Cable Tie Locking Head With Metallic Insert
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Solution Overview
Problem
Cable ties made of plastic material fail to maintain integrity and hold when subjected to traction forces above certain thresholds, leading to shearing, tearing, and deformation, which compromises their mechanical performance during wiring operations.
Innovation Solution
A cable tie design featuring a flexible, elastic locking insert with protrusions and saw-toothed ends embedded in the locking head, made through an injection molding process, which enhances the tie's mechanical performance by allowing increased traction forces without deformation or rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a metallic locking plate is driven into the locking head by ultrasound welding, then the cable tie can be produced efficiently, but the tie fails under high traction forces due to shearing, tearing, or deformation of the strip or plate
Solution Approach 1:
The patent changes the geometric parameters of the locking plate, specifically increasing its thickness to 2.5-3.5mm (compared to conventional thinner plates) and optimizing its dimensions to create a more robust structure that can withstand high traction forces without deformation or rotation, while maintaining compatibility with ultrasound welding processes
Solution Approach 2:
The patent employs a composite structure combining a plastic locking head with a metallic locking plate insert. This composite design leverages the advantages of both materials: the plastic provides ease of molding and integration, while the metal plate provides high strength and rigidity to resist traction forces up to 650N without deformation
2Strength
If the cable tie dimensions are kept unchanged, then the existing wiring infrastructure remains compatible, but the traction force capacity is limited and the tie can be ripped or torn
Solution Approach 1:
The patent applies local quality enhancement by concentrating structural reinforcement specifically in the locking head and locking plate regions where strength is most needed, while keeping the ribbon section dimensions unchanged. This allows the tie to maintain compatibility with existing wiring infrastructure while achieving significantly higher traction force capacity through localized strengthening
3Strength
If a thicker and wider strip is used, then the traction force capacity increases, but the complexity of the production process increases due to additional fixing steps
Solution Approach 1:
The patent merges the locking plate fabrication and attachment processes into a single integrated ultrasound welding operation. The locking plate is pre-formed with appropriate thickness and dimensions, then directly welded to the locking head in one step, eliminating the need for separate fixing operations and reducing production complexity despite the enhanced plate dimensions
4Reliability
If the metallic plate is made more robust to prevent deformation, then the tie hold improves, but the risk of shearing and tearing of the strip by the locking plate increases
Solution Approach 1:
The patent optimizes the geometric parameters of both the locking plate and the ribbon interface. The plate thickness is increased to 2.5-3.5mm to prevent deformation, while the plate edge geometry and ribbon engagement features are simultaneously optimized to distribute loads evenly and prevent stress concentration that could cause shearing or tearing of the strip
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 solution significantly increases the traction force capacity of cable ties while maintaining their integrity, preventing deformation and rotation, and simplifies the production process by eliminating the need for additional fixing steps, such as sharpening or welding.
Implementation Method 1
The locking head has been obtained by means of an injection molding process in which a locking plate, made of metallic material, has been incorporated in the body of the locking head
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A cable tie (1) comprising a strip (2) and a strip locking head (3) stably connected to an end of the strip (2) and comprising a structure defining a strip locking passage (4) and strip locking means provided with a metallic locking insert (5) which comprises an annular plate (6) stably incorporated in the strip locking head (3) and a pair of locking plates (7), which sticks out from the annular plate (6), so as to at least partially protrude within said strip locking passage (4); the strip locking head (3) is shaped so as to have a pair of protrusions (8), which are arranged within the strip locking passage (4) underneath the corresponding locking plates (7) and each has a saw toothed end (8a) arranged in contact with a respective locking plate (7) and defining, with the locking plate (7) itself, a stop ratchet (12) capable of preventing the backward motion of the strip (2) in the second direction (K2).