Hybrid Locking Cable Tie for Low Insertion Force and High Tensile Strength
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Solution Overview
Problem
Current cable ties either achieve high loop tensile strength at the expense of high thread insertion force or low thread insertion force at the cost of lower loop tensile strength, with no in-line threading cable ties meeting the required tensile strength without excessive thread force in the electrical contractor market.
Innovation Solution
A cable tie with a hybrid locking mechanism featuring a hinged locking wedge on one side and a fixed locking wedge on the other, laterally offset, providing increased passline clearance for low insertion force and enhanced tensile strength through a combination of teeth on both sides of the strap body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a fixed wedge locking mechanism is used, then loop tensile strength is improved, but thread insertion force increases
Solution Approach 1:
The locking mechanism is divided into two separate locking wedges: a first locking wedge and a second locking wedge. Each wedge engages with teeth on opposite sides of the strap, distributing the locking function across multiple components rather than relying on a single fixed wedge. This segmentation allows the strap to be engaged gradually from both sides, reducing the peak insertion force while maintaining strong loop tensile strength through dual-side engagement.
Solution Approach 2:
Different regions of the cable tie are given different properties: the first locking wedge is positioned to engage teeth on one side of the strap while the second locking wedge engages teeth on the opposite side. This local differentiation in engagement points allows the strap to be captured progressively, reducing insertion force, while the combined engagement provides superior loop tensile strength compared to single-sided locking mechanisms.
2Force
If a hinged flexible wedge locking mechanism is used, then thread insertion force is reduced, but loop tensile strength decreases
Solution Approach 1:
The invention merges the advantages of both fixed and hinged locking mechanisms by implementing two locking wedges that engage opposite sides of the strap. The combination of dual-sided engagement and the specific geometry of the wedges creates a system that achieves both low insertion force (through progressive engagement) and high loop tensile strength (through balanced locking on both sides), surpassing the limitations of single-sided hinged mechanisms.
Solution Approach 2:
The locking mechanism transitions from single-sided engagement to dual-sided engagement, adding a dimensional aspect to the locking approach. By engaging teeth on both the first and second sides of the strap simultaneously, the system creates a more balanced and effective locking configuration that improves loop tensile strength while maintaining low insertion force through the coordinated action of both wedges.
3Device complexity
If single side teeth engagement is used, then device complexity is reduced, but loop tensile strength is limited
Solution Approach 1:
The engagement function is segmented into two separate locking wedges, each responsible for engaging teeth on one side of the strap. This segmentation, while adding a component, creates a more effective locking system where the combined engagement of both sides provides superior loop tensile strength. The modular nature of the two-wedge system maintains relative simplicity while dramatically improving performance over single-sided engagement.
Data Source
AI summary
A one-piece cable tie, such as an in-line cable tie, includes a hybrid locking mechanism including both a fixed locking wedge and a hinged locking wedge. The hinged locking wedge may be laterally offset from the fixed locking wedge along a longitudinal axis of an internal passageway of the cable tie head. Preferably, the hinged locking wedge is located on a top surface of the passageway while the fixed locking wedge is located on a bottom surface of the passageway. The hinged locking wedge may be located close to the strap ingress. The cable tie is preferably made of Nylon 6.6, yet can achieve both a low thread insertion force and a high loop tensile strength suitable for demanding applications. Maximized strength is achieved through use of multiple teeth on each of the hinged and fixed locking wedges.