Strapping Tool

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable.

NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT

Not Applicable.

INCORPORATION BY REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISK

Not Applicable.

BACKGROUND OF THE INVENTION
1. Field of the Invention

The invention generally relates to a strapping tool. More particularly, the invention relates to a strapping tool that is configured to apply tension to a piece of strapping, and/or to notch or crimp a strapping seal member that secures end portions of the piece of strapping to one another.

2. Background

Various tools are known in the packaging art for performing numerous functions related to the manipulation of strapping, which is commonly used as a closing mechanism for packages, and as a convenient means for easily attaching two objects to one another (e.g., attaching a box to a pallet). Some of these conventional tools are powered directly from a centralized system, such as a building electrical system or a central pneumatic system. Other conventional packaging tools have a power supply that is an integral part of the tool. Both of the aforementioned types of conventional packaging tools have numerous limitations and drawbacks. For example, conventional combination strapping tools, which perform both tensioning and sealing operations, utilize a vast array of intricate components, resulting in these tools being overly complicated, and quite expensive. Also, because these conventional tools comprise many intricate components subject to failure, they are often not as reliable as desired by the users thereof.

Therefore, what is needed is a strapping tool that utilizes fewer and simpler components than conventional tools so as to reduce the overall complexity of the tool, and thereby provide a more cost effective alternative for performing strapping operations. Moreover, there is a need for a strapping tool that is more reliable than conventional strapping tools so as to minimize the disruption of strapping operations resulting from tool repairs and replacements. Furthermore, there is a need for a strapping tool that is easier to transport than conventional strapping tools. In addition, there is a need for a strapping tool that utilizes fewer and simpler components than conventional tools so as to reduce the overall complexity and weight of the tool, and thereby provide a more cost effective alternative for performing strapping operations.

BRIEF SUMMARY OF EMBODIMENTS OF THE INVENTION

Accordingly, the present invention is directed to a strapping tool that substantially obviates one or more problems resulting from the limitations and deficiencies of the related art.

In accordance with one or more embodiments of the present invention, there is provided a strapping tool. The strapping tool includes a motive power source; and a tensioning assembly operatively coupled to the motive power source, the tensioning assembly including a plurality of strapping foot members, the plurality of strapping foot members arranged side-by-side transversely across a strapping pass line, at least one of the plurality of strapping foot members being in a form of a tensioning foot member configured to apply tension to a piece of strapping while being driven in an oscillatory manner by the motive power source.

In a further embodiment of the present invention, the strapping tool further comprises at least one cam member, the at least one cam member operatively coupling the tensioning foot member to the motive power source.

In yet a further embodiment, the at least one cam member is in a form of an eccentric cam member.

In still a further embodiment, the at least one cam member is disposed on a drive shaft, the drive shaft operatively coupling the tensioning foot member to the motive power source by means of the at least one cam member.

In yet a further embodiment, at least another one of the plurality of strapping foot members is in a form of a holding foot member, the holding foot member being supported from the drive shaft that is operatively coupled to the tensioning foot member; and during the tensioning of the piece of strapping, the tensioning foot member continually grabs and applies tension to the piece of strapping, and the holding foot member prevents the piece of strapping from slipping back.

In still a further embodiment, strapping tool further comprises a tensioning leg operatively coupling the tensioning foot member to the at least one cam member, and a holding leg coupling the holding foot member to the drive shaft.

In yet a further embodiment, the strapping tool further comprising one or more one-way rotation restriction devices disposed on the drive shaft, the one or more one-way rotation restriction devices allowing the drive shaft to be rotated in a first rotational direction where the tensioning foot member applies tension to the piece of strapping, while preventing rotation of the drive shaft in a second rotational direction, which is opposite to the first rotational direction, so as to enable the tension to be maintained on the piece of strapping.

In still a further embodiment, the tensioning foot member is in a form of a first tensioning foot member, and at least another one of the plurality of strapping foot members comprises a second tensioning foot member configured to apply tension to the piece of strapping while being driven in an oscillatory manner by the motive power source.

In yet a further embodiment, the strapping tool further comprises at least a first cam member and a second cam member, the first cam member operatively coupling the first tensioning foot member to the motive power source, and the second cam member operatively coupling the second tensioning foot member to the motive power source.

In still a further embodiment, the first cam member and the second cam member are disposed on a drive shaft, the drive shaft operatively coupling the first tensioning foot member to the motive power source by means of the first cam member, and the drive shaft operatively coupling the second tensioning foot member to the motive power source by means of the second cam member.

In yet a further embodiment, the first cam member is in a form of a first eccentric cam member and the second cam member is in a form of a second eccentric cam member, the first eccentric cam member having a first lobe portion and the second eccentric cam member having a second lobe portion, and the first lobe portion of the first eccentric cam member being rotationally offset from the second lobe portion of the second eccentric cam member by approximately 180 degrees on the drive shaft.

In still a further embodiment, the strapping tool further comprises a first tensioning leg operatively coupling the first tensioning foot member to the first cam member, and a second tensioning leg operatively coupling the second tensioning foot member to the second cam member.

In yet a further embodiment, the strapping tool further comprises one or more bearings disposed on the drive shaft.

In still a further embodiment, during the tensioning of the piece of strapping, the first tensioning foot member is displaced in a first direction for applying tension to the piece of strapping, while the second tensioning foot member is displaced in a second direction that is opposite to the first direction so as to grip the piece of strapping that is being tensioned; and during the tensioning of the piece of strapping, the second tensioning foot member is displaced in the first direction for applying tension to the piece of strapping, while the first tensioning foot member is displaced in the second direction that is opposite to the first direction so as to grip the piece of strapping that is being tensioned.

In yet a further embodiment, the plurality of strapping foot members further comprises one or more additional tensioning foot members configured to apply tension to the piece of strapping while being driven in an oscillatory manner by the motive power source such that the strapping tool comprises three or more tensioning foot members.

In still a further embodiment, the drive shaft has a linear configuration such that the first tensioning foot member and the second tensioning foot member have an aligned common driving axis.

In yet a further embodiment, the motive power source comprises one of: (i) an electric motor, (ii) a pneumatic motor, and (iii) a liquid fuel-based motor.

In still a further embodiment, the motive power source comprises a battery-powered motor.

It is to be understood that the foregoing general description and the following detailed description of the present invention are merely exemplary and explanatory in nature. As such, the foregoing general description and the following detailed description of the invention should not be construed to limit the scope of the appended claims in any sense.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The invention will now be described, by way of example, with reference to the accompanying drawings, in which:

FIG. 1 is an assembled perspective view of a strapping tool, according to a first embodiment of the invention;

FIG. 2 is another perspective view of the strapping tool of FIG. 1, wherein the opposite side of the strapping tool is illustrated together with a piece of strapping and seal member;

FIG. 3 is a bottom perspective view of the strapping tool of FIG. 1, wherein the strapping tool is shown notching a seal member of a piece of strapping;

FIG. 4 is a perspective view of a cam assembly of the strapping tool of FIG. 1;

FIG. 5 is an exploded perspective view of the strapping tool of FIG. 1;

FIG. 6a is yet another perspective view of the strapping tool of FIG. 1, wherein the front cover of the sealing assembly has been removed, and the jaws of the sealing assembly are shown in an engaging, lowered state;

FIG. 6b is a front end view of the internal components of the sealing assembly of the strapping tool of FIG. 1, wherein the jaws of the sealing assembly are shown in the engaging, lowered state;

FIG. 7a is still another perspective view of the strapping tool of FIG. 1, wherein the front cover of the sealing assembly has been removed, and the jaws of the sealing assembly are shown in a raised state so that a piece of strapping may be loaded into the strapping tool, and wherein pieces of strapping with notched and unnotched seal members are additionally illustrated;

FIG. 7b is another front end view of the internal components of the sealing assembly of the strapping tool of FIG. 1, wherein the jaws of the sealing assembly are shown in the raised state so that a piece of strapping may be loaded into the strapping tool;

FIG. 8 is a side elevational view of the strapping tool of FIG. 1, wherein the cover of the tensioning assembly has been removed so as to illustrate the internal components of the tensioning assembly;

FIG. 9 is a perspective view of a front portion of the strapping tool of FIG. 1, which includes the sealing and tensioning assemblies;

FIG. 10 is an enlarged partial side view of the tensioning assembly shown together with a piece of strapping at a first position (Detail “A-1”);

FIG. 11a is another enlarged partial side view of the tensioning assembly shown together with the piece of strapping as the strapping is being advanced by the tensioning foot to a second position during an initial strap displacement cycle (Detail “A-2”);

FIG. 11b is a rear elevational view of the internal components of the tensioning assembly of the strapping tool of FIG. 1, wherein the distance between the center of the cam shaft and the surface of the tension cam is shown as the strapping is being advanced by the tensioning foot during the initial strap displacement cycle;

FIG. 12a is another enlarged partial side view of the tensioning assembly shown together with the piece of strapping at the second position as the tensioning foot is resetting for a subsequent strap displacement cycle (Detail “A-3”);

FIG. 12b is a rear elevational view of the internal components of the tensioning assembly of the strapping tool of FIG. 1, wherein the distance between the center of the cam shaft and the surface of the tension cam is shown as the tensioning foot is resetting for the subsequent strap displacement cycle;

FIG. 13a is yet another front end view of the internal components of the sealing assembly of the strapping tool of FIG. 1, wherein the jaws of the sealing assembly are shown in the engaging, lowered state after a piece of strapping and seal member has been loaded into the strapping tool;

FIG. 13b is a side perspective view of the strapping tool of FIG. 1, wherein the cover of the sealing assembly has been removed so as to illustrate the displaceable sealing cam plate members;

FIG. 14a is still another front end view of the internal components of the sealing assembly of the strapping tool of FIG. 1, wherein the front pair of the sealing jaws have been driven into engaged sealing positions by the displacement of the front sealing cam plate member, while the rear pair of the sealing jaw members are in disengaged positions;

FIG. 14b is another side perspective view of the strapping tool of FIG. 1, wherein the cover and guides of the sealing assembly have been removed so as to illustrate the displacement of the front sealing cam plate member;

FIG. 15 is yet another front end view of the internal components of the sealing assembly of the strapping tool of FIG. 1, wherein the rear pair of the sealing jaws have been driven into engaged sealing positions by the displacement of the rear sealing cam plate member, while the front pair of the sealing jaw members are in disengaged positions;

FIG. 16 is an enlarged front view of the front and rear pairs of sealing jaws, and a strapping seal member (Detail “B”), wherein the front sealing jaws are disposed in disengaged positions and the rear sealing jaws are disposed in engaged sealing positions;

FIG. 17 is yet another side perspective view of the strapping tool of FIG. 1, wherein the entire housing of the strapping tool has been removed to more clearly illustrate the cutting blade of the strapping tool in a disengaged, non-cutting position;

FIG. 18 is still another side perspective view of the strapping tool of FIG. 1, wherein the entire housing of the strapping tool has been removed to more clearly illustrate the cutting blade of the strapping tool in an engaged, cutting position;

FIG. 19 is a perspective view of a user utilizing the strapping tool of FIG. 1 to secure strapping around a bundle of timber members;

FIG. 20 is a perspective view of a strapping seal member illustrating the notched portions of the strapping seal member formed by the sealing assembly of the strapping tool described herein (Detail “C”);

FIG. 21 is an assembled perspective view of a strapping tool, according to a second embodiment of the invention, wherein the front cover of the sealing assembly has been removed, and the jaws on both sides of the sealing assembly are shown in an engaging, lowered state;

FIG. 22 is a front end view of the internal components of the sealing assembly of the strapping tool of FIG. 21, wherein the jaws on both sides of the sealing assembly are shown in the engaging, lowered state;

FIG. 23 is another front end view of the internal components of the sealing assembly of the strapping tool of FIG. 21 with the front bracket member shown removed to the side for more clearly illustrating components therebehind, wherein the jaws on one side (e.g., the right side) of the sealing assembly are shown in the raised state so that a piece of strapping and sealing member may be loaded into the strapping tool;

FIG. 24 is yet another front end view of the internal components of the sealing assembly of the strapping tool of FIG. 21;

FIG. 25 is still another front end view of the internal components of the sealing assembly of the strapping tool of FIG. 21, wherein the notching or crimping action of the jaws of the sealing assembly is illustrated;

FIG. 26 is an enlarged view of a portion of the front end view of FIG. 24 (Detail “D”), wherein the geometric parameters of the sealing jaw face are illustrated;

