Lashing support spacer tie

A one-piece lashing support spacer tie for securing two elongate articles or bundles in a parallel, spaced apart relationship is provided with a strap flexibly coupled to a head. The head is provided with a plurality of strap slots and passages through which to receive the strap. One of the strap passages mechanically engages the strap to prevent movement of the strap in at least one direction when in use, such as with a pawl physically engaging one or more serrations or teeth provided on the strap. The other strap slot may mechanically engage the strap in a similar manner, or the other slot may be provided with structure to establish one or more slidable, frictional engagements with the strap when it is inserted therethrough.

BACKGROUND OF THE INVENTION

The present invention relates generally to lashing support spacer tie devices. Such devices secure two elongate articles or bundles in a parallel, spaced apart relationship. The invention relates more specifically to systems and methods for securing a co-axial cable to an elongate support structure such as an aerial support cable in overhead locations.

Often times it is desirable to support a single wire, a bundle of wires, co-axial cable, or other elongate items by an offset distance from a suspended aerial support cable. SeeFIGS. 1 through 5which depict the installation and securement of a coaxial cable to an aerial support cable.

Some prior systems for performing this function are known to provide a plurality of separate and discrete stackable saddle spacers. See, for example FIGS. 1 and 8 in U.S. Pat. No. 4,562,982 (McSherry, et al.). These spacers positioned between the coaxial cable and aerial support cable and provide an offset spacing from the aerial support cable using a conventional metal or plastic cable tie, bundle tie, or zip tie. There are disadvantages of the prior art separate stackable saddle spacers including complicated assembly installation onsite in a telescoping boom bucket aerial lift truck. Multiple components must be threaded together with a cable tie surrounding two loosely spaced heavy cables, shown inFIG. 26, while holding the stackable saddle spacers against and in alignment with the cables. The cable tie is then tightened in order to compress the bundle while maintaining the alignment of the separate spacers and cable tie. In addition, installers are required to purchase and maintain an inventory of stackable saddle spacers and cable ties, and have available each component, for assembly, in the boom bucket of the aerial lift truck.

Another prior device shown in U.S. Pat. No. 3,654,669 (Fulton) includes a spacer and cable tie molded separately, whereby the cable tie is preassembled to the spacer by the manufacturer to provide an easier-to-use sub-assembly for the installation; however, some limitations exist. To determine the direction of inserting the strap into the locking frame to create loops around the bundles, the installer must locate published directions, and read and follow the prescribed procedure (or use trial and error until the correct assembly method is accomplished).

This and other prior art devices have other shortcomings including the tail of the strap is difficult to grasp and pull through the spacer, with a thumb and forefinger, because the strap tail contains all smooth surfaces. This becomes increasingly more difficult when larger bundle diameters are attempted to be secured (when there is not much excess strap to grasp). If attempted to be used in overhead aerial co-axial cable support applications (as depicted inFIG. 1throughFIG. 5herein) and to tension the encircled cables, this device requires the installer to pull the tail of the strap in an upward direction which is much more difficult compared to pulling downward. Additionally, the spacer design does not provide a cradle or saddle surface for the bundles to nest or reside in resulting in a loose separation between bundles, shown in FIG. 5 and FIG. 6 in U.S. Pat. No. 3,654,669 (Fulton), which allows the bundles to pivot at each installed device and further the bundles can “snake” (twist & turn) out of alignment with respect to each other in between each installed device.

