STRAPPING TOOL

Abstract

Various embodiments of the present disclosure provide a strapping tool configured to tension metal strap around a load and, after tensioning, attach overlapping portions of the strap to one another by cutting notches into a seal element positioned around the overlapping portions of the strap and into the overlapping portions of the strap themselves.

Description

FIELD

The present disclosure relates to strapping tools, and more particularly to strapping tools configured to tension strap around a load and to attach overlapping portions of the strap to one another to form a tensioned strap loop around the load.

BACKGROUND

Battery-powered strapping tools are configured to tension strap around a load and to attach overlapping portions of the strap to one another to form a tensioned strap loop around the load. To use one of these strapping tools to form a tensioned strap loop around a load, an operator pulls strap leading end first from a strap supply, wraps the strap around the load, and positions the leading end of the strap below another portion of the strap. The operator then introduces one or more (depending on the type of strapping tool) of these overlapped strap portions into the strapping tool and actuates one or more buttons to initiate: (1) a tensioning cycle during which a tensioning assembly tensions the strap around the load; and (2) after completion of the tensioning cycle, a sealing cycle during which a sealing assembly attaches the overlapped strap portions to one another (thereby forming a tensioned strap loop around the load) and during which a cutting assembly cuts the strap from the strap supply.

How the strapping tool attaches overlapping portions of the strap to one another during the sealing cycle depends on the type of strapping tool and the type of strap. Certain strapping tools configured for plastic strap (such as polypropylene strap or polyester strap) include friction welders, heated blades, or ultrasonic welders configured to attach the overlapping portions of the strap to one another. Some strapping tools configured for plastic strap or metal strap (such as steel strap) include jaws that mechanically deform (referred to as “crimping” in the strapping industry) or cut notches into (referred to as “notching” in the strapping industry) a seal element positioned around the overlapping portions of the strap to attach them to one another. Other strapping tools configured for metal strap include punches and dies configured to form a set of mechanically interlocking cuts in the overlapping portions of the strap to attach them to one another (referred to in the strapping industry as a “sealless” attachment).

SUMMARY

Various embodiments of the present disclosure provide a strapping tool configured to tension metal strap around a load and, after tensioning, attach overlapping portions of the strap to one another by cutting notches into a seal element positioned around the overlapping portions of the strap and into the overlapping portions of the strap themselves.

BRIEF DESCRIPTION OF THE FIGURES

FIGS. 1A and 1B are perspective views of one example embodiment of a strapping tool of the present disclosure.

FIG. 2 is a block diagram of certain components of the strapping tool of FIG. 1A.

FIGS. 3A-3C are perspective views of the working assembly of the strapping tool of FIG. 1A.

FIG. 4A is a perspective view of the tensioning assembly of the working assembly of FIG. 3A.

FIG. 4B is a perspective view of the tensioning-assembly gearing and the tension wheel of the tensioning assembly of FIG. 4A.

FIG. 4C is a cross-sectional perspective view of the tensioning assembly gearing and the tension wheel of FIG. 4B taken along line 4C-4C of FIG. 4B.

FIG. 4D is an exploded perspective view of the tensioning-assembly gearing and the tension wheel of FIG. 4B.

FIG. 5A is a perspective view of the decoupling assembly of the working assembly of FIG. 3A.

FIG. 5B is a cross-sectional perspective view of the decoupling assembly of FIG. 5A taken along line 5B-5B of FIG. 5A.

FIG. 5C is an exploded perspective view of the decoupling assembly of FIG. 5A.

FIG. 5D is a perspective view of part of the working assembly of FIG. 3A including parts of the decoupling assembly of FIG. 5A and parts of the tensioning assembly of FIG. 4A.

FIGS. 6A and 6B are perspective views of part of the trigger assembly of the working assembly of FIG. 3A.

FIGS. 7A, 8A, and 9A are cross-sectional side views of part of the working assembly of FIG. 3A (taken along different planes) showing the tensioning assembly in its strap-tensioning position and the trigger in its home position.

FIGS. 7B, 8B, and 9B are cross-sectional side views of part of the working assembly of FIG. 3A (taken along different planes) showing the tensioning assembly in its strap-tensioning position and the trigger in its intermediate position.