FIG. 27 is an assembled perspective view of a strapping tool, according to a third embodiment of the invention, wherein the front cover of the sealing assembly has been removed, and the jaws on both sides of the sealing assembly are shown in an engaging, lowered state;

FIG. 28 is a partially exploded perspective view of the strapping tool of FIG. 27, wherein the components of the sealing assembly have been exploded from the remainder of the tool;

FIG. 29 is a front end view of the internal components of the sealing assembly of the strapping tool of FIG. 27, wherein the jaws on both sides of the sealing assembly are shown in the engaging, lowered state;

FIG. 30 is another front end view of the internal components of the sealing assembly of the strapping tool of FIG. 27 with the front bracket member shown removed to the side for more clearly illustrating components therebehind, wherein the jaws on one side (e.g., the right side) of the sealing assembly are shown in the raised state so that a piece of strapping and a sealing member may be loaded into the strapping tool;

FIG. 31 is yet another front end view of the internal components of the sealing assembly of the strapping tool of FIG. 27, wherein a front jaw on one side (e.g., the right side) and the front bracket member of the sealing assembly have been removed so as to better illustrate the jaw locking mechanism when it is in its engaged state;

FIG. 32 is still another front end view of the internal components of the sealing assembly of the strapping tool of FIG. 27, wherein a front jaw on one side (e.g., the right side) and the front bracket member of the sealing assembly have been removed so as to better illustrate the jaw locking mechanism when it is in its disengaged state so as to allow the jaws on that side to be raised;

FIG. 33 is a perspective view of a strapping tool, according to a fourth illustrative embodiment of the invention;

FIG. 34 is a front elevational view of the strapping tool of FIG. 33;

FIG. 35 is a rear elevational view of the strapping tool of FIG. 33;

FIG. 36 is a first side elevational view of the strapping tool of FIG. 33;

FIG. 37 is a second side elevational view of the strapping tool of FIG. 33;

FIG. 38 is a bottom plan view of the strapping tool of FIG. 33;

FIG. 39 is a top plan view of the strapping tool of FIG. 33;

FIG. 40 is a bottom perspective view of the strapping tool of FIG. 33, wherein the strapping tool is shown tensioning a piece of strapping that has been inserted in the strapping tool;

FIG. 41 is an exploded perspective view of the strapping tool of FIG. 33;

FIG. 42 is another perspective view of the strapping tool of FIG. 33, wherein a cover plate of the strapping tool has been removed in order to depict a one-way bearing at an outer end of a drive shaft;

FIG. 43 is an enlarged perspective view of a tensioning assembly of the strapping tool of FIG. 33;

FIG. 44 is an enlarged perspective view of a tensioning leg and foot member of the strapping tool of FIG. 33;

FIG. 45 is an enlarged perspective view of a holding leg and foot member of the strapping tool of FIG. 33;

FIG. 46 is an underside perspective view of a camshaft of the strapping tool of FIG. 33;

FIG. 47 is a top side perspective view of a camshaft of the strapping tool of FIG. 33;

FIG. 48 is a sectional side view cut through the strapping tool of FIG. 33, wherein the sectional view is cut along the cutting-plane line A-A in FIG. 34 through the holding leg and foot member of the strapping tool;

FIG. 49 is an enlarged partial side view of the leg and foot members of the strapping tool depicted in FIG. 48, wherein the leg and foot members are shown together with a piece of strapping (“Section A-A Detail”);

FIG. 50 is a sectional side view cut through the strapping tool of FIG. 33, wherein the sectional view is cut along the cutting-plane line B-B in FIG. 34 through the leg spacer on the camshaft of the strapping tool;

FIG. 51A is an enlarged partial side view of the tensioning leg and foot member of the strapping tool of FIG. 33, wherein the tensioning leg and foot member is shown in a first position together with a piece of strapping;

FIG. 51B is another enlarged partial side view of the tensioning leg and foot member of the strapping tool of FIG. 33, wherein the tensioning leg and foot member is shown in a second position together with the piece of strapping;

FIG. 51C is yet another enlarged partial side view of the tensioning leg and foot member of the strapping tool of FIG. 33, wherein the tensioning leg and foot member is shown in a third position together with the piece of strapping;

FIG. 52 is a perspective view of a strapping tool, according to a fifth illustrative embodiment of the invention, wherein a cover plate of the strapping tool has been removed in order to depict a bearing at an outer end of a drive shaft;

FIG. 53 is an enlarged perspective view of a tensioning assembly of the strapping tool of FIG. 52;

FIG. 54 is a first side perspective view of a camshaft of the strapping tool of FIG. 52;

FIG. 55 is a second side perspective view of a camshaft of the strapping tool of FIG. 52;

FIG. 56 is a sectional side view cut through the strapping tool of FIG. 52, wherein the sectional view is cut along the cutting-plane line C-C in FIG. 52 through the interior tensioning leg and foot member of the strapping tool;

FIG. 57A is an enlarged partial side view of the tensioning leg and foot members of the strapping tool of FIG. 52, wherein the tensioning leg and foot members are shown in a first position together with a piece of strapping;

FIG. 57B is another enlarged partial side view of the tensioning leg and foot members of the strapping tool of FIG. 52, wherein the tensioning leg and foot members are shown in a second position together with the piece of strapping; and

FIG. 57C is yet another enlarged partial side view of the tensioning leg and foot members of the strapping tool of FIG. 52, wherein the tensioning leg and foot members are shown in a third position together with the piece of strapping.

It should be understood all references to direction and position in the drawings, unless otherwise indicated, refer to the orientation of the strapping tools as presented in the drawings. For example, in FIG. 6a and other front end views depicted in the drawings, the left side of the tool refers to the left side of the front end view, and the right side of the tool refers to right side of the front end view.

Throughout the figures, the same parts are always denoted using the same reference characters so that, as a general rule, they will only be described once.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

A first illustrative embodiment of the strapping tool is seen generally at 100 in FIGS. 1-20. An exploded perspective view of the assemblies that form the strapping tool 100 is depicted in FIG. 5. Initially with reference to the illustrative embodiment of FIGS. 1 and 2, it can be seen that the strapping tool 100 generally comprises a motive power source 78; a tensioning assembly 96 operatively coupled to the motive power source 78, and configured to apply tension to a piece of strapping; and a sealing assembly 94 operatively coupled to the motive power source 78, and configured to notch a strapping seal member 106 so as to secure a piece of strapping with strapping portions 102, 104 (see FIGS. 2 and 3) around a package or bundle of items. For example, as shown in FIG. 19, first and second straps 128, 130 may be secured around a package of wood timber members 126. Initially, as shown in FIG. 19, a user 124 utilizes the tensioning assembly 96 of the strapping tool 100 for tensioning the strap 128 (e.g., in the direction indicated by arrow 138). Then, after the strap is pulled tight using the tensioning assembly 96, the sealing assembly 94 of the strapping tool 100 is used to notch the strapping seal members 132 so as to secure the end portions of the straps 128, 130 to one another. As shown in the detail view of FIG. 20, the free end 130a of the strap 130 is secured using the seal member 132 by forming notched portions 134 in the strap 130 and seal member 132 by utilizing the sealing assembly 94 of the strapping tool 100. In FIG. 20, it can be seen that the notched portions 134 are bent upwardly so as to be separated from the unnotched edges 136 of the seal member 132.

While the sealing assembly 94 of the strapping tool 100 notches the strapping seal member 106 in the illustrative embodiment, it is to be understood that, in other embodiments, the sealing assembly of the strapping tool may crimp the seal member rather than notch the seal member. That is, in these other embodiments, the strapping tool may be used with a crimp-type seal member, rather than the illustrated notch-type seal member 106.

In the illustrative embodiment, with reference to FIGS. 5, 10-12b, 17, and 18, it can be seen that the tensioning assembly 96 generally includes a tension cam member 92 and a tensioning leg 60 with a tensioning foot member 58 disposed at the bottom end thereof. The tension cam member 92 operatively couples the tensioning foot member 58 to the motive power source 78. As will be described in detail hereinafter, the tensioning foot member 58 of the tensioning assembly 96 is configured to apply tension to a piece of strapping 104 (see FIG. 11a) while being driven in an oscillatory manner by the motive power source (e.g., motor 78). As shown in the exploded view of FIG. 5 and the rear views of FIGS. 11b and 12b, in the illustrative embodiment, the tensioning assembly 96 of the strapping tool 100 further comprises a holding bar 52, a holding bar foot 54, a holding bar pin 56, a tension frame housing 72, a tension leg pin 74, and a tension cam bracket 76. When the piece of strapping 104 is being tensioned (as shown in FIGS. 11a and 12a), the holding bar or leg 52 with associated foot 54 holds the strap 104 in place so that the strap is unable to slide in a direction opposite to the tensioning direction. In the illustrative embodiment, the holding leg 52 is pivotally mounted to the tension frame housing 72 by means of the holding bar pin 56. During the tensioning of the strap 104, the holding leg 52 is not driven by the motor 78, but rather is manually pivotable about the holding bar pin 56. In the illustrative embodiment, the holding foot 54, which is disposed at the bottom of the holding leg 52, may be formed from a suitable rubber material so that the foot 54 is able to frictionally engage, and hold the strap 104 in place as it is being tensioned (see FIGS. 10, 11a, and 12a). The tensioning foot member 58, which is driven by the motor 78 during the tensioning of the strap 104, is pivotable about the leg pin 74 during the tensioning of the strap 104. The leg pin 74 connects the tensioning leg 60 to the tension cam bracket 76, and is received within an oval-shaped aperture in the tension frame housing 72 (see FIGS. 5 and 11a).

Now, with reference primarily to FIGS. 10-12b, the functionality of the tensioning assembly 96 of the strapping tool 100 will be described. Initially, when the cam shaft 118 is driven in a tensioning direction by the motor 78, the tension cam member 92 is rotated by the cam shaft 118. As the tension cam member 92 rotates through its cycle, the tension cam bracket 76, which acts as a cam follower (the cam 92 fits inside cam bracket 76), is either driven up or down (see FIGS. 11b and 12b) by the tension cam member 92, which is in the form of an eccentric cam member in the illustrative embodiment. In turn, the up and down displacement of the tension cam bracket 76 causes the tensioning leg member 60, which is operatively coupled to the tension cam bracket 76 by the pin 74, to oscillate backwards and forwards so as to apply tension to the strap 104. In other embodiments, the displacement of the tension cam bracket 76 may include lateral displacements as well as the generally vertical displacements of the illustrative embodiment (e.g., the tension cam bracket 76 may be diagonally displaced). In particular, referring to FIG. 10, it can be seen that the end of the strap 104 being tensioned initially is disposed at the location E1 before tension has been applied thereto. Then, turning to FIG. 11a, as tension is being applied to the strap 104 during a first cycle by the tensioning foot 58 on the end of the tensioning leg member 60, the end of the strap 104 has been displaced to the location E2 (i.e., the strap 104 has been displaced to the right in FIG. 11a). As shown in FIG. 11b, when the tensioning foot 58 is disposed in its tensioning position of FIG. 11a, the distance D1 defines the distance between the center of the cam shaft 118 and the location where the cam surface of tension cam member 92 contacts the bottom surface of the central recess of the tension cam bracket 76 (i.e., the tension cam bracket 76 is driven downwardly by the thick section of the cam 92 in FIG. 11b so that the tensioning foot 58 is pushed downwardly against the strap 104 for tensioning). FIG. 11b depicts the state of the cam 92 and tension cam bracket 76 when foot 58 is fully extended. Finally, referring to FIG. 12a, after tension has been applied to the strap 104 during the first cycle by the tensioning foot 58, the tensioning foot 58 is shown resetting for the second cycle, as the holding foot 54 is shown pivoting so as to engage the tensioned strap 104 and maintain the tension force thereon throughout the tensioning operation until the strap 104 is cut by the cutting blade 50, as described hereinafter. As shown in FIG. 12b, when the tensioning foot 58 is disposed in its resetting position of FIG. 12a during the resetting phase thereof, the distance D2 defines the distance between the center of the cam shaft 118 and the location where the cam surface of tension cam member 92 contacts the bottom surface of the central recess of the tension cam bracket 76 (i.e., the tension cam bracket 76 travels upwardly when the thin section of the cam 92 in FIG. 12b contacts the bottom surface of the central recess of the tension cam bracket 76 so that the tensioning foot 58 is reset for the tensioning cycle). In the illustrative embodiment, during the resetting of the tensioning foot 58, the foot 58 may be held down against the strap 104 by a spring (i.e., a downward spring force is applied to the foot 58 to maintain the foot 58 in contact with the strap 104 during the resetting thereof). In FIG. 12a, the position of the foot 58 is exaggerated slightly to better distinguish the resetting stroke from the tensioning stroke. FIG. 12b depicts the state of the cam 92 and tension cam bracket 76 when the foot 58 is retracted back to start the cycle over. In FIG. 12a, location E3 designates the future location of the end of the strap 104 after the second cycle of tensioning has concluded (i.e., the strap 104 will be displaced to the right in FIG. 12a to the location E3 after the second tensioning cycle). In the illustrative embodiment, during the tensioning operation of the strapping tool 100, the tensioning foot 58 advances the tensioned strap 104 a predetermined amount (e.g., one-eighth of an inch) during each cycle. During the tensioning operation, the tensioning foot 58 continually grabs and pulls a predetermined amount of strapping 104 through the seal member and the holding foot 54 prevents the strapping 104 from slipping back. During each tensioning cycle, the foot 58 resets and grabs another predetermined amount of strap 104 (e.g., one-eighth of an inch) as it is forced down and out the back of the tool 100. After sufficient tension is applied to the strap, the tensioning operation is concluded, the motor 78 reverses, and the sealing operations described hereinafter are performed.