Further, another prior art device is shown in U.S. Pat. No. RE31,689 (Bulanda et al.). This cable tie is a single molded component containing an integrally molded spacer with a locking pawl; however, many limitations exist. In overhead aerial co-axial cable installations (as again depicted inFIG. 1throughFIG. 5herein) to tension the encircled cables, this device requires the installer to pull the tail of the elongated strap in an upward direction which is more difficult compared to pulling downward. The advantage to pulling downward is the installer uses his or her body weight (and gravity) to secure the cables. This device further requires a pliers tool, (see FIG. 6C of U.S. Pat. No. RE31,689) to obtain leverage for final tensioning. Tensioning and cutting off excess strap length with a common cable tie tension and cutoff tool is not possible with the protruding teeth on the device's strap. The large teeth on the outside of the strap contain geometry that may contribute to critical stress which cause stress whitening when the strap is flexed adjacent to the large teeth. Further, the large teeth on the outside of the strap limit/restrict the use of this device with the aforementioned prior art stackable saddle spacers because the large teeth tend to jam against interior edges of stackable saddle spacers. Also, the large teeth on the outside of the strap snag and get caught on adjacent components and passages when using this device on harnesses whereby the harnesses are routed and pulled through equipment, automobile chassis, appliances, aircraft fuselage, etc. The first bundle to be secured is limited to a small bundle diameter due to the small narrow edges of the pair of leg members and the location of the strap attachment to the spacer. This device design does not contain an end wall for reinforcement and there is no broad supporting saddle surface on either side of the spacer that contacts the secured cables or bundles; this structurally limits reinforcement strength of the spacer for use in bundle-to-spacer-to-bundle (sandwich) compression applications. The elongated strap cross section profile does not provide enough surface area to allow long lengths of plastic resin to flow though; therefore, the device is limited to short strap lengths which limits both of the bundle diameter sizes that are attempted to be secured.

SUMMARY OF THE INVENTION

The present invention solves all the aforementioned issues. The lashing support spacer tie provides permanently engraved assembly instructions adjacent each passage opening in the head guiding the installer where to insert the elongated strap into the head and the order for inserting the strap to provide the first bundle loop and second bundle loop. The tail of the strap is easy to grasp and pull through the head, with a thumb and forefinger, because the strap tail contains conical protrusions on both sides of the tail end which provide a highly frictional engagement while grasping between the thumb and forefinger. This is especially beneficial when larger bundle diameters are being secured (when there is not much excess strap to grasp). For overhead aerial co-axial cable installations, as depicted inFIG. 1throughFIG. 5herein, to tension the encircled bundles, this device allows the installer to pull the tail of the strap in a downward direction. This allows the installer to use his or her body weight (and gravity) to lower repetitive physical energy/effort. This device includes an optional friction tab that engages the elongated strap after the first bundle is circumferentially wrapped and passed into the head which frees up the installer's hands after circumferentially looping the strap around the first bundle. The length of the friction tab is adjusted to allow the strap to be withdrawn or released by applying a higher extraction force on the strap; this enables the installer to add more wires, cables, or other elongate items to the first bundle during assembly. The head design provides opposing “V” shaped saddle surfaces for the elongate articles or bundles of articles to nest or reside in when the strap is tensioned around the encircled bundles. The saddle surfaces also align the bundles with each installed device. This device can be installed by hand and further precisely tensioned and excess strap cutoff with a common cable tie tension & cutoff tool. The exterior strap surface is substantially flush with non-protruding teeth thereby introducing no critical stresses into the elongated strap. Further, since the overall strap surface is substantially flush with non-protruding teeth on the exterior, there are no protruding teeth to catch or snag on adjacent components or in passages. This device is capable of securing a large range (from 0.25 inch to 4.50 inch combined diameters for both bundles) of bundle diameters on either side of the substantially “V” shaped saddle surfaces. Each of the first and second opposing saddle surfaces provides high compressive strength with its broad bundle contact surfaces and “I” beam internal reinforcement. The elongated strap cross section profile is conducive to allowing long lengths of plastic resin to flow though the manufacturing mold; therefore, the device is available in long strap lengths which thereby enable securing larger bundle diameter sizes. Also since the overall strap surface is flush with non-protruding teeth, this invention allows the addition of stackable saddle spacers to add more bundles in the aligned spacing arrangement or increased spacing of the bundles. The assembly strength of this device is 120 lbs which is sufficient strength for aerial co-axial cable support applications subjected to weather extremes. Likewise the 120 lbs assembly strength of this device is suitable for use on heavy harnesses whereby the harnesses are routed and pulled through equipment, automobile chassis, appliances, aircraft fuselage, etc. The major advantage of this invention is that this device is a single injection molded component that does not require the additional time and cost of sub-assembly and provides all the aforementioned performance attributes.