FIGS. 7C, 8C, and 9C are cross-sectional side views of part of the working assembly of FIG. 3A (taken along different planes) showing the tensioning assembly in its strap-insertion position and the trigger in its actuated position.

FIG. 10A is an elevational view of part of the sealing assembly of the working assembly of FIG. 3A with the jaws in their home positions.

FIG. 10B is an elevational view of the sealing assembly of FIG. 10A with the jaws in their home positions.

FIG. 11 is a diagrammatic elevational view of the strap and the seal element positioned around a load before being tensioned and sealed by the strapping tool.

FIG. 12 is a perspective view of the notched seal element.

DETAILED DESCRIPTION

While the systems, devices, and methods described herein may be embodied in various forms, the drawings show and the specification describes certain exemplary and non-limiting embodiments. Not all of the components shown in the drawings and described in the specification may be required, and certain implementations may include additional, different, or fewer components. Variations in the arrangement and type of the components; the shapes, sizes, and materials of the components; and the manners of connections of the components may be made without departing from the spirit or scope of the claims. Unless otherwise indicated, any directions referred to in the specification reflect the orientations of the components shown in the corresponding drawings and do not limit the scope of the present disclosure. Further, terms that refer to mounting methods, such as mounted, connected, etc., are not intended to be limited to direct mounting methods but should be interpreted broadly to include indirect and operably mounted, connected, and like mounting methods. This specification is intended to be taken as a whole and interpreted in accordance with the principles of the present disclosure and as understood by one of ordinary skill in the art.

FIGS. 1A-3C show one example embodiment of the strapping tool 50 of the present disclosure (sometimes referred to as the “tool” in the Detailed Description for brevity) and certain assemblies and components thereof. The strapping tool 50 is configured to carry out a strapping cycle including: (1) a tensioning cycle during which the strapping tool tensions strap (metal strap in this example embodiment) around a load; and (2) a sealing cycle during which the strapping tool, after tensioning the strap, attaches overlapping portions of the strap to one another by cutting notches into a seal element positioned around the overlapping portions of the strap and into the overlapping portions of the strap themselves (referred to as “notching” in the strapping industry and in this Detailed Description) and cuts the strap from the strap supply.

The strapping tool 50 includes a housing 100 (FIGS. 1A and 1B), a working assembly 200 (FIGS. 3A-3C), a display assembly 1300 (FIGS. 1A-2), an actuating assembly 1400 (FIGS. 1A-2); a power supply (not shown); a controller 1600 (FIG. 2), and one or more sensors 1700 (FIG. 2).

The housing 100, which is best shown in FIGS. 1A and 1B, is formed from multiple components (not individually labeled) that collectively at least partially enclose and/or support some (or all) of the other assemblies and components of the strapping tool 50. In this example embodiment, the housing 100 includes a front housing section that at least partially encloses and/or supports at least some of the components of the working assembly 200, the display assembly 1300, and the actuating assembly 1400; a rear housing section that defines a receptacle 190 sized, shaped, and otherwise configured to receive and at least partially enclose and/or support the power supply and the controller 1600; and a connector housing section that extends between and connects the bottoms of the front and rear housing sections and defines a handle 150. This is merely one example, and in other embodiments the components of the strapping tool may be supported and/or enclosed by any suitable portion of the housing 100. The housing 100 may be formed from any suitable quantity of components joined together in any suitable manner. In this example embodiment, the housing 100 is formed from plastic, though it may be made from any other suitable material in other embodiments.

The working assembly 200, which is best shown in FIGS. 3A-3C, includes the majority of the components of the strapping tool 50 that are configured to carry out the strapping cycle to tension the strap around the load, attach the overlapping portions of the strap to one another, and cut the strap from the strap supply. Specifically, the working assembly 200 includes a support 300, a tensioning assembly 400, a sealing assembly 500, a drive assembly 700 including a conversion assembly 800, a trigger assembly 900, and a decoupling assembly 1900.