While only the tensioning foot 58 is driven in the illustrative embodiment, it is to be understood that, in other embodiments, both feet 54, 58 may be driven by the motor 78 of the strapping tool 100.

In the illustrative embodiment, referring again to the exploded view of FIG. 5, it can be seen that the tensioning assembly 96 may further include a plurality of cover plates 68, 70 that attach to the tension frame housing 72 so as to cover portions of the tensioning assembly 96 components. In the illustrative embodiment, the plurality of cover plates 68, 70 may be formed from a polymeric material or suitable plastic. In one or more embodiments, the cover plate 70 may be transparent (i.e., in the form of a clear window) so that internal components of the tensioning assembly 96 are visible to the user during the operation of the strapping tool 100 (e.g., so the feet 54, 58 are visible to the user to facilitate the loading of the tool 100).

Referring again to FIGS. 3-5, in the illustrative embodiment, the motor 78 supplies power to both the sealing assembly 94 and the tensioning assembly 96 by means of the single cam drive shaft 118. In the illustrative embodiment, with reference to the cam and bearing subassembly 30 depicted in FIG. 4, the strapping tool 100 further comprises a plurality of one-way bearings 114, 116 disposed on the cam drive shaft 118 so as to enable the tensioning assembly 96 to be actuated by rotating the cam drive shaft 118 in a first rotational direction (e.g., a counterclockwise direction), and the sealing assembly 94 and the cutting operations to be actuated by rotating the drive shaft 118 in a second rotational direction (e.g., a clockwise direction) that is opposite to the first rotational direction. As a result of the one-way bearings 114, 116, the sealing cams 110, 112 do not rotate when the cam drive shaft 118 rotates in the first rotational direction, and the tension cam member 92 does not rotate when the cam drive shaft 118 rotates in the second rotational direction. As shown in FIG. 4, in addition to the one-way bearings 114, 116, the cam and bearing subassembly 30 further includes a front sealing cam 110, a rear sealing cam 112, a cut cam 62, and the tension cam member 92 disposed on the one-way bearing 116.

While one-way bearings 114, 116 are utilized in the illustrative embodiment for regulating the tensioning, sealing, and cutting operations of the strapping tool 100, other means for controlling the directional rotation of the cam drive shaft 118 may be used. For example, in one or more alternative embodiments, a clutch subassembly may be operatively coupled to the cam drive shaft 118 rather than the one-way bearings 114, 116 so as to enable the tensioning assembly 94 to be actuated by rotating the drive shaft 118 in a first rotational direction and the sealing assembly 96 and the cutting operations to be actuated by rotating the drive shaft 118 in a second rotational direction that is opposite to the first rotational direction. As another example, in one or more other alternative embodiments, a one-way ratchet subassembly or one-way indexing subassembly may be operatively coupled to the cam drive shaft 118 rather than the one-way bearings 114, 116 so as to enable the tensioning assembly 94 to be actuated by rotating the drive shaft 118 in a first rotational direction and the sealing assembly 96 and the cutting operations to be actuated by rotating the drive shaft 118 in a second rotational direction that is opposite to the first rotational direction.

In the illustrative embodiment, the motive power source 78 is in the form of electric motor powered by the battery pack 80. However, in other embodiments, other types of motive power sources may be used, such as pneumatic motors, liquid fuel-based motors (e.g., gasoline-powered motors), motors driven by mechanical spring assemblies, and manually-actuated power sources (e.g., a power source driven by the turning of a crank by user, etc.).

Also, while a single electric motor 78 drives both the tensioning assembly 96 and the sealing assembly 94 in the illustrative embodiment, separate motors may be used for the tensioning and sealing assemblies 96, 94 in alternative embodiments.

Next, with reference primarily to FIGS. 4, 5, and 13a-16, the sealing assembly 94 of the illustrative strapping tool 100 will be described in detail. In the illustrative embodiment, referring initially to FIGS. 4, 5, 13a, and 13b, it can be seen that the sealing assembly 94 generally includes a plurality of cam members 110, 112, a plurality of cam follower members 28, 32, and a plurality of sealing jaw members 16, 18, 44, 46. As shown in FIG. 4, the plurality of cam members 110, 112 of the sealing assembly 94 comprises a first cam member 110 (i.e., a front sealing cam 110) and a second cam member 112 (i.e., a rear sealing cam 112) disposed on the cam shaft 118 driven by motor 78. In the illustrative embodiment, each of the cam members 110, 112 is eccentric, and thus has a variable radii cam surface geometry. Also, in the illustrative embodiment, the plurality of sealing jaw members 16, 18, 44, 46 of the sealing assembly 94 comprises a front pair of sealing jaw members 16, 18 and a rear pair of sealing jaw members 44, 46. As shown in FIGS. 5 and 13a-15, it can be seen that the sealing jaw members 16, 18, 44, 46 each comprise respective sealing teeth for forming the notched portions 108 in the seal member 106 (see FIG. 2). In addition, referring to FIGS. 4, 13b, and 14b, each of the first and second cam members 110, 112 is operatively coupled to the electric motor 78 by means of the cam shaft 118 (i.e., the cams 110, 112 are both simultaneously rotated by the cam shaft 118). The first cam member 110 is operatively coupled to the front pair of sealing jaw members 16, 18 by the front cam follower member 28 so as to selectively activate the front pair of sealing jaw members 16, 18 (see FIGS. 13a, 14a, and 15). The second cam member 112 is operatively coupled to the rear pair of sealing jaw members 44, 46 by the rear cam follower member 32 so as to selectively activate the rear pair of sealing jaw members 44, 46 (see FIGS. 13b, 14b, 17, and 18). Turning again to FIGS. 13a-15, 17, and 18, it can be seen that the front pair of sealing jaw members 16, 18 are operatively coupled to the front cam follower member 28 by a first pair of cam bearings 14, 20, while the rear pair of sealing jaw members 44, 46 are operatively coupled to the rear cam follower member 32 by a second pair of cam bearings 48. In the illustrative embodiment, the front and rear cam follower members 28, 32 are in form of front and rear sealing cam plate members with respective central apertures formed therein for receiving the respective first and second cam members 110, 112. In the illustrative embodiment, the front and rear cam subassemblies of the sealing assembly 94 may be in the form of positive drive cams where the cam follower members 28, 32 are disposed around, and circumscribe their respective cam members 110, 112.

In the illustrative embodiment, as shown in FIGS. 5, 17, and 18, the sealing assembly 94 further comprises first and second sealing guide members 38, 40 for constraining the displacement of the front and rear cam follower members 28, 32 to a direction normal to a surface of the piece of strapping 104 (i.e., an upward/downward displacement). As best shown in FIGS. 5, 17, and 18, the front and rear cam follower members 28, 32 comprise grooves on the outer sides thereof that slidingly engage with protruding rails formed on the first and second sealing guide members 38, 40 such that the front and rear cam follower members 28, 32 slide up and down relative to the first and second sealing guide members 38, 40 when follower members 28, 32 are displaced by the cam members 110, 112.

Referring again to FIGS. 13a-15, 17, and 18, it can be seen that the lower end portions of the front sealing jaw members 16, 18 are connected together by means of a front connector member 22, while the lower end portions of the rear sealing jaw members 44, 46 are connected together by means of a rear connector member 66. The front and rear connector members 22, 66 act as jaw spacer members. Elongate jaw pivot pins 34, 36 extend in the front-to-back direction of the strapping tool 100, and pass through spaced-apart apertures in the front and rear connector members 22, 66 so as to couple the front pair of sealing jaw members 16, 18 to the rear pair of sealing jaw members 44, 46 (see FIGS. 5, 13b, 14b, 17, and 18). The sealing jaw members 16, 44 disposed on the first side of the strapping tool 100 both pivot about the jaw pivot pin 36 during the notching of the seal member 106, while the sealing jaw members 18, 46 disposed on the second side of the strapping tool 100 both pivot about the jaw pivot pin 34 during the notching of the seal member 106. Also, referring to FIGS. 5, 13b, 14b, 17, and 18, it can be seen that the sealing assembly 94 further comprises a pair of center jaw spacer members 42 for providing front-to-back spacing between the sealing jaw members 16, 44 on the first side of the strapping tool 100, and front-to-back spacing between the sealing jaw members 18, 46 on the second side of the strapping tool 100.

As best shown in FIGS. 1, 2, 5, and 6a, in the illustrative embodiment, the internal components of the sealing assembly 94 are housed within the front housing member 10 of the strapping tool 100 and rear housing member 64. Collectively, the front and rear housing members 10, 64 enclose the constituent components of the sealing assembly 94. Also, as shown in FIGS. 1, 2, and 5, it can be seen that that the strapping tool 100 is provided with a rechargeable battery pack 80 that is removable from its battery mount on the rear end portion of the strapping tool 100 so that the battery 80 can be easily charged. In the illustrative embodiment, the rechargeable battery pack 80 is capable of powering both the electric motor 78 that drives both the tensioning assembly 96 and the sealing assembly 94.

Now, with reference primarily to FIGS. 13a-15, the functionality of the sealing assembly 94 of the strapping tool 100 will be described. Initially, when the cam shaft 118 is driven in a sealing direction by the motor 78, the first and second cam members 110, 112 are rotated by the cam shaft 118. As the first and second cam members 110, 112 rotate through their cycles, the front and rear cam follower members 28, 32 are either raised or lowered by the cam members 110, 112, which are in the form of eccentric cam members in the illustrative embodiment. In turn, the up and down displacement of the cam follower members 28, 32 causes sealing jaw members 16, 44 to rotate about jaw pivot pin 36 and the sealing jaw members 18, 46 to rotate about jaw pivot pin 34. The sealing jaw members 16, 44 rotate about the jaw pivot pin 36 in an oscillatory manner between engaged and disengaged positions, while the sealing jaw members 18, 46 rotate about the jaw pivot pin 34 in an oscillatory manner between engaged and disengaged positions. Different operational positions of the sealing assembly 94 are illustrated in FIGS. 13a-15. In FIGS. 13a and 13b, both the front and rear pairs of sealing jaw members 16, 18, 44, 46 are in their disengaged positions. FIGS. 13a and 13b depict the positions of the sealing jaw members 16, 18, 44, 46 after the jaw lifting assembly (as will be described hereinafter) lifts the jaw members 16, 18, 44, 46, and strap and seal member 106 have been inserted into the strapping tool 100. In FIGS. 14a and 14b, the front sealing jaw members 16, 18 are in their engaged sealing positions, while the rear sealing jaw members 44, 46 are in their disengaged positions. In the operational state depicted in FIGS. 14a and 14b, the front sealing jaw members 16, 18 notch the seal member 106 while the seal member 106 is held in place by the rear sealing jaw members 44, 46. During the notching of the seal member 106, the first and second cam members 110, 112 rotate out of sync with one another (i.e., cam surface portions are not aligned) such that one of the cam follower members 28, 32 is in a raised position and the other of the cam follower members 28, 32 is in a lowered position. In the operational state depicted in FIGS. 14a and 14b, the front cam follower member 28 is in a lowered position, while the rear cam follower member 32 is in a raised position. Finally, in FIGS. 15 and 16, the front sealing jaw members 16, 18 are in their disengaged positions and the rear sealing jaw members 44, 46 are in their engaged sealing positions. In the operational state depicted in FIGS. 15 and 16, the front sealing jaw members 16, 18 hold the seal member 106 while the seal member 106 is notched by the rear sealing jaw members 44, 46. Also, in the operational state depicted in FIGS. 15 and 16, the front cam follower member 28 is in a raised position, while the rear cam follower member 32 is in a lowered position.