In addition the present invention is not limited to securing co-axial cable to aerial support cables. Other applications may be accommodated such as securing and separating parallel bundles for the purpose of electrical separation to prevent cross conduction in copper wiring, securing and separating electrical wires from grounded plumbing lines, separation for static noise or interference reduction for routing wires to-and-from electronic equipment, thermal separation in air conditioning Freon lines from high temp water hoses, securing and separating a bundle running parallel to a rod like support, and in the horticulture industry, securing and separating a young transplanted tree to a support post.

Embodiments according to the present invention provide for an improved component, manufacturing process, procurement, distribution, replacement, and installation assembly method related to securing and spacing a bundle to another bundle or an elongate support structure.

An elongate lashing support spacer tie is provided with a strap flexibly coupled to a saddle spacer head. The saddle spacer head is provided with a plurality of strap passages or slots through which to receive the strap. At least one of the strap slots mechanically engages the strap to prevent movement of the strap in at least one direction when in use, such as with a pawl physically engaging one or more serrations or teeth provided on the strap. The other strap slot may mechanically engage the strap in a similar manner, or the other slot may be provided with structure to establish one or more slidable, frictional engagements with the strap when it is inserted therethrough. The head is provided with top and bottom saddle surfaces having transverse valleys, preferably defined by an angular intersection of at least two substantially planar wall sections. While the angular intersection of the top and bottom valleys may be substantially similar or identical, the depths of the valleys may be different, such as the top being shallower than the bottom, to help accommodate elongate articles of different diameters.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Turning now to the figures,FIG. 6throughFIG. 15, shows a first embodiment of a cable tie100according to the present invention. The tie100extends from a first end102to a second end104, and includes a strap110and a spacer head150, which are preferably formed as a unitary member. The strap110extends from the first end102towards the spacer head150, and may be formed as a generally substantially planar strap along a strap length112and having a strap width114. The strap110preferably has a gripping portion116and a securing portion118. The gripping portion116extends from the first end102along a gripper length116atowards the securing portion118having a first strap thickness120. The gripping portion116preferably includes a gripping tab122disposed at the first end102, the tab122being preferably having the first strap thickness120and extending from the remainder of the gripping portion116at an angle124of between about thirty degrees to about sixty degrees, and more preferably about forty-five degrees. The gripping portion116preferably includes at least one, but preferably a plurality of gripping elements126disposed on at least one of a top surface116band a bottom surface116cof the gripping portion116. The gripping elements126may be formed as conical or domed projections, preferably of the same material as the gripping portion116.

The securing portion118of the strap110is preferably disposed along the strap110and between the gripping portion116and the spacer head150. The securing portion118extends along a length118a, from the gripping portion116towards the spacer head150. The securing portion118generally includes a top surface118band a bottom surface118c, separated by a maximum thickness118d. The maximum thickness118dis preferably provided at least along longitudinal edges of the securing portion118, such as along parallel rails128. Disposed preferably at least substantially perpendicular to and between the securing rails128is at least one, but more preferably a plurality of, an engagement teeth or serrations129. Each engagement tooth129is preferably provided with a sloped leading edge129aand a trailing edge129b, which is substantially perpendicular to the securing portion length118a.

As indicated, the strap110is preferably coupled to the spacer head150. While a variety of coupling arrangements are possible, a preferred coupling member includes a yoke130, extending between and coupling the strap110and the spacer head150. The yoke130preferably includes a first yoke arm132and a second yoke arm134coupled to the strap110, generally in a “Y” or “V” formation. The yoke130extends along a yoke length130a, measured parallel to a longitudinal orientation of the strap110, and is provided with a top surface130band a bottom surface130cseparated by a yoke thickness130d. The yoke thickness130dmay be substantially uniform throughout the yoke shape, but preferably the yoke130has an area of reduced thickness or web136disposed between the first yoke arm132and the second yoke arm134. This area of reduced thickness or web136is preferably not attached to the spacer head150.