The support 300, which is best shown in FIGS. 3A-3C, serves as a direct or indirect common mount for the tensioning assembly 400, the sealing assembly 500, the drive assembly 700, the trigger assembly 900, and the decoupling assembly 1900. The support 300 includes a body 310, a foot 320 extending transversely from a bottom of the body 310, a tensioning-assembly-mounting element 330 extending rearward from the body 310, and a drive-and-conversion-assembly-mounting element 340 extending upwardly from the body 310. A roller 380 is coupled to and freely rotatable relative to the foot 320.

The tensioning assembly 400, which is best shown in FIGS. 4A-4D, is configured to tension the strap around the load during the tensioning cycle. The tensioning assembly 400 includes a tensioning-assembly support 410, tensioning-assembly gearing 420, a tension wheel 440 driven by the tensioning-assembly gearing 420, and one or more covers (not labeled) mounted to the tensioning-assembly support 410 to partially or completely enclose certain components of the tensioning-assembly gearing 420 and the tension wheel 440.

The tensioning-assembly gearing 420 includes: a driven gear 421; a first sun gear 422; first planet gears 423a, 423b, and 423c; a carrier 424; a first ring gear 425; a bearing bushing 426; a second ring gear 427; a tension-wheel mount 428; second planet gears 429a, 429b, and 429c; and a key 420k. The components of the tensioning-assembly gearing 420 (with the exception of the key 420k) are centered on-and certain of them are rotatable about-a tension-wheel rotational axis 440a. The carrier 424 includes a first planet-gear carrier 424a to which the first planet gears 423a-423c are rotatably mounted (such as via respective bearings and mounting pins) and a second sun gear 424b rotatable with (and here integrally formed with) the planet-gear carrier 424a about the tension-wheel rotational axis 440a. The first ring gear 425 includes internal teeth 425it and external teeth 425ot. The second ring gear 427 includes internal teeth 427it. The tension-wheel mount 428 includes a second planet-gear carrier 428a and a tension-wheel shaft 428b rotatable with (and here integrally formed with) the second planet-gear carrier 428a about the tension-wheel rotational axis 440a. The second planet gears 429a-429c are rotatably mounted to the second planet-gear carrier 428a (such as via respective bearings and mounting pins). The tension-wheel shaft 428b defines an opening (not labeled) sized to receive the key 420k.

The first sun gear 422 is fixedly mounted to the driven gear 421 (such as via a splined connection) such that the driven gear and the first sun gear rotate together about the tension-wheel rotational axis 440a. The first sun gear 422 meshes with and drivingly engages the first planet gears 423a-423c. The first planet gears mesh with the internal teeth 425it of the first ring gear 425. The second planet gears mesh with the internal teeth 427it of the second ring gear 427. The bearing bushing 426 rotatably supports the first ring gear 425 and separates it from the driven gear 421. The second sun gear 424b meshes with and drivingly engages the second planet gears 429a-429c. The tension wheel 440 is fixedly mounted to the tension-wheel shaft 428b via a keyed connection with the key 420k such that the tension-wheel shaft and the tension wheel rotate together about the tension-wheel rotational axis 440a. Specifically, the tension wheel 440 defines a slot sized to receive the key 420k when pushed onto the tension-wheel shaft 428b.

The tensioning-assembly gearing 420 is mounted to the tensioning-assembly support 410. The second ring gear 427 is fixed in rotation about the tension-wheel rotational axis 440a relative to the tensioning-assembly support 410 (that is, the second ring gear 427 is not rotatable about the tension-wheel rotational axis 440a relative to the tensioning-assembly support 410). In this example embodiment, pins (which are shown but not labeled) are positioned between the outer surface of the second ring gear 427 and the tensioning-assembly support 410 to prevent relative rotation, though any suitable components (such as set screws, glue, or high-friction components or fasteners) may be used to do so. The decoupling assembly 1900 (except when actuated, as described below) fixes the first ring gear 425 in rotation about the tension-wheel rotational axis 440a relative to the tensioning-assembly support 410 (so the first ring gear cannot rotate about the tension-wheel rotational axis 440a relative to the tensioning-assembly support 410).