In the illustrative embodiment, the strapping tool 100 further comprises a control system operatively coupled to the electric motor 78 for controlling the operation of the tensioning and sealing assemblies 96, 94. As shown in FIGS. 1 and 2, the control system of the illustrative strapping tool 100 includes a single control button 90 configured to control the operation of both the tensioning assembly 96 and the sealing assembly 94 (i.e., when depressed by a user, the control button 90 initiates the tensioning and sealing operations of the strapping tool 100). Although, while a single control button 90 is used in the illustrative embodiment, in other alternative embodiments, the control system of the strapping tool 100 includes a plurality of control buttons for controlling the tensioning and sealing operations of the tool 100. In these alternative embodiments, at least a first one of the control buttons may be configured to control the operation of the tensioning assembly 96, while at least a second one of the control buttons may be configured to control the operation of the sealing assembly 94. In the illustrative embodiment, the control system of the strapping tool 100 further comprises a microcontroller for performing the central processing operations for the control of the strapping tool 100.

Next, with reference to FIGS. 6a-7b, the jaw lifting assembly of the illustrative strapping tool 100 will be described. The jaw lifting assembly of the strapping tool 100 is configured to raise the sealing jaw members 16, 18, 44, 46 out of a strapping pass line of the strapping tool 100 so that the piece of strapping 102, 104 is capable of being inserted into the strapping tool 100 (see e.g., FIG. 7a). As will be described hereinafter, in the illustrative embodiment, the jaw lifting assembly raises a portion of the sealing assembly 94 that includes the sealing jaw members 16, 18, 44, 46, but does not raise the entire sealing assembly 94. As best shown in the exploded view of FIG. 5, in the illustrative embodiment, each of the sealing jaw members 16, 18, 44, 46 comprises a body portion with an elongate aperture formed therethrough. The diagonally-oriented elongate aperture of each sealing jaw member 16, 18, 44, 46 enables the sealing jaw members 16, 18, 44, 46 to be retractably displaced into the strapping tool when the sealing jaw members 16, 18, 44, 46 are simultaneously raised by the jaw lifting assembly (as shown in FIGS. 7a and 7b). As shown in FIGS. 13a-15, 17, and 18, the head portion of each cam bearing 14, 20, 48 is disposed in a respective diagonally-oriented elongate aperture of a respective sealing jaw member 16, 18, 44, 46 so as to operatively couple the sealing jaw members 16, 18, 44, 46 to the front and rear cam follower members 28, 32. When the sealing jaw members 16, 18, 44, 46 are actuated by the electric motor 78 into a sealing position for notching the strapping seal member 106 (as described above), the cam bearing members 14, 20, 48 are displaced within their respective elongate apertures of their respective sealing jaw members 16, 18, 44, 46 while the sealing jaw members 16, 18, 44, 46 are pivoted about rotational axes passing through the center of the jaw pivot pins 34, 36.

Referring again to FIGS. 6a and 7a, in the illustrative embodiment, the jaw lifting assembly further comprises a displaceable handle portion 86 operatively coupled to the sealing jaw members 16, 18, 44, 46. As shown in these figures, the displaceable lower handle portion 86 is received within the upper handle portion 88 that is affixed to the housing of the strapping tool 100. As shown in the exploded view of FIG. 5, the front pin 82 attaches the immovable upper handle portion 88 to the front housing 10, while the rear pin 84 forms the pivotal axis for the displaceable lower handle portion 86 relative to the immovable upper handle portion 88 (i.e., the rear pin 84 pivotably couples the rear end of the lower handle portion 86 to the upper handle portion 88). When the handle portion 86 is depressed by a user, the sealing jaw members 16, 18, 44, 46 are raised out of the strapping pass line of the strapping tool 100. In the illustrative embodiment, the sealing assembly 94 of the strapping tool 100 is not pivotably coupled to the tensioning assembly 96 of the strapping tool 100, but rather the raising of the sealing jaw members 16, 18, 44, 46 allows the strapping pass line to be cleared of the jaw obstruction so that the strapping can be loaded into the strapping tool 100.

Now, with reference primarily to FIGS. 6a-7b, the functionality of the jaw lifting assembly of the strapping tool 100 will be described. Initially, when the displaceable lower handle portion 86 is depressed by a user, the jaw lifter arms 24, 26, which are coupled to the lower handle portion 86 by the jaw lifter connector bar 12, are raised upwardly and the lower ends of the jaw lifter arms 24, 26 are spread apart from one another (see FIG. 7b). As the jaw lifter arms 24, 26 are raised and their lower ends are spread apart from one another, the jaw pivot pins 34, 36 are displaced in a diagonally upward manner within the diagonally-oriented elongate apertures of front and rear connector members 22, 66 (see FIGS. 7a and 7b). In turn, the upward and outward displacement of the jaw pivot pins 34, 36 causes the sealing jaw members 16, 18, 44, 46 to be raised upwardly and out of the strapping pass line of the strapping tool 100 so that the piece of strapping 102, 104 and seal member 106 is capable of being inserted into the strapping tool 100. Different operational positions of the jaw lifting assembly are illustrated in FIGS. 6a-7b. In FIGS. 6a and 6b, the sealing jaw members 16, 18, 44, 46 are depicted in their lowered, engaging state prior to a user squeezing the displaceable lower handle portion 86 to raise the sealing jaw members 16, 18, 44, 46 to load the strapping 102, 104 and seal member 106 into the strapping tool 100. In FIGS. 7a and 7b, the sealing jaw members 16, 18, 44, 46 are depicted in their raised, disengaging state after the user has pulled up on the displaceable lower handle portion 86 (as diagrammatically indicated by the curved arrow 98 in FIG. 7a), so as to raise the sealing jaw members 16, 18, 44, 46 so that the strapping 102, 104 and seal member 106 is able to be loaded into the strapping tool 100 for the performance of the tensioning and sealing operations. In FIG. 7a, the loading of the strapping 102, 104 and seal member 106 is diagrammatically illustrated by the curved arrow 120, while the removal of the strapping 102, 104 and seal member 106 after the tensioning and sealing operations have been performed is diagrammatically illustrated by the curved arrow 122.

Turning to FIGS. 5, 17, and 18, it can be seen that, in the illustrative embodiment, the sealing assembly 94 of the strapping tool 100 further comprises a cutting blade 50 for cutting the piece of strapping (see FIG. 18). As shown in FIG. 18, the cutting cam 62 pushes down on the top edge of the cutting blade 50 so as to cut the piece of strapping. As such, when the cutting cam 62 reaches a predetermined rotational position, the cutting cam 62 drives the cutting blade 50 downwardly so as to slice through the piece of strapping (i.e., the cutting blade 50 is slidably displaced in a downward direction by the cutting cam 62 so as to assume its engaged, cutting position). As shown in FIGS. 17 and 18, the cutting blade 50 is enclosed within a cutting blade housing 51, and the cutting blade 50 slides relative to the stationary cutting blade housing 51. Referring to FIGS. 17 and 18, it can be seen that the cutting blade 50 is disposed adjacent to the rear pair of sealing jaw members 44, 46. In the illustrative embodiment, the cutting cam 62 is also driven by the cam drive shaft 118 that provides power to the sealing assembly 94 and the tensioning assembly 96. After the rear pair of sealing jaw members 44, 46 applies the notch to the rear portion of the seal member, the cutting cam 62 revolves around the drive shaft 118 and physically pushes the cutting blade 50 down through the strapping, thereby slicing the excess end portion of the strap so that it can be removed from the remainder of the strap.

Now, referring to FIGS. 6a-20, the tensioning and sealing operation of the strapping tool 100 of the illustrative embodiment will now be described. Initially, a piece of strapping 128, 130 (i.e., a piece of steel strapping, poly strapping, or cord strapping) of one of a number of sizes is looped around the package or bundle 126 that requires the restraint (see e.g., FIG. 19). Then, the user threads a first free end of the strapping through a seal member or banding clip 132. After which, the user bends the first free end of the strapping back so that it is not able to be pulled out of the seal member 132 (e.g., as shown in FIGS. 2, 3, and 7a). Next, the user inserts the second free end of the strapping through the seal member 132 so that a continuous loop is formed around the bundle 126. Then, the strapping 128, 130 and seal member 132 are loaded into the strapping tool 100 by using the jaw lift assembly described above in conjunction with FIGS. 6a-7b to lift the sealing jaw members 16, 18, 44, 46 out of the strapping pass line. The actuation of the jaw lifting assembly by the depressing of the handle portion 86 allows the strapping 128, 130 and seal member 132 to be inserted into the tool 100 (see FIG. 3). As shown in FIG. 3, the strapping 128, 130 is inserted into the slot of the tool 100 between the tensioning foot 58 and the wedge-shaped plate on the bottom of the tool 100. Once the seal member 132 is in the correct position, the handle portion 86 is released by the user, the sealing jaw members 16, 18, 44, 46 return back to their engaged position with the seal member 132. At this point, the strapping 128, 130 and seal member 132 is held in place prior to the initiation of the tensioning and sealing operations. Then, the control button 90 is depressed by the user so that the tension is applied to the strapping 128, 130 by the tensioning assembly 96 in the manner described above in conjunction with FIGS. 10-12b. Finally, once the strapping has been pulled tight by the tensioning assembly 96 of the tool 100, the motor 78 reverses direction so that the sealing teeth of the sealing jaw members 16, 18, 44, 46 notch the metal seal member or banding clip (see FIGS. 2, 7a, and 20) and the cutting blade 50 cuts the excess portion of the strap from the strapping around the bundle 126. The notched seal member ensures that the strapping around the bundle 126 does not release its tension. Once the excess portion of the strap is cut by the cutting blade 50, the user squeezes the handle portion 86 to retract the sealing jaw members 16, 18, 44, 46, thereby freeing the strapping 128, 130 and seal member 132 from the tool 100.

A second illustrative embodiment 200 of a strapping tool is illustrated in FIGS. 21-26. Referring to these figures, it can be seen that, in many respects, the second illustrative embodiment of the strapping tool is similar to that of the first illustrative embodiment. Moreover, many elements are common to both such embodiments. For example, the tensioning assembly 296 of the strapping tool 200 is generally the same as the tensioning assembly 96 described above with regard to the strapping tool 100. However, the sealing assembly 294 of the strapping tool 200 differs from the sealing assembly 94 of the strapping tool 100 described above, and thus shall be described hereinafter. In particular, unlike the sealing assembly 94 of the strapping tool 100, the sealing jaw members on only one side of the strapping tool 200 are lifted for the loading of the strapping.