Turning now to the spacer head150that is coupled to the strap110, the spacer head150generally includes a plurality of head sidewalls, which are preferably of at least substantially similar thickness T which helps during the manufacturing process. The sidewall thickness T may be substantially similar or identical to the maximum strap thickness118d. The head150extends along a head height.151measured perpendicular to the head medial plane164. The plurality of sidewalls includes a front sidewall152, a rear sidewall154, a bottom sidewall156and a top sidewall158. All four of the sidewalls preferably scan a head width160between lateral head sides162L and162R disposed preferably perpendicular to a head medial plane164. The front sidewall152is disposed closest to the strap110, and includes a first substantially planar front surface152a, preferably parallel to the head medial plane164and perpendicular to the strap110during forming, and a second substantially planar front surface152bextending angularly from the first surface152atowards the top sidewall158and sloped towards the head medial plane164. The first front surface152ais preferably spaced from and not connected to the strap110, the yoke130, or the bottom sidewall156. Rather, the first surface152ais preferably provided with a flexion gap166which allows the yoke arms132and134and/or the bottom sidewall156to flex with respect to the spacer head150.

The rear sidewall154is disposed furthest from the strap110and preferably forms the second end104of the device100. The rear sidewall154includes a first substantially planar rear surface154a, preferably parallel to the head medial plane164and perpendicular to the strap110during forming, and a second substantially planar rear surface154bextending angularly from the first surface154atowards the top sidewall158and sloped towards the head medial plane164.

The bottom sidewall156scans a bottom head length168, preferably as an extension of the yoke130. The bottom sidewall156may be provided as a first bottom sidewall156L and a second bottom sidewall156R, which have coplanar wall sections156a,b. The first wall section156aextends from the second end104towards the head medial plane164, and the second wall section156bextends from the first section156atowards the yoke130and is preferably integrally formed as an extension of each yoke arm132,134. A reinforcement rib156cmay be coupled between and formed integrally with two or more of the sections156a,b. The first sections156aare preferably provided with an extension of the flexion gap166provided through the first front sidewall surface152a. Each first section156ais preferably disposed in an angular arrangement with respect to a second section156bat an obtuse angle156dof less than 180 degrees.

The top sidewall158spans a top head length169, preferably centered over the head medial plane164. The top sidewall158may be provided as a first top sidewall158L and a second top sidewall158R, which have coplanar wall sections158a,b. The first wall section158aextends from the rear sidewall154towards the head medial plane164, and the second wall section158bextends from the first section158atowards the front sidewall152. A reinforcement rib158cmay be coupled between and formed integrally with two or more of the sections158a,b. Each first section158ais preferably disposed in an angular arrangement with respect to a second section158bat an obtuse angle158dof less than 180 degrees. In this embodiment, the angle156dformed by the bottom sidewall156and the angle158dformed by the top sidewall158are substantially similar or identical, whereas the top head length169is shorter than the bottom head length168.

Generally, the head150is adapted to receive the strap110through one or more strap slots. Preferably provided are two slots, a rear strap slot170and a front strap slot172. The rear strap slot170extends through the head150between the head medial plane164and the rear sidewall154, through a bottom opening170aformed through the rear sidewall154and/or the bottom sidewall156, and a top opening170bformed through the rear sidewall154and/or the top sidewall158. In this embodiment, the rear strap slot170preferably provides one or more frictional engagements with a strap110inserted therethrough. A first frictional engagement may be provided by at least one contact point. A contact point is provided by an edge of the reinforcement rib158cat or near a top surface of the top sidewall158, the second contact point to slidably receive the preferably smooth bottom surface118cof the strap118.

