:

Principle #40Composite materials

2Strength

If serrations with sharp corners are used to increase engagement, then the locking capability improves, but stress concentrations increase making the strap more susceptible to breakage

Engineering Contradiction:

Improveengagement strengthVSAvoidbreakage resistance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent applies curvature to the serration geometry, replacing sharp corners with rounded edges. This eliminates stress concentration points while maintaining the interlocking engagement between the wedge teeth and strap serrations, resolving the contradiction between engagement strength and breakage resistance

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Ease of operation

If the button head aperture provides excessive clearance for strap width, then ease of insertion improves, but proper engagement of serrations with wedge teeth cannot be achieved

Engineering Contradiction:

Improveinsertion easeVSAvoidengagement reliability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent introduces asymmetric features in the aperture geometry, including a tapered configuration and positioning elements that guide the strap into the correct orientation. This ensures proper alignment between serrations and wedge teeth while still allowing easy insertion, resolving the contradiction between insertion ease and engagement reliability

Inventive Principle:

Principle #4Asymmetry

4Strength

If the wedge angle is increased to improve wedging action, then the locking capability improves, but the strap insertion force increases

Engineering Contradiction:

Improvelocking capabilityVSAvoidinsertion force

Core Design Contradiction:

StrengthVSForce

Solution Approach 1:

The patent incorporates preliminary action through guide surfaces and tapered entry zones in the aperture that prepare the strap and wedge for engagement. This reduces the peak insertion force required while maintaining the high wedge angle for strong locking capability, resolving the contradiction between locking strength and insertion force

Inventive Principle:

Principle #10Preliminary action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The improved design reduces brittleness and breakage, ensures secure engagement of the strap, and provides higher loop tensile strength, preventing unexpected bundle release and enhancing the overall reliability and structural integrity of the tie.

Implementation Method 1

The wedge also has teeth on it that are functionally adapted to engage with the serrations on the tie strap when the strap is looped back through the aperture of the button head

Methodology Applied

Scientific EffectMechanical interlocking: Mechanical Fastener

Implementation Method 2

the button head is greatly reinforced with a radial truss work structure

Methodology Applied

Scientific EffectTruss structure: Tensegrity

Data Source

PatentUS8281461B2Button head tie

Publication Date: 2012.10.09 HELLERMANNTYTON CORP

AI summary

A button head tie has a button head and a tie strap. The button head is a generally flat member having an aperture for receiving the tie strap. The aperture includes lead-in ramps to facilitate tie strap insertion and is configured to prevent angled tie strap insertion. The tie strap is a flat elongate member having a wedge that is captured within the aperture. The remainder of the strap passes through the aperture. The wedge and strap have teeth and serrations on both sides, respectively, the teeth and serrations being engageable. In use, the strap is looped around a bundle and inserted into the aperture to either side of the wedge. Strap insertion force is reduced by standoff tabs which elevate the wedge out of aperture, temporarily, during installation. When loop tension is applied to the bundle, the wedge is pulled into the aperture, compressively locking the strap.