During the tensioning cycle, the drive assembly 700 drives the driven gear 421, as described below. The driven gear 421 begins rotating itself and the first sun gear 422 about the tension-wheel rotational axis 440a in a tensioning rotational direction (clockwise from the perspective of FIG. 4B in this example embodiment). The first sun gear 422 drives the first set of planet gears 423a-423c. Since the decoupling assembly 1900 prevents the first ring gear 425 from rotating about the tension-wheel rotational axis 440a, rotation of the planet gears 423a-423c causes the carrier 424—including the second sun gear 424b—to rotate about the tension-wheel rotational axis 440a in the tensioning rotational direction. The second sun gear 424b drives the second set of planet gears 429a-429c. Since the second ring gear 427 cannot rotate about the tension-wheel rotational axis 440a, rotation of the planet gears 429a-429c causes the tension-wheel mount 428 and the tension wheel 440 mounted thereto to rotate about the tension-wheel rotational axis 440a in the tensioning rotational direction. Accordingly, the tensioning-assembly gearing 420 operatively connects the drive assembly 700 to the tension wheel 440 to rotate the tension wheel 440 about the tension-wheel rotational axis 440a in the tensioning rotational direction.

The tensioning assembly 400 is movably mounted to the tensioning-assembly-mounting element 330 of the support 300 and configured to pivot relative to the support 300—and particularly relative to the foot 320 of the support 300—under control of the trigger assembly 900 (as described below) and about a tensioning-assembly-pivot axis 405a of a tensioning-assembly-pivot shaft 405 between a strap-tensioning position (FIGS. 7A and 7B) and a strap-insertion position (FIG. 7C). When the tensioning assembly 400 is in the strap-tensioning position, the tension wheel 440 is adjacent to (and in this embodiment contacts) the roller 380 of the support 300 (or the upper surface of the strap if the strap has been inserted into the strapping tool 50). When the tensioning assembly 400 is in the strap-insertion position, the tension wheel 440 is spaced-apart from the roller 380 to enable the top portion of the strap (described below) to be inserted between the tension wheel 440 and the roller 380. A tensioning-assembly-biasing element 400s (FIG. 3B), which is a torsion spring in this example embodiment but may be any other suitable type of biasing element, biases the tensioning assembly 400 to the strap-tensioning position.

The decoupling assembly 1900, which is best shown in FIGS. 5A-5D, is configured to, after the tensioning process is complete, enable the tension wheel 440 to rotate about the tension-wheel rotational axis 440a in a direction opposite the tensioning rotational direction to release the tension to facilitate removal of the tool 50 from the strap. The decoupling assembly 1900 includes a decoupling-assembly shaft 1910, a decoupling-assembly housing 1920, a first engageable element 1930, an expandable element 1940, and a second engageable element 1950.

The decoupling-assembly shaft 1910 includes a body 1912 having a first end 1912a having an irregular cross-section and second end 1912b having teeth. A first bearing support 1914 extends from the first end 1912a, and a second bearing support 1916 extends from the second end 1912b. The decoupling-assembly housing 1920 includes a tubular body 1922 having teeth 1924 extending around its outer circumference. The body 1922 defines an opening therethrough. The first engageable element 1930 comprises a tubular bushing having a cylindrical outer surface and an interior surface having a perimeter that matches the perimeter of the first end 1912a of the body 1912 of the decoupling-assembly shaft 1910. The expandable element 1940 includes a torsion spring having a first end 1940a and a second end 1940b. The second engageable element 1950 includes a tubular body 1952 and an annular flange 1954 at one end of the body 1952. An opening 19540 is defined through the flange 1954.

The first engageable element 1930 is mounted on the first end 1912a of the body 1912 of the decoupling-assembly shaft 1910 for rotation therewith and is disposed within the body 1922 of the decoupling-assembly housing 1920. The second engageable element 1950 is also disposed within the body 1922 of the decoupling-assembly housing 1920 such that the body 1952 of the second engageable element 1950 is adjacent the first engageable element 1930 and such that at least part of the decoupling-assembly shaft 1910 extends through the second engageable element 1950. The expandable element 1940, which is a torsion spring in this example embodiment, is disposed within the body 1922 of the decoupling assembly housing 1920 and circumscribes the first engageable element 1930 and the body 1952 of the second engageable element 1950. The outer diameters of the first engageable element 1930 and the body 1952 of the second engageable element are substantially the same and are equal to or larger than the resting inner diameter of the torsion spring 1940. This means that the torsion spring 1940 exerts a compression force on the first engageable element 1930 and the body 1952 of the second engageable element that prevents those components (and the decoupling-assembly shaft 1910) from rotating relative to one another. The first end 1940a of the expandable element 1940 is received in the opening 19540 defined through the flange 1954 of the second engageable element 1950, and the second end 1940b of the expandable element 1940 is received in the opening 1922o defined in the body 1922 of the decoupling-assembly housing 1920. Bearings (not shown) are mounted on the first and second bearing supports 1914 and 1916, respectively, of the decoupling-assembly shaft 1910.

