Bi-Level Metal Locking Cleat With Multi-Loop Impulse Resistance
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Solution Overview
Problem
Existing metal locking cleats, such as metal ball locking ties and stainless steel strap cable cleats, face challenges in manufacturing complexity, installation difficulty, and inability to withstand strong impulse forces or short circuit events.
Innovation Solution
A bi-level metal locking cleat with a multi-level housing, a tie body, and a metal locking head, which allows for easy installation by wrapping the tie body around a cable bundle and through the housing, and provides enhanced strength through multiple loops and deformation upon tightening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a bi-level head is used in metal ball locking ties to improve tensile strength, then strength is improved, but manufacturing complexity increases and installation becomes difficult
Solution Approach 1:
The device is divided into separate functional components: a standard-level housing for basic locking function and an extended-level support structure for impulse force resistance. This segmentation allows each part to be manufactured independently using standard processes, avoiding the need for complex bi-level head stamping while achieving the same strength benefits.
Solution Approach 2:
The extended support function is extracted from the head structure itself and placed into a separate extended-level housing component. This extraction simplifies the head design to a standard level while providing impulse force resistance through the extended housing that supports the head during high-stress events.
2Strength
If stainless steel strap cable cleats are used to improve strength and impulse resistance, then strength is improved, but installation difficulty increases
Solution Approach 1:
The tie body is designed to be self-threading through the multi-level housing with no additional tools required. The flexible tie body can be easily manipulated through the extended level and standard level openings, allowing installers to complete the securing operation without specialized tools while maintaining high strength and impulse resistance capabilities.
Solution Approach 2:
The housing is designed with optimized opening sizes and geometries at both levels that facilitate easy threading of the tie body. The extended level provides a larger opening for initial threading, while the standard level provides structural support, creating a parameter configuration that balances ease of installation with mechanical strength.
3Ease of manufacture
If a single-level housing is used to simplify manufacturing, then manufacturing complexity is reduced, but impulse force resistance is insufficient
Solution Approach 1:
The housing is segmented into two distinct levels: an extended level for providing floor support during impulse events and a standard level for basic locking function. This segmentation allows each level to be optimized for its specific function while maintaining manufacturability through standard stamping processes for each component.
Solution Approach 2:
The housing transitions from a conventional single-level structure to a multi-level vertical arrangement, adding the dimension of vertical stacking. The extended level protrudes beyond the standard level to provide enhanced floor support, creating a dimensional solution that improves impulse resistance without requiring complex lateral extensions.
4Strength
If multiple stamping stations and large presses are used to manufacture bi-level heads, then tensile strength is achieved, but productivity decreases
Solution Approach 1:
The device is segmented into separately manufacturable components (housing, tie body, locking head) that can be produced using standard single-station stamping processes. This segmentation eliminates the need for complex multi-station progressive dies and large press beds, allowing parallel production of components and significantly improving manufacturing throughput while maintaining strength requirements.
Data Source
AI summary
A metal locking cleat secures cable bundles while withstanding impulse forces and short circuit events. The metal locking cleat has a housing, a tie body, and a metal locking head. The housing has a top, a bottom, sides, a front, a back, an upper level, and a lower level. The tie body is positioned in the lower level of the housing and the metal locking head is positioned in the upper level of the housing. The tie body wraps around a cable bundle, through the lower level of the housing for multiple loops, through the upper level of the housing, and through the metal locking head to secure the metal locking cleat.