Insert-Molded Cable Tie With Interlocking Strap
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Solution Overview
Problem
Existing two-piece cable ties have limited load ratings due to issues like strap failure, pawl failure, and insert-mold failure, and are costly to produce, especially when requiring multiple molds for varying lengths and complex mechanical processes.
Innovation Solution
A cable tie design featuring a strap and a front portion made from different plastic materials with enhanced mechanical interlocking elements, such as teeth, holes, and cutouts, to increase the strength of the connection between the strap and the front portion, allowing for higher load ratings without significantly increasing production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If cable ties are formed from two separately molded plastic components, then adaptability for custom lengths is improved, but device complexity increases due to the need for joining mechanisms
Solution Approach 1:
The cable tie is divided into two separately molded components: a head portion and a strap portion. This segmentation allows each component to be manufactured independently using standard molds, enabling adaptability for custom lengths while maintaining manufacturing efficiency. The strap can be produced in various lengths without requiring different head molds.
Solution Approach 2:
The strap end is inserted into a cavity within the head portion, creating a nested structure. This nesting approach provides a compact joining mechanism that reduces overall device complexity while maintaining the benefits of separate component manufacturing. The insert-molded connection integrates the two components into a unified structure.
2Strength
If metal rivets are used to join head and strap portions, then connection strength is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The mechanical riveting process is replaced with an insert-molding process. Instead of using metal rivets that require complex mechanical driving operations, the strap end is directly molded into the head portion cavity. This substitution eliminates the need for secondary joining operations while maintaining connection strength, thereby reducing manufacturing complexity and cost.
Solution Approach 2:
The joining of head and strap portions is merged into a single insert-molding operation. The strap end is inserted into the head cavity before the final molding step, combining the attachment process with the manufacturing process itself. This integration eliminates separate joining steps and reduces overall manufacturing complexity.
3Strength
If insert molding is used to join strap to front portion, then connection strength is improved, but manufacturing cost increases
Solution Approach 1:
The insert-molding process serves multiple functions simultaneously: it joins the strap to the head portion, creates the mechanical interlocking structure, and forms the final integrated component. This multi-functionality reduces the need for separate operations and tooling, thereby offsetting the additional cost of insert molding with efficiency gains.
Solution Approach 2:
The insert-molding process is applied locally only at the connection point between the strap end and head portion cavity, rather than throughout the entire component. This localized application minimizes material usage and processing time, reducing manufacturing cost while maintaining the strength benefits of insert molding at the critical connection point.
Data Source
AI summary
A two-piece cable tie for bundling a plurality of objects, such as cables or wires, includes a front portion that is insert-molded onto a connective segment of a flexible strap, the front portion being constructed out of a higher tensile strength plastic than the strap to maximize the load rating of the tie without significantly increasing material costs. In one embodiment, the connective segment of the strap is shaped to include a pair of opposing semi-circular cutouts in its side rails to enhance the strength of mechanical bonding achieved by the front portion around the strap. In addition, the connective segment is shaped to include a circular hole that is offset longitudinally from the opposing cutouts, the diameter of the circular opening not exceeding 40% of the maximum width of the strap to ensure the integrity and strength of the strap along the entirety of its length.