Regarding the mechanical engagement member in the rear strap slot170, a pawl member194extends into the slot170towards the head medial plane164, depending from the rear sidewall154. The pawl member194is adapted to engage one or more of the teeth129provided on the top surface118bof the strap118bto substantially impede movement of the strap118in one direction in the slot170. Thus, in this embodiment100, while a frictional engagement may still be provided in a variety of fashions as described above, the pawl member194may provide a mechanical engagement with the strap118.

A mechanical strap engagement is provided within the front strap slot172, which includes a top opening172aand a bottom opening172b. That is, not only may there by frictional engagement, but there is a locking mechanical engagement that occurs to prevent motion of the strap118within the slot172, at least in one direction. The mechanical engagement is preferably provided by a toothed pawl186coupled to the front sidewall152by a living hinge188. The pawl186may cooperate with the bunton184to pinch the strap118therebetween after the strap118has been inserted into the top opening172aand the pawl186has become engaged with one or more of the engagement teeth129provided on the top surface118bof the strap118. Also preferably provided in the front strap slot172are one or more strap feeding rails190, which serve to guide the first end102outward from the head150in a convenient manner to be grasped by a human hand or a bundle tie tensioning tool (cable tie tension and cut off tool).

Turning now toFIGS. 13-15, the embodiment100may be seen in use. InFIG. 8, the bottom sidewall156of the head150has been placed against an elongate article or bundle of articles10(shown in phantom for ease of illustration) and the strap118has been inserted through the rear strap slot170and held in the slot170through frictional engagement as described above. Additionally or alternatively, the strap118may be inserted through the slot170prior to being placed around the elongate article10. Regardless, the frictional engagement provided in the slot170on the strap118may be advantageous for temporary positioning of the tie100, as the engagement is preferably completely reversible, simply by pulling the head150away from the article10, or pulling on the strap118along its length112with sufficient release force. When the strap118is engaged in any of the three mentioned frictional engagements it is preferable that the release force required to release the strap118from such engagement is greater than any longitudinal force that may be exerted by the spring force of the strap118, itself, such that the strap118remains frictionally engaged after placement about an elongate object10. Such continued frictional engagement may provide a positionable circumferentially or longitudinally slidable engagement, as further described below.

Once a support structure, such as a suspended cable20, is identified and the tie100or several ties100have been positioned about one or more elongate objects10and the strap18is frictionally engaged within the rear strap slot170, the strap118can be positioned about the support structure20and through the front strap slot172and mechanically engaged therein by the pawl186cooperating with the bunton184, as shown inFIGS. 9 and 10. In this fashion, the top sidewall158of the head150is drawn into secure abutment with the support structure20as the strap118is pulled further through the front strap slot172. Once a desired securement has been attained, the elongate article10will be spaced from the support structure20by a spacer height192, and the strap118may be severed near the outside of the head150, proximate the front sidewall152, to remove any undesirable length thereof.

Turning now toFIGS. 16-22, a second embodiment200of a bundle tie according to the present invention is shown, where similar reference numerals refer to similar or identical structure when compared to the first embodiment100, and the description above should be referenced with respect thereto, unless contradictory description is provided below. In this embodiment200, however, there are a few differences from the first embodiment, namely front and rear sidewall profile shapes, additional top sidewall coplanar sections, and a mechanical engagement member disposed within the rear strap slot.

With respect to front and rear sidewall profiles of this second embodiment200, the front sidewall252and the rear sidewall254are preferably provided as substantially planar sidewalls extending parallel to the head medial plane264. With respect to the top sidewall258of this embodiment200, the top sidewall258is provided with a pair of third coplanar wall sections258edisposed on opposite sides of the head medial plane and joining a respective first coplanar wall section258aand the rear sidewall254, and second coplanar wall section258band the front sidewall252. The third coplanar sections258eare preferably disposed at least substantially perpendicular to the head medial plane264.