Now, with reference to FIGS. 21-26, the sealing assembly 294 of the illustrative strapping tool 200 will be described in detail. Referring initially to FIG. 21, in the second illustrative embodiment, the sealing assembly 294 generally includes a plurality of cam members (e.g., including front cam 298 and a similar rear cam), a plurality of cam follower members (e.g., including front cam follower member 228 and a similar rear cam follower member), and a plurality of sealing jaw members (e.g., including front sealing jaws 216, 218 and similar rear sealing jaws). Similar to that described above for the first illustrative embodiment, the plurality of sealing cam members of the sealing assembly 294 are disposed on a cam shaft driven by motor 278. In the illustrative embodiment, each of the sealing cam members is eccentric, and thus has a variable radii cam surface geometry. Also, similar to the aforedescribed first embodiment, the plurality of sealing jaw members of the sealing assembly 294 comprises a front pair of sealing jaw members 216, 218 and a similar rear pair of sealing jaw members. As shown in FIGS. 21-26, it can be seen that the sealing jaw members 216, 218 each comprise respective sealing teeth for forming the notched portions in the seal member 106 (see e.g., FIG. 2). The front cam member 298 is operatively coupled to the front pair of sealing jaw members 216, 218 by the front cam follower member 228 so as to selectively activate the front pair of sealing jaw members 216, 218, and the rear cam member is operatively coupled to the rear pair of sealing jaw members by the rear cam follower member so as to selectively activate the rear pair of sealing jaw members. Turning again to the front view of FIG. 25, it can be seen that the front sealing jaw member 216 on the first side (i.e., the left side) is operatively coupled to the front cam follower member 228 by upper and lower roller members 214a, 214b, while the front sealing jaw member 218 on the second side (e.g., the right side) is operatively coupled to the front cam follower member 228 by upper and lower roller members 220a, 220b. The arcuate displacement of the front sealing jaw members 216, 218 during the notching of the seal member is represented diagrammatically by the curved arrows 238 in FIG. 25. The rear pair of sealing jaw members is operatively coupled to the rear cam follower member by similar pairs of roller members. In the illustrative embodiment, the front cam follower member 228 and the rear cam follower member are in form of front and rear sealing cam plate members with respective central apertures formed therein for receiving the respective front and rear cam members. Also, in the illustrative embodiment, the front and rear sealing cam plate members forming front cam follower member 228 and the rear cam follower member may have a central slot-like cavity disposed therein with an interior face 232 for accommodating roller members 214a, 214b, 220a, 220b and the upper diagonal leg portions of the sealing jaw members (see FIGS. 21 and 25). Advantageously, because the cam members apply forces centrally to the cam follower members, and the cam follower members apply forces centrally to the jaw sealing members (by virtue of the roller members being centrally located in the cam follower plate members, generally symmetrical notches are formed in the sealing member during the sealing operation of the tool 200. In addition, in the illustrative embodiment, the front and rear cam subassemblies of the sealing assembly 294 may be in the form of positive drive cams where the cam follower members are disposed around, and circumscribe their respective cam members.

With reference again to FIGS. 21-26, elongate jaw pivot pins 234, 236 extend in the front-to-back direction of the strapping tool 200, and pass through apertures in the front pair of sealing jaw members 216, 218 and the rear pair of sealing jaw members so as to define axes of rotation for the sealing jaw members. The sealing jaw members disposed on the first side (i.e., the left side) of the strapping tool 200 both pivot about the jaw pivot pin 234 during the notching of the seal member 106, while the sealing jaw members disposed on the second side (e.g., the right side) of the strapping tool 200 both pivot about the jaw pivot pin 236 during the notching of the seal member 106.

In the second illustrative embodiment, similar to the first illustrative embodiment described above, the internal components of the sealing assembly 294 are housed within a front housing member (not shown) of the strapping tool 200 and rear housing member 264 (see FIG. 21). Collectively, the front and rear housing members enclose the constituent components of the sealing assembly 294. Also, as shown in FIG. 21, it can be seen that that the strapping tool 200 is provided with a rechargeable battery pack 280 that is removable from its battery mount on the rear end portion of the strapping tool 200 so that the battery 280 can be easily charged. In the illustrative embodiment, the rechargeable battery pack 280 is capable of powering both the electric motor 278 that drives both the tensioning assembly 296 and the sealing assembly 294. As shown in FIG. 21, similar to that described above for the first embodiment, the control system of the illustrative strapping tool 200 may include a single control button 290 (or start button 290) configured to control the operation of both the tensioning assembly 296 and the sealing assembly 294 (i.e., when depressed by a user, the start button 290 initiates the tensioning and sealing operations of the strapping tool 200). In addition, as shown in FIG. 21, the illustrative strapping tool 200 may further include a rocker switch 291 that allows the tool 200 to be used in a manual tension and seal mode. Because the notching functionality of the sealing assembly 294 is similar to the sealing assembly 94 described above, a description of the sealing assembly will not be repeated with regard to the second illustrative embodiment.

Next, with reference to FIGS. 21-26, the jaw lifting assembly of the illustrative strapping tool 200 will be described. In the second illustrative embodiment, the jaw lifting assembly of the strapping tool 200 is configured to raise the sealing jaw members on one side of the tool (e.g., on the right side) out of a strapping pass line of the strapping tool 200 so that the piece of strapping 102, 104 is capable of being inserted into the strapping tool 200. As will be described hereinafter, in the second illustrative embodiment, the jaw lifting assembly raises a portion of the sealing assembly 294 that includes the sealing jaw members on one side (e.g., the right side), but does not raise the sealing jaw members on the other side (e.g., the left side) of the sealing assembly 294. As best shown in FIG. 23, in the illustrative embodiment, the bracket member 222 is provided with a circular aperture 225 on the left side, and diagonally-oriented elongate aperture 227 on the right side. The diagonally-oriented elongate aperture 227 of the bracket member 222 enables the jaw pivot pin 236 on the right side to travel upwardly in the elongate aperture 227 when it is desired to raise the sealing jaw members on the right side, but the circular aperture 225 on the left side of the bracket member 222 constrains the jaw pivot pin 234 on the left side such that the sealing jaw members on the left side are not able to be raised. The sealing jaw members on the right side are retractably displaced into the strapping tool 200 when the sealing jaw members are raised by the jaw lifting assembly (as shown in FIG. 23).

Referring again to the perspective view of FIG. 21, in the illustrative embodiment, the jaw lifting assembly further comprises a displaceable upper handle portion 288 operatively coupled to the sealing jaw members on the right side of the tool 200. As shown in these figures, the displaceable upper handle portion 288 is pivotally coupled to the lower handle portion 286 by means of a pivot pin 282, which forms the pivotal axis for the displaceable upper handle portion 288 relative to the immovable lower handle portion 286 (i.e., the rear pin 282 pivotably couples the middle of the upper handle portion 288 to the lower handle portion 286). With combined reference to FIGS. 21-26, it can be seen that the front pin 244 couples the displaceable upper handle portion 288 to the linking components of the jaw lifting assembly. In the illustrative embodiment, with combined reference to FIGS. 21-26, it can be seen that the displaceable upper handle portion 288 is operatively coupled to the displaceable jaws on the right side of the tool 200 by rod end body 242, jaw lifter bracket 240, and jaw lifter vertical link 224. When the upper handle portion 288 is pressed down by a user (as diagrammatically indicated by the downward arrow 289 in FIG. 23), the jaw lifting assembly components 224, 240, 242 are displaced (as diagrammatically indicated by the curved arrow 230 in FIG. 23), and the sealing jaw members on the right side of the tool 200 are raised out of the strapping pass line of the strapping tool 200. In the illustrative embodiment, the sealing assembly 294 of the strapping tool 200 is not pivotably coupled to the tensioning assembly 296 of the strapping tool 200, but rather the raising of the sealing jaw members on the right side of the tool 200 allows the strapping pass line to be cleared of the jaw obstruction so that the strapping can be loaded into the strapping tool 200.

In the illustrative embodiment, the tool 200 advantageously is provided with several features to prevent the inadvertent lifting of the sealing jaw members on the right side of the tool 200. First of all, with reference to FIG. 23, it can be seen that the bracket member 222 is provided with a downwardly extending protrusion 223 that prevents the sealing jaw members on the right side of the tool 200 from inadvertently opening when the tool is placed against a surface (e.g., against the package on which the strapping or banding is being applied). For example, in the case where the tool 200 is placed against a package surface, the downwardly extending protrusion 223 of the bracket member 222 contacts the package surface, rather than the sealing jaw members on the right side, thus preventing the inadvertent lifting of the sealing jaws on the right side. In addition, the downwardly extending protrusion 223 of the bracket member 222 also prevents the sealing jaw members on the right side from inadvertently opening when the tool 200 is rested on a floor or other surface. In addition, with reference to FIG. 26, as another way to prevent the inadvertent lifting of the sealing jaw members on the right side of the tool 200, the geometry of the jaw face 219 of each right side sealing jaw member is configured such that it forms a first predetermined angle θ₁relative to the centerline of the diagonally-oriented elongate aperture 227 in the bracket member 222, and a second predetermined angle θ₂relative to a vertical reference line. In addition, as shown in FIG. 26, the sealing jaw members on the right side are configured such that there is predetermined spacing distance D3 between the centerline of the pivot pin 236 and the upper face 221 of each sealing jaw member 218 that contacts the upper roller members 220a. In the illustrative embodiment, the first predetermined angle θ₁between the jaw face 219 and the centerline of the diagonally-oriented elongate aperture 227 may be approximately 5 degrees, the second predetermined angle θ₂between the jaw face 219 and the vertical reference line may be approximately 40 degrees, and the determined spacing distance D3 between the centerline of the pivot pin 236 and the upper jaw face 221 may be approximately 0.88. Advantageously, these geometric parameters (i.e., θ₁, θ₂, D3) of the sealing jaw members on the right side of the tool 200 holds the sealing jaw members in a locked position during the notching of the seal member, and prevents inadvertent lifting of the sealing jaw members on the right side of the tool 200 (i.e., because of these geometric parameters, the pivot pin 236 is maintained in its “sealing home position” where it is pushed against the lower curved end of the elongate aperture 227 during sealing). Further, as yet another way to prevent the inadvertent lifting of the sealing jaw members on the right side of the tool 200, in the illustrative embodiment, the tool 200 is provided with a pre-grip cycle prior to the execution of the tensioning cycle described above. After the user presses the start button 290 on the tool 200, the pre-grip cycle is initiated (e.g., in the first ½ second of the tool operational sequence), and the sealing jaw members rotate and slightly pinch the sealing member. Then, the tool operational sequence follows with the aforedescribed tensioning cycle, and then the aforedescribed sealing cycle. In the illustrative embodiment, once the rotation starts for actuating the sealing jaw members, the pivot pin 236 is pulled tight into its “sealing home position” against the lower curved end of the elongate aperture 227, and it remains in tight engagement with the lower curved end of the elongate aperture 227 during the entire sealing operation.

A third illustrative embodiment 300 of a strapping tool is illustrated in FIGS. 27-32. Referring to these figures, it can be seen that, in many respects, the third illustrative embodiment is similar to that of the first and second illustrative embodiments. Moreover, many elements are common to all of the embodiments. For example, the tensioning assembly 396 of the strapping tool 300 is generally the same as the tensioning assemblies 96, 296 described above with regard to the strapping tools 100, 200. However, the sealing assembly 394 of the strapping tool 300 differs from the sealing assemblies 94, 294 of the strapping tools 100, 200 described above, and thus shall be described hereinafter. Although, similar to the sealing assembly 294 of the strapping tool 200, the sealing jaw members on only one side of the strapping tool 300 are lifted for the loading of the strapping.

Now, with reference to FIGS. 27-32, the sealing assembly 394 of the illustrative strapping tool 300 will be described in detail. Referring initially to the exploded view of FIG. 28, in the second illustrative embodiment, the sealing assembly 394 generally includes a plurality of cam members 398, 399, a plurality of cam follower ring members 328, 332, and a plurality of sealing jaw members 316, 318, 344, 346. As shown in FIG. 28, the plurality of cam members 398, 399 of the sealing assembly 394 comprises a first cam member 398 (i.e., a front sealing cam 398) and a second cam member 399 (i.e., a rear sealing cam 399) disposed on the cam shaft driven by a motor 378. In the illustrative embodiment, each of the cam members 398, 399 is eccentric, and thus has a variable radii cam surface geometry. Also, in the illustrative embodiment, the plurality of sealing jaw members 316, 318, 344, 346 of the sealing assembly 394 comprises a front pair of sealing jaw members 316, 318 and a rear pair of sealing jaw members 344, 346. As shown in FIGS. 27, 28, and 30, it can be seen that the sealing jaw members 316, 318, 344, 346 each comprise respective sealing teeth for forming the notched portions 108 in the seal member 106 (see FIG. 2). In addition, similar to that described above for the first two embodiments, each of the first and second cam members 398, 399 is operatively coupled to the electric motor 378 by means of a cam shaft (i.e., the cams 398, 399 are both simultaneously rotated by the cam shaft about a rotational axis passing through the center of the hexagonal fastener of the cam shaft in FIGS. 29-32). The end of the cam shaft is rotatably supported by a roller bearing 314 (see FIG. 28). The first cam member 398 is operatively coupled to the front pair of sealing jaw members 316, 318 by the front cam follower ring member 328 so as to selectively activate the front pair of sealing jaw members 316, 318 (see FIGS. 30 and 31). The second cam member 399 is operatively coupled to the rear pair of sealing jaw members 344, 346 by the rear cam follower ring member 332 so as to selectively activate the rear pair of sealing jaw members 344, 346 (see FIGS. 27 and 28). Turning again to FIGS. 27 and 28, it can be seen that the front pair of sealing jaw members 316, 318 are operatively coupled to the front cam follower ring member 328 by a first pair of linkage arm members 338, 340, while the rear pair of sealing jaw members 344, 346 are operatively coupled to the rear cam follower ring member 332 by a second pair of linkage arm members 348, 350. The upper ends of the linkage arm members 338, 340 are coupled to the front cam follower ring member 328 by means of a ring pin 320, while the lower ends of the linkage arm members 338, 340 are coupled to respective sealing jaw members 316, 318 by respective jaw pins 322. Similarly, the upper ends of the linkage arm members 348, 350 are coupled to the rear cam follower ring member 332 by means of a ring pin 320, while the lower ends of the linkage arm members 348, 350 are coupled to respective sealing jaw members 344, 346 by respective jaw pins 322. In the illustrative embodiment, the front and rear cam follower ring members 328, 332 are in form of ring members with respective central apertures formed therein for receiving the respective first and second cam members 398, 399. In the illustrative embodiment, the front and rear cam subassemblies of the sealing assembly 394 may be in the form of positive drive cams where the cam follower members 328, 332 are disposed around, and circumscribe their respective cam members 398, 399.