As best shown in FIGS. 3B, 5D, and 7A-9C, the decoupling assembly 1900 is mounted to the tensioning-assembly support 410 and operatively connected to the tensioning-assembly gearing 420. More specifically, the decoupling assembly 1900 is mounted to the tensioning-assembly support 410 via a fastener (not labeled) that fixes the second engageable element 1950 in rotation relative to the tensioning-assembly support 410 such that the second engageable element 1950—and the first end 1940a of the expandable element 1940 received in the opening 19540 of the flange 1954 of the second engageable element 1950—cannot rotate relative to the tensioning-assembly support 410. As shown in FIG. 5D, intermediary gears 1990a and 1990b (here, spur gears mounted to (and freely rotatable relative to) the tensioning-assembly support 410) operably connect the body 1912 to the first ring gear 425 of the tensioning-assembly gearing 420. Specifically, the teeth on the second end 1912b of the body 1912 of the decoupling-assembly shaft 1910 mesh with a first gear 1990a, which meshes with a second gear 1990b, which meshes with the outer teeth 425ot of the first ring gear 425 of the tensioning-assembly gearing 420 of the tensioning assembly 400. Since the body 1952 is fixed in rotation relative to the tensioning-assembly support 410 and the decoupling-assembly shaft 1910 is fixed in rotation with the first engageable element 1930, the decoupling-assembly shaft 1910—and thus the intermediary gears 1990a and 1990b—are fixed in rotation relative to the tensioning-assembly housing 410. Since the intermediary gear 1990b meshes with the outer teeth 425ot of the first ring gear 425 of the tensioning-assembly gearing 420, the decoupling assembly 1900 prevents the first ring gear 425 from rotating about the tension-wheel rotational axis 440a.

The decoupling assembly 1900 is actuatable (such as by the trigger assembly 900 as described below) to eliminate the connection between the torsion spring 1940 and the first engageable element 1930 such that the first engageable element 1930 and the decoupling-assembly shaft 1910 may rotate relative to the second engageable element 1930. As explained above, the second engageable element 1950 and the first end 1940a of the expandable element 1940 (that is received in the opening 19540 of the flange 1954 of the second engageable element 1950) are fixed in rotation relative to the tensioning-assembly support 410. To eliminate the connection between the torsion spring 1940 and the first engageable element 1930, the decoupling-assembly housing 1920 is rotated relative to the tensioning-assembly support 410, the first end 1940a of the torsion spring 1940, and the second engageable element 1950. The second end 1940b of the torsion spring 1940, which is received in the opening 1922o defined in the body 1922 of the decoupling-assembly housing 1920, rotates with the decoupling-assembly housing 1920. As this occurs, the inner diameter of the torsion spring 1940 near its second end 1940b begins expanding, and eventually expands enough (thereby reducing the compression force or eliminating it altogether) to enable the first engageable element 1930 and the decoupling-assembly shaft 1910 to rotate relative to the second engageable element 1950 (and the torsion spring 1940).