Regarding the mechanical engagement member in the rear strap slot270, a pawl member294extends into the slot270towards the head medial plane264, depending from the rear sidewall254. The pawl member294is adapted to engage one or more of the teeth229provided on the top surface218bof the strap218bto substantially impede movement of the strap218in one direction in the slot270. Thus, in this embodiment200, while a frictional engagement may still be provided in a variety of fashions as described above (such as along a friction line278), the pawl member294may provide a mechanical (or higher frictional) engagement with the strap218.

As can be seen inFIGS. 23-25, when the strap218is inserted into the rear strap slot270, it is mechanically engaged by the pawl member294therein. InFIG. 18, the strap218has been so engaged, and it may be tightened to a preferred tension about the elongate article10. The preferred tension may statically hold the strap218about the article10, may maintain a positionable, circumferentially or longitudinally slidable engagement between the strap218and article10, or may maintain the strap218in a loose loop about the article10. It is to be understood that the positionable slidable engagement and loose loop are to be distinguished as follows: if the strap218is placed about the article10and the article10is positioned longitudinally vertically, the strap218will maintain its position on the article10in the positionable slidable engagement, whereas in the loose loop arrangement, the strap218would slide freely along the article10simply by the force of gravity.

AS best shown inFIGS. 8 and 9andFIGS. 18 and 19(as well asFIGS. 6 and 16), indicia144and244are provided to direct the user as to the order of strap100insertion into spacer head150. This eliminates the need for the user to consult with written instructions or to engage in trial and error installation techniques.

Embodiments of devices according to the present invention are preferably formed as unitary members that are injection molded or otherwise molded from a desirable material, such as a plastic material. As a unitary member, the devices provide easier installation than prior devices, allowing a sole person to temporarily place the device about an elongate article (e.g. with two hands) and then elevate and support the elongate article with one hand while finalizing installation on, coupling to, or support on a support structure (e.g. an aerially supported cable) with the other hand. Integral double “V” saddle structures with a strap emanating in an outward projection provided the single part unitary construction and the “snowman” shape, strap routing profile, thereby circumferentially securing (compressing) the bundles against the double “V” saddles.

The cable routing direction allows for pulling downward on the strap for the final loop securing of the lashing support spacer tie. This is more ergonomic (pulling with gravity) Bundles are secured within the centerline of the saddle structure by means of bifurcated strap that is attached near the midpoint bottom of the saddle.

When small bundle diameters are secured, in the lower saddle, the bifurcated strap section pulls away from the lower saddle and provides tight circumferential secure bundling of the coaxial cable (or other wiring or elongate items), self-centering of the bundle against the saddle (pulls the bundle into the “V” notch saddle which in turn is aligned with the supporting support cable above).

Further, the bifurcated “Y” section adjusts to larger diameter coaxial cables (or other wiring or elongate items) and the bundle will remain centered in the “V” notch saddle. The bifurcated strap thickness is reduced at the inside “Y” section which provides clearance for the strap tail exit. The reduced bifurcated “Y” section provides an unrestricted area to deflect the strap tail, into the installers grasp, for ease of strap pull through. The reduced bifurcated “Y” section deflects the strap tail, into the installers grasp, for blind installations (overhead installation or above Installers eyes). The reduced bifurcated “Y” section maintains flexibility to enable circumferentially securing smaller bundle diameters. The bifurcated strap “Y” section contains an opening in the upper “Y” section, = yet is designed to maintain the same strength as the single strap section. The opening is required to allow molding of internal pawl. The opening also allows the bifurcated “Y” section to flex downward to adjust to small bundle diameters.

The reverse bent tail with conic grips, to direct the strap tail, upon exit, to deflect upward—away from the bundle—into the installers grasp, for ease of strap pull through.

The wide flange around the saddle perimeter provides broad surface contact against the bundle. This reduces compression of softer bundles, protects bundles from chafing, and provides more lateral/longitudinal support.