In the illustrative embodiment, as best shown in the exploded view of FIG. 28, the sealing assembly 394 further comprises first and second bracket members 312, 342 for constraining the displacement of the ring pins 320 at the upper ends of the linkage arm members 338, 340, 348, 350 to a direction normal to a surface of the piece of strapping 104 (i.e., an upward/downward displacement). As shown in FIGS. 28-32, the front and rear bracket members 312, 342 comprise vertical elongate slots 313, 341 formed therein such that the ring pins 320 are guided up and down within the slots 313, 341 when follower ring members 328, 332 are displaced by the cam members 398, 399.

With reference again to FIGS. 27 and 28, elongate jaw pivot pins 334, 336 extend in the front-to-back direction of the strapping tool 300, and pass through apertures in the front pair of sealing jaw members 316, 318 and the rear pair of sealing jaw members 344, 346 so as to define axes of rotation for the sealing jaw members 316, 318, 344, 346. The sealing jaw members 316, 344 disposed on the first side (i.e., the left side) of the strapping tool 300 both pivot about the jaw pivot pin 334 during the notching of the seal member 106, while the sealing jaw members 318, 346 disposed on the second side (e.g., the right side) of the strapping tool 300 both pivot about the jaw pivot pin 336 during the notching of the seal member 106.

In the third illustrative embodiment, similar to the first and second illustrative embodiments described above, the internal components of the sealing assembly 394 are housed within a front housing member 310 of the strapping tool 300 and a rear housing member 364 (see FIG. 28). Also, in the third illustrative embodiment, a top housing member 374 covers the top portion of the sealing assembly 394. The top housing member 374 may be secured using fastener members 376 (e.g., cap screws 376). Collectively, the front, rear, and top housing members 310, 364, 374 enclose the constituent components of the sealing assembly 394. Also, as shown in FIGS. 27 and 28, it can be seen that that the strapping tool 300 is provided with a rechargeable battery pack 380 that is removable from its battery mount on the rear end portion of the strapping tool 300 so that the battery 380 can be easily charged. In the illustrative embodiment, the rechargeable battery pack 380 is capable of powering both the electric motor 378 that drives both the tensioning assembly 396 and the sealing assembly 394. Also, similar to the first two embodiments described above, the control system of the illustrative strapping tool 300 may include a single control button (or start button) configured to control the operation of both the tensioning assembly 396 and the sealing assembly 394 (i.e., when depressed by a user, the start button initiates the tensioning and sealing operations of the strapping tool 300). Because the notching functionality of the sealing assembly 394 is similar to the sealing assembly 94 described above, a description of the sealing assembly will not be repeated with regard to the third illustrative embodiment.

Next, with reference to FIGS. 27-32, the jaw lifting assembly of the illustrative strapping tool 300 will be described. In the third illustrative embodiment, similar to the second embodiment described above, the jaw lifting assembly of the strapping tool 300 is configured to raise the sealing jaw members on one side of the tool (e.g., on the right side) out of a strapping pass line of the strapping tool 300 so that the piece of strapping 102, 104 is capable of being inserted into the strapping tool 300. As will be described hereinafter, in the third illustrative embodiment, the jaw lifting assembly raises a portion of the sealing assembly 394 that includes the sealing jaw members on one side (e.g., the right side), but does not raise the sealing jaw members on the other side (e.g., the left side) of the sealing assembly 394. As best shown in the exploded view of FIG. 28, in the illustrative embodiment, first and second bracket members 312, 342 are provided with a circular aperture 315, 343 on the left sides thereof, and a diagonally-oriented elongate aperture 317, 345 on the right sides thereof. The diagonally-oriented elongate apertures 317, 345 of the first and second bracket members 312, 342 enable the jaw pivot pin 336 on the right side to travel upwardly in the elongate apertures 317, 345 when it is desired to raise the sealing jaw members 318, 346 on the right side (i.e., after the jaw locking arm 358 is disengaged, which will be explained hereinafter), but the circular apertures 315, 343 on the left sides of the first and second bracket members 312, 342 constrain the jaw pivot pin 334 on the left side such that the sealing jaw members 316, 344 on the left side are not able to be raised. The sealing jaw members 318, 346 on the right side are retractably displaced into the strapping tool 300 when the sealing jaw members are raised by the jaw lifting assembly (as shown in FIG. 30).

Referring again to FIGS. 27 and 28, in the illustrative embodiment, the jaw lifting assembly further comprises a displaceable upper handle portion 388 operatively coupled to the sealing jaw members 318, 346 on the right side of the tool 300. As shown in these figures, the displaceable upper handle portion 388 is pivotally coupled to the lower handle portion 386 by means of a pivot pin 382, which forms the pivotal axis for the displaceable upper handle portion 388 relative to the immovable lower handle portion 386 (i.e., the rear pin 382 pivotably couples the middle of the upper handle portion 388 to the lower handle portion 386). With combined reference to FIGS. 27-30, it can be seen that the fastener member 384 (e.g., cap screw 384) couples the displaceable upper handle portion 388 to the linking components of the jaw lifting assembly. In the illustrative embodiment, with combined reference to FIGS. 27, 28, and 30, it can be seen that the displaceable upper handle portion 388 is operatively coupled to the displaceable jaws 318, 346 on the right side of the tool 300 by bracket member 372, slidable carriage member 368 with flat washer 370, and jaw lifter vertical link 324. When the upper handle portion 388 is pressed down by a user (as diagrammatically indicated by the downward arrow 389 in FIG. 30), the jaw lifting assembly components 372, 368, and 324 are displaced (as diagrammatically indicated by the curved arrow 390 in FIG. 30), and the sealing jaw members 318, 346 on the right side of the tool 300 are raised out of the strapping pass line of the strapping tool 300. When the upper handle portion 388 is pressed down by the user, the slidable carriage member 368 slides vertically upward in the vertical slot of L-shaped bracket 366 so as to raise the jaw lifter vertical link 324, and to lift the sealing jaw members 318, 346 operatively coupled to the jaw lifter vertical link 324. In the illustrative embodiment, the sealing assembly 394 of the strapping tool 300 is not pivotably coupled to the tensioning assembly 396 of the strapping tool 300, but rather the raising of the sealing jaw members 318, 346 on the right side of the tool 300 allows the strapping pass line to be cleared of the jaw obstruction so that the strapping can be loaded into the strapping tool 300.

In the third illustrative embodiment, similar to the second illustrative embodiment, the tool 300 advantageously is provided with several features to prevent the inadvertent lifting of the sealing jaw members 318, 346 on the right side of the tool 300. First of all, with reference to FIGS. 28-30, it can be seen that the sealing jaw members 318, 346 on the right side of the tool 300 are provided with a jaw locking mechanism 352, 356, 358 (e.g., in the form of a knuckle press joint) that locks the sealing jaw members 318, 346 in the down position so as to prevent the sealing jaw members 318, 346 from inadvertently raising from their engaged sealing position. As such, in the third embodiment, before a user is able to lift the sealing jaw members 318, 346 by pressing the upper handle portion 388, he or she must manually disengage the jaw locking arm 358, which then allows the sealing jaw members 318, 346 to be raised. As best shown in the exploded view of FIG. 28, in addition to the jaw locking arm 358, the jaw locking mechanism of the tool 300 further comprises the center spacer member 352, small lock pin members 354, rotating arm 356, and large lock pin member 360. The center spacer member 352 is connected to first and second bracket members 312, 342 by elongate fastener members 326 (e.g., elongate screws 326). When the jaw locking arm 358 is disengaged by the user, the rotating arm 356 is able to rotate clockwise and the lower end of the jaw lifter vertical link 324 is able to be raised upward so that the sealing jaw members 318, 346 are able to be lifted once the user presses down on the upper handle portion 388. The locked position of the sealing jaw members 318, 346 is depicted in FIG. 31, and the unlocked position of the sealing jaw members 318, 346 is depicted in FIG. 32. In addition, as another way to prevent the inadvertent lifting of the sealing jaw members 318, 346 on the right side of the tool 300, the geometry of the jaw faces of the right side sealing jaw members 318, 346 may be geometrically configured in the same manner as described above for the second embodiment (e.g., using a first predetermined angle θ₁of approximately 5 degrees, a second predetermined angle θ₂of approximately 40 degrees, and a predetermined spacing distance D3 of approximately 0.88). Further, as yet another way to prevent the inadvertent lifting of the sealing jaw members 318, 346 on the right side of the tool 300, the tool 300 also may be provided with the pre-grip cycle described above with regard to the second embodiment.

It is readily apparent that the aforedescribed strapping tools 100, 200, 300 offer numerous advantages. First, the strapping tools 100, 200, 300 utilize fewer and simpler components than conventional tools so as to reduce the overall complexity of the tool, and thereby provide a more cost effective alternative for performing strapping operations. Secondly, the strapping tools 100, 200, 300 are more reliable than conventional strapping tools so as to minimize the disruption of strapping operations resulting from tool repairs and replacements. Thirdly, the aforedescribed strapping tools 100, 200, 300 are easier to transport than conventional strapping tools (i.e., the strapping tools 100, 200, 300 are more mobile than conventional strapping tools).

A fourth illustrative embodiment of a strapping tool is illustrated in FIGS. 33-51C. An exploded perspective view of the components that form the strapping tool is depicted in FIG. 41. In the fourth illustrative embodiment, the strapping tool is in a form of a strap tensioner with an external power source (e.g., a battery-powered drill). In particular, the strapping tool of the fourth illustrative embodiment is configured to apply tension to a piece of strapping being around a package or bundle of items. In particular, the fourth illustrated embodiment depicts an 18-volt battery-powered strap tensioner. While the external power source of the fourth embodiment is in a form of a battery-powered drill, those of ordinary skill in the art will appreciate that other suitable external power sources may be substituted for the drill. For example, an alternative external power source in the form of a 120-volt AC drill or pneumatic drill could be used. Also, a suitable circular saw or grinder could be used to power the strap tensioner. In general, the external power required to drive the strapping tool could be supplied by a variety of different sources including, but not limited to, battery, air, alternating-current (AC) electricity, hydraulic or fluid power.

Referring initially to FIGS. 33 and 41, the strapping tool of the fourth illustrative embodiment is seen generally at 400. Initially, with reference to FIGS. 33 and 41, it can be seen that the strapping tool 400 generally comprises a motive power source (e.g., electric motor 464); and a tensioning assembly operatively coupled to the motive power source 464, the tensioning assembly including a plurality of strapping foot members 442, 446, the plurality of strapping foot members 442, 446 arranged side-by-side transversely across a strapping pass line (see e.g., FIGS. 43, 48, and 49), at least one of the plurality of strapping foot members being in a form of a tensioning foot member 442 configured to apply tension to a piece of strapping 490 while being driven in an oscillatory manner by the motive power source 464. Referring to FIG. 40, a user utilizes the strapping tool 400 for tensioning the strap 490 (e.g., in the direction indicated by arrow 494). Then, after the strap is pulled tight using the strapping tool 400, another tool may be utilized to secure a sealing member 496 to the strap 490. As shown in FIG. 40, the free end 492 of the strap 490 may be folded over so as not to be pulled through the sealing member 496 when tension is being applied to the strap 490.