Upon completion of the tensioning cycle, the tension wheel 440 holds a significant amount of tension in the strap, and the strap exerts a counteracting force (or torque) on the tension wheel 440 in a direction opposite the tensioning direction. Actuation of the decoupling assembly 1900 enables the tension wheel 440 to rotate in the direction opposite the tensioning direction to release that tension in a controlled manner. Specifically, upon completion of the tensioning cycle, the decoupling-assembly shaft 1910 (via the intermediary gears 1990a and 1990b) continues to prevent the first ring gear 425 of the tensioning-assembly gearing 420 from rotating about the tension-wheel rotational axis 440, which prevents the tension wheel 440 from rotating in the direction opposite the tensioning direction. As the decoupling-assembly housing 1920 is rotated (such as via actuation of the trigger assembly 900 as described below), the inner diameter of the torsion spring 1940 near its second end 1940b begins expanding. Eventually, the force the first ring gear 425 exerts on the decoupling-assembly shaft 1910 exceeds the compression force the torsion spring 1940 exerts on the first engageable element 1930. When this occurs, the first ring gear 425 rotates in the direction opposite the tensioning direction about the tension-wheel rotational axis 440a. Since the first sun gear 422 is fixed in rotation (by the drive assembly 700), this causes the first planetary gears 423a-423c to rotate in the direction opposite the tensioning direction about the tension-wheel rotational axis 440a. This (as explained above) causes the tension wheel 440 to rotate in the direction opposite the tensioning direction about the tension-wheel rotational axis 440a.

In other embodiments, only one or more than two intermediary gears may operably connect the decoupling-assembly shaft to the first ring gear. In still further embodiments, the second end of the body of the decoupling-assembly shaft directly meshes with the outer teeth of the first ring gear (rather than via one or more intermediary gears).

The trigger assembly 900, which is best shown in FIGS. 6A-9C, is operably connected to: (1) the tensioning assembly 400 and configured to move the tensioning assembly 400 relative to the support 300 from the strap-tensioning position to the strap-insertion position; and (2) the decoupling assembly 1900 and configured to actuate the decoupling assembly, thereby enabling the tension wheel 440 to rotate in the direction opposite the tensioning rotational direction. The trigger assembly 900 includes a trigger 910, a trigger pivot pin 910p1, a trigger travel pin 910p2, a trigger-gear-engaging pin 910p3, a trigger-biasing element 910s, a trigger gear 930, and a trigger-gear biasing element 930s.

The trigger 910 includes a trigger body 912, a trigger head 914 extending from the trigger body 912 and defining a travel-pin slot 914s (shown in FIGS. 9A-9C), and a blocking foot 916 extending downwardly from the trigger body 912. The trigger gear 930 includes a trigger-gear mounting head 932 defining a stop surface 932a, a trigger-gear arm 934 extending from the trigger-gear mounting head 932, and a trigger-gear foot 936 connected to the trigger-gear arm 934 and including trigger-gear teeth 936t.

The trigger pivot pin 910p1 and the trigger travel pin 910p2 attach the trigger 910 to the tensioning assembly 400 such that the trigger 910 is pivotable relative to the tensioning assembly 400 between a home position (FIGS. 7A, 8A, and 9A) and an intermediate position (FIGS. 7B, 8B, and 9B). Specifically, the trigger pivot pin 910p1 extends through openings (not shown) defined through the tensioning-assembly support 410 and the trigger head 914 of the trigger 910 such that the trigger 910 is pivotable about the trigger pivot pin 910p1—which defines a trigger pivot axis (not shown)—and relative to the tensioning assembly 400 and the decoupling assembly 1900. The trigger travel pin 910p2 extends through an opening (not shown) defined through the tensioning-assembly support 410 and through the travel-pin slot 914s of the trigger head 914.

As the trigger 910 pivots about the trigger pivot pin 910p1 (and the trigger pivot axis) and relative to the tensioning assembly 400 and the support 300, the travel-pin slot 914s moves relative to the trigger travel pin 910p2 (which is mounted to the tensioning-assembly support 410). The size, shape, position, and orientation of the travel-pin slot 914s constrain the pivoting movement of the trigger 910 about the pivot pin 910p1 between the home and intermediate positions. As shown in FIG. 9A, when the trigger 910 is in its home position, the trigger travel pin 910p2 is positioned at and engages the upper end (not labeled) of the travel-pin slot 914s, preventing the trigger 910 from further rotation relative to the tensioning assembly 400 in the clockwise direction. Conversely, and as shown in FIG. 9B, when the trigger 910 is in its intermediate position, the trigger travel pin 910p2 is positioned at the lower end (not labeled) of the travel-pin slot 914s, preventing the trigger 910 from further rotation relative to the tensioning assembly 400 in the counter-clockwise direction. The trigger biasing element 910s, which is a torsion spring in this example embodiment but may be any other suitable component, biases the trigger 910 to its home position. When the trigger 910 is in its home position, the blocking foot 916 engages the tensioning assembly 400 to prevent further clockwise rotation of the trigger 910 and retain the trigger 910 in its home position.

