Dissimilar Material Barb Cable Tie Design
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Solution Overview
Problem
Conventional cable ties made from a single material have limited hold strength due to the material strength of the locking mechanism being compromised by the need for flexibility, and two-piece cable ties with steel barbs require a sensitive insertion process that can be affected by environmental factors and are undesirable in some applications.
Innovation Solution
A cable tie design featuring a barb made of a harder material, such as glass-filled nylon or hard plastic, embedded within a body made of a flexible material like nylon, where the barb is constrained to allow rotational movement and is molded over the body using a multi-shot injection molding process, eliminating the need for sensitive steel barb insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single material is used for the entire cable tie, then the manufacturing process is simple, but the holding strength is limited due to the need to compromise material strength for flexibility
Solution Approach 1:
The cable tie is divided into two distinct segments: a flexible body portion and a harder locking mechanism (barb). The body is made of a flexible material that allows easy insertion, while the barb is made of a harder material that provides superior holding strength. This segmentation allows each part to be optimized for its specific function without compromising the other.
Solution Approach 2:
The cable tie employs composite construction by combining two different materials: a flexible polymer for the body and a harder material (such as glass-filled nylon or hard plastic) for the barb. This composite approach enables the cable tie to simultaneously achieve flexibility for insertion and high strength for locking, resolving the contradiction between ease of manufacture and holding strength.
2Strength
If steel barbs are used in two-piece cable ties, then the holding strength is improved, but the insertion process becomes sensitive to environmental factors and is undesirable in some applications
Solution Approach 1:
The material of the barb is changed from steel to a harder polymer or plastic material. This parameter change maintains the holding strength advantage of steel barbs while eliminating the sensitivity to environmental factors (moisture, temperature variations) that affects steel insertion. The harder polymer barb provides consistent performance across different environmental conditions.
Solution Approach 2:
The patent replaces expensive and sensitive steel barbs with more economical and environmentally stable polymer barbs. While steel provides high strength, the polymer material offers sufficient holding strength while being less sensitive to environmental factors and more suitable for disposable or single-use applications where insertion reliability is critical.
3Strength
If a harder material is used for the barb, then the holding force is increased, but the flexibility of the cable tie body is compromised
Solution Approach 1:
The cable tie is segmented into a flexible body portion and a rigid locking portion (barb). The body is made of a soft, flexible material that can be easily bent and inserted, while the barb is made of a harder material that provides the necessary holding force. This segmentation allows each part to have the optimal material properties for its function without compromising the other.
Data Source
AI summary
A cable tie includes a body of a first material molded over at least one barb of a second material. The body includes a head section configured to secure the barb in a configuration that permits rotational movement of the barb, permit insertion of a tail section into the head section, and prevent extraction of the tail section from the head section by engagement of the barb. In one implementation, the cable tie is manufactured using a multi-shot molding process.