In the illustrative embodiment, with reference to FIGS. 43-47, it can be seen that the tensioning assembly of the strapping tool 400 generally includes a dual leg camshaft 430 with an eccentric cam member 434, a tensioning leg 440 with tensioning foot member 442 disposed at the bottom end thereof, and a holding leg 444 with a holding foot member 446 disposed at the bottom end thereof. The eccentric cam member 434 operatively couples the tensioning leg and foot members 440, 442 to the motive power source 434 by means of the drive shaft portion of the camshaft 430. As will be described in detail hereinafter, the tensioning foot member 442 of the tensioning assembly is configured to apply tension to a piece of strapping 490 (see FIG. 40) while being driven in an oscillatory manner by the motive power source (e.g., motor 464). Like the tensioning leg 440, the holding leg 444 with holding foot member 446 is also supported from the dual leg camshaft 430 (see FIG. 43). More specifically, the holding leg 444 is supported on concentric shaft portion 432 of camshaft 430 so that the holding leg 444 does not oscillate when the camshaft 430 is rotated. During the tensioning of the piece of strapping 490, the tensioning foot member 442 continually grabs and applies tension to the piece of strapping 490, while the holding foot member 446 prevents the piece of strapping 490 from slipping back. As shown in FIGS. 46 and 47, in the illustrative embodiment, the camshaft 430 of the strapping tool 400 further comprises outer concentric shaft portion 431 extending to cover plate 415, spacer wall 435, bearing zone portion 436, and a keyed end 439 that fits into planetary gear plate 451. When the piece of strapping 490 is being tensioned (as shown in FIG. 40), the holding leg 444 with associated foot member 446 holds the strap 490 in place so that the strap is unable to slide in a direction opposite to the tensioning direction. In the illustrative embodiment, the holding leg 444 is pivotally coupled to the concentric shaft portion 432 of camshaft 430 by means of roller bearing 445. During the tensioning of the strap 490, the holding leg 444 is not driven by the motor 464, but rather is manually pivotable about the camshaft 430. In the illustrative embodiment, the holding foot 446, which is disposed at the bottom of the holding leg 444, may be formed from a suitable metallic material, such as carbide, so that the foot 446 is able to frictionally engage, and hold the strap 490 in place as it is being tensioned. The tensioning foot member 442, which is driven by the motor 464 during the tensioning of the strap 490, also may be formed from a suitable metallic material, such as carbide.

In the illustrative embodiment, with reference to FIGS. 41-43, it can be seen that the cam drive shaft of the camshaft 430 has a linear configuration such that the tensioning foot member 442 and the holding foot member 446 have an aligned central axis.

Now, with reference primarily to FIGS. 41 and 51A-51C, the functionality of the strapping tool 400 will be described. Initially, the camshaft 430 is rotated by the motor 464 by means of the gearbox reducer assembly 451-463. When the camshaft 430 is driven in a tensioning direction by the motor 464, the eccentric cam member 434 disposed on the drive shaft of the camshaft 430 is rotated. As the eccentric cam member 434 rotates through its cycle, the tensioning leg 440 oscillates forwards and backwards so as to apply tension to the strap 490. In particular, referring to FIG. 51A, it can be seen that the tensioning foot member 442 is shown at a first position (e.g., a rearmost position) in the beginning of the tensioning cycle with reference point 472 diagrammatically denoting the rotational position of the eccentric cam member 434. Then, turning to FIG. 51B, as tension is being applied to the strap 490 during the tensioning cycle by the tensioning foot 442 on the end of the tensioning leg member 440, the eccentric cam member 434 has rotated approximately 180 degrees as indicated by the reference point 472. Finally, referring to FIG. 51C, after tension has been applied to the strap 490 during the tensioning cycle by the tensioning foot 442, the tensioning foot 442 is shown back in its original position (e.g., its rearmost position) with the reference point 472 on the eccentric cam member 434 being in approximately the same location as in FIG. 51A. In the illustrative embodiment, as shown in FIGS. 43 and 51A-51C, tensioning leg 440 with tensioning foot 442 is held down against the strap 490 by a spring 474 (i.e., a downward spring force is applied to the leg 440 to maintain the foot 442 in contact with the strap 490 during the resetting thereof). Similarly, referring again to FIGS. 43 and 51A-51C, in the illustrative embodiment, the holding leg 444 with holding foot 446 is held down against the strap 490 by a spring 450 (i.e., a downward spring force is applied to the leg 444 to maintain the foot 446 in contact with the strap 490). In the illustrative embodiment, during the tensioning operation of the strapping tool 400, the tensioning foot 442 advances the tensioned strap 490 a predetermined amount (e.g., one-eighth of an inch) during each cycle. During the tensioning operation, the tensioning foot 442 continually grabs and pulls a predetermined amount of strapping 490 through the seal member and the holding foot 446 prevents the strapping 490 from slipping back. During each tensioning cycle, the foot 442 resets and grabs another predetermined amount of strap 490 (e.g., one-eighth of an inch) as it is forced back and forth in the tool 400. After sufficient tension is applied to the strap 490, the tensioning operation is concluded. In the tensioning cycle, on the return stroke of the powered tensioning leg 440, the static holding leg 444 stops the strap 490 from releasing tension. If the static leg 444 were not there, the strap 490 would move back, and then forward as long as there was power. The static leg 444 is like a one-way stop, the strap 490 can move in tension and then hold for powered leg 440 to reverse. In the fourth illustrative embodiment, the outer holding foot 446 essentially operates as a friction brake to keep the strap 490 from slipping.

In the illustrative embodiment, referring again to the exploded view of FIG. 41, it can be seen that the tensioning assembly may further include housing portions 402, 410 and a removable side cover 415 so as to cover portions of the tensioning assembly components.

Referring again to FIGS. 41, 43, 46, and 47, in the illustrative embodiment, the motor 464 supplies power to the tensioning assembly by means of the camshaft 430, which includes a central drive shaft portion with eccentric cam member 434. In the illustrative embodiment, with reference to the tensioning assembly depicted in FIG. 43, the strapping tool 400 further comprises one or more one-way rotation restriction devices (e.g., one-way bearings 414) disposed on the central drive shaft portion of the camshaft 430 so as to allow the cam drive shaft to be rotated in a first rotational direction where the tensioning foot member 442 applies tension to the piece of strapping 490, while preventing rotation of the cam drive shaft in a second rotational direction (i.e., the drive shaft is prevented from twisting backwards), which is opposite to the first rotational direction, so as to enable the tension to be maintained on the piece of strapping 490. In the fourth illustrative embodiment, one-way bearings 414 further prevent the strapping 490 from slipping back at the end of the tensioning cycle by keeping the cam 434 from reversing under the significant strain of a tensioned strap 490.

While one-way bearings 414, 416 are utilized in the illustrative embodiment for regulating the tensioning operations of the strapping tool 400, other means for controlling the directional rotation of the cam drive shaft may be used. For example, in one or more alternative embodiments, a clutch subassembly may be operatively coupled to the cam drive shaft, rather than the one or more one-way bearings 414. As another example, in one or more other alternative embodiments, a one-way ratchet subassembly or one-way indexing subassembly may be operatively coupled to the cam drive shaft, rather than the one or more one-way bearings 414.

In the illustrative embodiment, the motive power source 464 is in the form of an electric motor powered by the battery pack 406. However, in other embodiments, other types of motive power sources may be used, such as pneumatic motors, liquid fuel-based motors (e.g., gasoline-powered motors), motors driven by mechanical spring assemblies, and manually-actuated power sources (e.g., a power source driven by the turning of a crank by user, etc.).

In the fourth illustrative embodiment, the strapping tool 400 uses two side-by-side legs 440, 444 with respective feet 442, 446, one leg 444 to hold (i.e., the static/non-moving leg 444), and another leg 440 (i.e., the active/moving leg 440) to pull tension. The advantage of putting the legs 440, 444 with feet 442, 446 beside each other are several. Using the same shaft cuts the part quantity and required space in half. This gives the advantage of a simpler and lighter tool. In the illustrative embodiment, each foot 442, 446 has a knurled bottom surface for better gripping of the strapping (see e.g., FIGS. 44 and 45).

A fifth illustrative embodiment of a strapping tool is illustrated in FIGS. 52-57C. Referring to these figures, it can be seen that, in many respects, the fifth illustrative embodiment of the strapping tool is similar to that of the fourth illustrative embodiment. Moreover, many elements are common to both such embodiments. For the sake of brevity, the elements that the fifth embodiment of the strapping tool has in common with the fourth embodiment will not be discussed because these components have already been described above.

Unlike the fourth illustrative embodiment described above, the fifth illustrative embodiment of a strapping tool utilizes a plurality of driven tensioning foot members (e.g., two or more driven tensioning foot members in contact with the strapping), rather than just a single driven tensioning foot member.

Referring initially to FIGS. 52 and 53, the strapping tool of the fifth illustrative embodiment is seen generally at 500. Initially, with reference to FIGS. 52 and 53, it can be seen that the strapping tool 500 generally comprises a motive power source (e.g., electric motor); and a tensioning assembly operatively coupled to the motive power source, the tensioning assembly including a plurality of strapping foot members 542, 546, the plurality of strapping foot members 542, 546 arranged side-by-side transversely across a strapping pass line (see e.g., FIGS. 57A-57C), at least two of the plurality of strapping foot members comprising first and second tensioning foot members 542, 546 configured to apply tension to a piece of strapping 490 while being driven in an oscillatory manner by the motive power source. Similar to the fourth illustrative embodiment, a user utilizes the strapping tool 500 for tensioning the strap 490. Then, after the strap is pulled tight using the strapping tool 500, another tool may be utilized to secure a sealing member to the strap 490.

In the illustrative embodiment, with reference to FIGS. 53-55, it can be seen that the tensioning assembly of the strapping tool 500 generally includes a dual leg camshaft 530 with a first eccentric cam member 534 and a second eccentric cam member 532, a first tensioning leg 540 with tensioning foot member 542 disposed at the bottom end thereof, and a second tensioning leg 544 with tensioning foot member 546 disposed at the bottom end thereof. The first eccentric cam member 534 operatively couples the first tensioning leg and foot members 540, 542 to the motive power source by means of the drive shaft portion of the camshaft 530, while the second eccentric cam member 532 operatively couples the second tensioning leg and foot members 544, 546 to the motive power source by means of the drive shaft portion of the camshaft 530. In the illustrative embodiment, the first eccentric cam member 534 has a first lobe portion and the second eccentric cam member 532 has a second lobe portion, and the first lobe portion of the first eccentric cam member 534 is rotationally offset from the second lobe portion of the second eccentric cam member 532 by approximately 180 degrees on the cam drive shaft. As will be described in detail hereinafter, the tensioning foot members 542, 546 of the tensioning assembly are configured to apply tension to a piece of strapping 490 while being driven in an oscillatory manner by the motive power source (e.g., electric motor). During the tensioning of the piece of strapping 490, the tensioning foot members 542, 546 continually grab and apply tension to the piece of strapping 490. As shown in FIGS. 54 and 55, in the illustrative embodiment, the camshaft 530 of the strapping tool 500 further comprises outer concentric shaft portion 531 extending to cover plate 515, spacer wall 535, bearing zone portion 536, and a keyed end 539 that fits into a planetary gear plate. When the piece of strapping 490 is being tensioned, the first tensioning foot member 542 is displaced in a first direction for applying tension to the piece of strapping 490, while the second tensioning foot member 546 is displaced in a second direction that is opposite to the first direction so as to grip the piece of strapping 490 that is being tensioned. Then, when the piece of strapping 490 is being tensioned, the second tensioning foot member 546 is displaced in the first direction for applying tension to the piece of strapping 490, while the first tensioning foot 542 member is displaced in the second direction that is opposite to the first direction so as to grip the piece of strapping 490 that is being tensioned. In the illustrative embodiment, the first tensioning leg 540 is operatively coupled to the first eccentric cam member 534 by a bearing ring 541, and the second tensioning leg 544 is operatively coupled to the second eccentric cam member 532 by a bearing ring 545. During the tensioning of the strap 490, in the fifth illustrative embodiment, both tensioning legs 540, 544 are driven by the motor. In the illustrative embodiment, the first tensioning foot member 542, which is driven by the motor during the tensioning of the strap 490, may be formed from a suitable metallic material, such as carbide. Similarly, the second tensioning foot member 546, which is driven by the motor during the tensioning of the strap 490, also may be formed from a suitable metallic material, such as carbide.

In the illustrative embodiment, with reference to FIGS. 52-55, it can be seen that the cam drive shaft of the camshaft 530 has a linear configuration such that the first tensioning foot member 542 and the second tensioning foot member 546 have an aligned common driving axis.