As best shown in FIG. 6A, the trigger-gear mounting head 932 is mounted to the travel pin 910p2. The trigger-gear biasing element 930s biases (via engagement with a pin 930p) the stop surface 932a of the trigger-gear mounting head 932 into contact with the trigger-gear-engaging pin 910p3, which is fixedly attached to the trigger 910. As a result, the trigger gear 930 is rotatable about the travel pin 910p2 as the trigger rotates between its home and intermediate positions. That is, the trigger 910 is operably connected to the trigger gear 930 and configured to rotate the trigger gear 930 about the trigger travel pin 910b as the trigger 910 pivots from its home position to its intermediate position. As the trigger gear 930 rotates, it actuates the decoupling assembly 1900, as described above. More specifically, as the trigger gear 930 rotates, its teeth 936t mesh with the teeth 1924 of the body 1922 of the decoupling-assembly housing 1920, thereby forcing the decoupling-assembly housing 1920 to rotate (thereby actuating the decoupling assembly 1900).

As explained above and as shown in FIG. 9B, once the trigger 910 reaches its intermediate position, the trigger travel pin 910p2 is positioned at the lower end of the travel pin slot 914s, preventing the trigger 910 from further rotation relative to the tensioning assembly 400 in the counter-clockwise direction. At this point, if the tensioning assembly 400 is in its strap-tensioning position, as shown in FIG. 7B, continued application of force on the trigger 910 towards the handle 150 causes the trigger 910 and the tensioning assembly 400 to rotate together about the tensioning-assembly-pivot axis 405a until the trigger 910 reaches an actuated position and the tensioning assembly 400 reaches its strap-insertion position. FIG. 7C shows the trigger 910 in its actuated position and the tensioning assembly 400 in its strap-insertion position.

The sealing assembly 500, which is best shown in FIGS. 3A, 10A, and 10B, is configured to attach overlapping portions of the strap to one another to form a tensioned strap loop around the load during the sealing cycle by notching both a seal element positioned around the overlapping portions of the strap and the overlapping portions of the strap themselves. The sealing assembly 500 includes a front cover (not labeled), a back cover (not labeled), and a jaw assembly 520 partially enclosed between the front and back covers. The back cover is mounted to the support 300 (not shown).

The jaw assembly 520 includes a coupler 522, a coupler pivot 524, first and second coupler/jaw linkages 526 and 528, a first jaw 536, a second jaw 538, a first jaw connector 550, a second jaw connector (not shown), first and second linkage pins 540a and 540b, and first and second pivot pins 560a and 560b. The first and second jaws 536 and 538 form a pair of opposing jaws. The first and second coupler/jaw linkages 526 and 528 are each pivotably connected to the coupler 522 near their respective upper ends via the coupler pivot 524. This pivotable connection enables the first and second coupler/jaw linkages 526 and 528 to pivot relative to the coupler 522 and the coupler pivot 524 about a longitudinal axis (not shown) of the coupler pivot 524. Here, the coupler pivot 524 includes a pivot pin retained via a retaining ring (not shown), though it may be any other suitable pivot in other embodiments. The rear end of the coupler pivot 524 is positioned in a slot (not labeled) defined in the back cover so the slot limits the coupler pivot 524 to moving vertically between an upper and a lower position.

The respective upper portions of each of the first and second jaws 536 and 538 are pivotably connected to the respective lower ends of the coupler/jaw linkages 526 and 528 via the linkage pins 540a and 540b, respectively. These pivotable connections enable the jaws to pivot relative to the coupler/jaw linkages about their respective longitudinal axes (not shown). The respective lower portions of each of the first and second jaws 536 and 538 are pivotably connected by the pivot pins 560a and 560b to the first jaw connector 550 and the second jaw connector. The pivotable connections enable the jaws to pivot relative to the jaw connectors about their respective longitudinal axes (not shown) between respective home positions (FIG. 10A) and sealing positions (FIG. 10B). Each jaw 536 and 538 has a lower tooth 536a and 538a that forces the seal element against the jaw connectors and cuts a notch in the seal element and the overlapping portions of the strap during the sealing cycle (described below).