Now, with reference primarily to FIGS. 53 and 57A-57C, the functionality of the strapping tool 500 will be described. Initially, the camshaft 530 is rotated by the motor by means of the gearbox reducer assembly (e.g., similar to gearbox reducer assembly 451-463 of the fourth embodiment). When the camshaft 530 is driven in a tensioning direction by the motor, the first and second eccentric cam members 534, 532 disposed on the drive shaft of the camshaft 530 are rotated. As the first eccentric cam member 534 rotates through its cycle, the first tensioning leg 540 oscillates forwards and backwards so as to apply tension to the strap 490. Similarly, as the second eccentric cam member 532 rotates through its cycle, the second tensioning leg 544 oscillates forwards and backwards so as to apply tension to the strap 490. In particular, referring to FIG. 57A, it can be seen that the second tensioning foot 546 (i.e., outer foot 546) is shown at a start position and is ready to tension strap 490, while the first tensioning foot 542 (i.e., inner foot 542) is shown is in a return position (e.g., a rearmost position) in the beginning of the tensioning cycle with reference point 572 diagrammatically denoting the rotational position of the camshaft 530. Then, turning to FIG. 57B, it can be seen that the second tensioning foot 546 (i.e., outer foot 546) is shown at a return position (end of tension stroke), while the first tensioning foot 542 (i.e., inner foot 542) has moved to a ready position to start a tension stroke. In FIG. 57B, camshaft 530 has rotated approximately 180 degrees as indicated by the reference point 572. Finally, referring to FIG. 57C, it can be seen that the second tensioning foot 546 (i.e., outer foot 546) has returned to the start position and is ready for a new tensioning cycle, while the first tensioning foot 542 (i.e., inner foot 542) has tensioned strap 490 and is ready to return to the tension position. In FIG. 57C, the reference point 572 on the camshaft 530 is in approximately the same location as in FIG. 57A. In the illustrative embodiment, as shown in FIGS. 56 and 57A-57C, the tensioning legs 540, 544 with tensioning feet 542, 546 are held down against the strap 490 by respective springs 550 (i.e., a downward spring force is applied to the legs 540, 544 to maintain the feet 542, 546 in contact with the strap 490). In the illustrative embodiment, during the tensioning operation of the strapping tool 500, the tensioning feet 542, 546 advance the tensioned strap 490 a predetermined amount (e.g., one-eighth of an inch) during each cycle. During the tensioning operation, the tensioning feet 542, 546 grab and pull a predetermined amount of strapping 490 through the seal member. During each tensioning cycle, the feet 542, 546 reset and grab another predetermined amount of strap 490 (e.g., one-eighth of an inch) as they are forced back and forth in the tool 500. After sufficient tension is applied to the strap 490, the tensioning operation is concluded.

Next, referring to FIGS. 52-56, the functionality of the strapping tool 500 will be further described. In the illustrative embodiment, when the trigger 505 is pulled, the motor rotates. Then, the motor shaft goes through a planetary gear set to reduce the speed and increase the power. The final planetary gear set attaches to the keyed end 539 of camshaft 530. In the fifth illustrative embodiment, the camshaft 530 comprises dual offset cams 532, 534. In an alternative embodiment, more than two offset cams could be provided, which would result in more than two legs and grippers. In the fifth illustrative embodiment, as the leg/gripper 540, 542 or 544, 546 pushes to the rear of the tool, the strapping is pulled tight. The leg works for one-half of the stroke (or more accurately 1 over number of lobes (i.e., a 3 lobe tool=⅓)). During half of the stroke the leg moves toward the front of the tool 500 and the opposite leg takes over and tensions the strapping 490. The wedge angle of the leg 540, 544 lets it pull tension in one direction. In the other direction, the gripper lets go and drags barely on the strapping 490 to return home. In a reverse direction, the only pressure is from the spring 550. The lobes of the cams 532, 534 push the legs 540, 544, which push the grippers 542, 546. As such, the strapping tool 500 has a generally linear drivetrain configuration.

In the illustrative embodiment, referring again to the perspective view of FIG. 52, it can be seen that the tensioning assembly may further include housing portions 502, 510 and a removable side cover 515 so as to cover portions of the tensioning assembly components. In the illustrative embodiment, each foot 542, 546 has a knurled bottom surface for better gripping of the strapping (see e.g., FIGS. 57A-57C).

Referring again to FIGS. 52-56, in the illustrative embodiment, a motor supplies power to the tensioning assembly by means of the camshaft 530, which includes a central drive shaft portion with eccentric cam members 532, 534. In the illustrative embodiment, with reference to the tensioning assembly depicted in FIG. 53, the strapping tool 500 further comprises one or more bearings 514, 548 disposed on the central drive shaft portion of the camshaft 530 so as to facilitate the rotation of the cam drive shaft.

In the illustrative embodiment, the motive power source is in the form of electric motor powered by the battery pack 506. However, in other embodiments, other types of motive power sources may be used, such as pneumatic motors, liquid fuel-based motors (e.g., gasoline-powered motors), motors driven by mechanical spring assemblies, and manually-actuated power sources (e.g., a power source driven by the turning of a crank by user, etc.).

In one or more further embodiments, the strapping tool further comprises one or more additional tensioning foot members configured to apply tension to the piece of strapping while being driven in an oscillatory manner by the motive power source such that the strapping tool comprises three, four, five, or more tensioning foot members.

The following is a list of reference characters that are utilized in the drawings of the fourth and fifth illustrative embodiments described above together with the components that they are used to represent:

- 400 Strapping Tool (Fourth Embodiment)
- 402 Main Housing for Motor and Planetary Gears
- 404 Handle
- 405 Trigger
- 406 Battery Pack
- 410 Cam Housing Cover
- 411 Base Plate of Cam Housing Cover
- 412 Nose Piece of Base (Seal Member Stops Against Nose Piece)
- 414 One-Way Bearing
- 415 Side Cover
- 416 One-Way Bearing Cavity on Side Cover
- 417 Dowel Pin Between Cover Plate and Cam Housing
- 418 Cover Plate Screws
- 420 Deck Surface to Rest Strap On
- 430 Dual Leg One Cam Camshaft
- 431 Centered Shaft of Cam that fits inside Front Cover
- 432 Centered Shaft of Cam Area for Exterior Leg
- 434 Eccentric Cam Member for Interior Leg
- 435 Spacer Between Feet
- 436 Shaft Zone For Bearing
- 439 Keyed End that fits into Planetary Gear Plate
- 440 Interior Tensioning Leg
- 441 Needle Roller Bearing
- 442 Tensioning Foot of Interior Leg
- 443 Needle Roller Bearing that sits on Cam Shaft to Align and Support
- 444 Exterior Holding Leg
- 445 Needle Roller Bearing
- 446 Holding Foot of Exterior Leg
- 448 Needle Roller Bearing
- 450 Holding Leg Spring
- 451 Planetary Gear Plate
- 452 Gear
- 453 Planetary Gear Pins
- 454 Planetary Gears
- 455 Large Washer
- 456 Cap
- 457 Cap Screws
- 458 Shifter Ring
- 459 Second Drive Plate
- 460 Planetary Gears-Middle Gears
- 462 Reducer Housing
- 463 Ball Bearing
- 464 Motor
- 465 Ball Bearing
- 466 Outer Housing Plate
- 470 Center of the Outermost Extrusion of the Dual Leg One Cam Camshaft
- 472 Cam Shaft Rotational Reference Point
- 474 Tensioning Leg Spring
- 490 Strap
- 492 Folded End Portion of Strap
- 494 Strap Tensioning Direction
- 496 Seal Member
- 500 Strapping Tool (Fifth Embodiment)
- 502 Motor Housing
- 504 Handle
- 505 Trigger
- 506 Battery Pack
- 510 Cam/Leg Housing
- 511 Base Plate of Cam Housing Cover
- 514 Bearing for Cam to Cover Plate Connection
- 515 Side Cover
- 516 Aperture in Cover Plate
- 518 Screws for Cover Plate
- 520 Strap Slot
- 530 Dual Leg Dual Cam Camshaft
- 531 Outer End of Camshaft
- 532 Eccentric Cam Portion for Exterior Tensioning Leg
- 534 Eccentric Cam Portion for Interior Tensioning Leg
- 535 Spacer Wall of Camshaft
- 536 Bearing Shaft Area of Camshaft
- 539 Keyed End of Cam Shaft that fits into Planetary Gear Plate
- 540 Interior Tensioning Leg
- 541 Bearing Ring for Interior Tensioning Leg
- 542 Foot of Interior Tensioning Leg
- 544 Exterior Tensioning Leg
- 545 Bearing Ring for Exterior Tensioning Leg
- 546 Foot of Exterior Tensioning Leg
- 548 Roller Bearing
- 550 Tensioning Leg Spring
- 570 Center of the Dual Leg Dual Cam Camshaft
- 572 Cam Shaft Rotational Reference Point

In one or more further embodiments, the motor turns the drive shaft (or gearbox that turns the drive shaft). In these one or more further embodiments, the drive shaft is concentric in the bearing(s), but not necessarily concentric with the motor. The legs hang off the drive shaft. The leg(s) can be on a concentric shaft, or on an offset portion of the shaft. The leg(s) hang down and come in contact with a strap. The end of the leg can have a foot or gripper, or the foot or gripper can be incorporated into the leg. If the leg is on a concentric drive shaft, when the drive shaft spins, the leg will not rotate and stay static. If the leg(s) is on an offset, the leg will move with the cam lobe on the shaft. If the legs are on offsets at 180 degrees apart, one leg will be moving forward as the other moves backward. The legs work like a wedge or a dog. The legs let the strap move/slide through in one direction, and in the other direction the strap is stopped, which pushes the strap tight with the movement. For example, in these one or more further embodiments, if there are five (5) non-concentric shafts, two (2) shafts are pushing, two (2) shafts are holding, and the first shaft could be in either direction. With one leg on concentric, and one on an offset, the offset leg will push the strap in roughly one-half the stroke, and when it retracts, the concentric leg will stop the strap.

One important advantage of the strapping tool configurations described above is how few parts are needed to make the strapping work. Traditionally tensioners use gearboxes with big reductions to get the power they need. There may be a multi-stage planetary gearbox, sometimes also in combination with a worm or right angle gear. With the strapping tools 400, 500 described herein, part of the speed reduction is done with an offset. When the shaft of tools 400, 500 rotates the cam will move the leg a certain amount. With a conventional tool, the motor spins at a very fast rate. The gearbox might reduce the speed/increase the torque 30 times. In a conventional tool, one turn of the motor accomplishes a certain distance of strapping calculated by figuring out the circumference, and distance traveled by each motor rotation. This also gives the tool total tension, also referred to as power. The offset of the strapping tools 400, 500 described herein has a huge advantage of using far fewer components, which is also an advantage for little weight. Advantageously, the side-by-side arrangement of the legs and associated feet of the strapping tools 400, 500 described herein allows a single drive shaft to be used, which results in a substantial reduction in the number of components and a significant reduction in both the size and weight of the strapping tool.

It is readily apparent that the aforedescribed embodiments of the strapping tool 400, 500 offer numerous advantages. The strapping tools 400, 500 described herein are lighter, smaller in size, and simpler in design than conventional tools used to tension steel or poly strapping systems. The above described strapping tools 400, 500 may use a packaged drill as the external power source, and modify the operation of the drill controls to perform the strap tensioning operation in a novel manner.

Any of the features or attributes of the above described embodiments and variations can be used in combination with any of the other features and attributes of the above described embodiments and variations as desired.

Although the invention has been shown and described with respect to a certain embodiment or embodiments, it is apparent that this invention can be embodied in many different forms and that many other modifications and variations are possible without departing from the spirit and scope of this invention

While exemplary embodiments have been described herein, one of ordinary skill in the art will readily appreciate that the exemplary embodiments set forth above are merely illustrative in nature and should not be construed as to limit the claims in any manner. Rather, the scope of the invention is defined only by the appended claims and their equivalents, and not, by the preceding description.

	Number	Date	Country
	62633138	Feb 2018	US
	63682753	Aug 2024	US

	Number	Date	Country
Parent	16282235	Feb 2019	US
Child	17486227		US

	Number	Date	Country
Parent	17486227	Sep 2021	US
Child	19011361		US

Strapping Tool

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Abstract

Description

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CROSS-REFERENCE TO RELATED APPLICATIONS

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