Although not shown here, a cutter is positioned in and movable within a recess defined in the back cover and mounted to the coupler pivot 524. Movement of the coupler pivot 524 downwards causes the coupler pivot 524 to force the cutter downward to cut the strap from the strap supply, and movement of the coupler pivot 524 back upward causes the cutter to move back upward.

The drive assembly 700, which is best shown in FIG. 3C, is operably connected to the tensioning assembly 400 and configured to rotate the tension wheel 440 to tension the strap and is operably connected to the sealing assembly 500 to attach the overlapping portions of the strap to one another. The drive assembly 700 includes a working-assembly actuator 710, a first transmission 720, a second transmission 730, a first belt 740, a third transmission 750, a second belt 760, and a conversion assembly 800.

In this example embodiment, the working-assembly actuator 710 includes a motor (and is referred to herein as the motor 710), and particularly a brushless direct-current motor that includes a motor output shaft 712 having a motor-output-shaft rotational axis (though the motor 710 may be any other suitable type of motor in other embodiments). The motor 710 is operably connected to (via the motor output shaft 712) and configured to drive the first transmission 720, which (as described below) is configured to selectively transmit the output of the motor 710 to either the tensioning assembly 400 or the sealing assembly 500. In other embodiments, the strapping tool includes separate tensioning and sealing actuators respectively configured to actuate the tensioning assembly and the sealing assembly rather than a single actuator configured to actuate both.

The first transmission 720 includes any suitable gearing and/or other components that are configured to selectively transmit the output of the motor 710 to the second transmission 730 via the first belt 740 and to the third transmission 750 via the second belt 760. More specifically, the first transmission 720 is configured such that: (1) rotation of the motor output shaft 712 in a first rotational direction causes the first transmission 720 to transmit the output of the motor 710 to the second transmission 730 via the first belt 740 and not to the third transmission 750; and (2) rotation of the motor output shaft 712 in a second rotational direction opposite the first rotational direction causes the first transmission 720 to transmit the output of the motor 710 to the third transmission 750 via the second belt 760 and not to the second transmission 730. Thus, in this embodiment, a single motor (the motor 710) is configured to actuate both the tensioning and sealing assemblies 400 and 500.

To accomplish this selective transmission of the motor output, the first transmission 720 includes a first belt pulley 714a (or other suitable component) mounted on a first freewheel (not labeled) that is mounted on the motor output shaft 712 and a second belt pulley 714b (or other suitable component) mounted on a second freewheel (not labeled) that is mounted on the motor output shaft 712. The first belt pulley 714a is operatively connected (via the first belt 740) to the second transmission 730, and the second belt pulley 714b is operatively connected (via the second belt 760) to the third transmission 750. When the motor output shaft 712 rotates in the first direction: (1) the first freewheel and the first belt pulley 714a rotate with the motor output shaft 712, thereby transmitting the motor output to the second transmission 730 via the first belt 740; and (2) the motor output shaft 712 rotates freely through the second freewheel, which does not rotate the second belt pulley 714b. Conversely, when the motor output shaft 712 rotates in the second direction: (1) the second freewheel and the second belt pulley 714b rotate with the motor output shaft 712, thereby transmitting the motor output to the third transmission 750 via the second belt 760; and (2) the motor output shaft 712 rotates freely through the first freewheel, which does not rotate the first belt pulley 714a. This is merely one example embodiment of the first transmission 720, and it may include any other suitable components in other embodiments.

An anti-rotation gear 790 is mounted to a freewheel (not shown) that is, in turn, rotatably mounted to the support 300 adjacent the second belt 760 such that the second belt 760 drivingly engages the anti-rotation gear 790. The freewheel is configured such that the anti-rotation gear 790 is freely rotatable in the second rotational direction (clockwise from the perspective shown in FIG. 3C) and is not rotatable in the first rotational direction (counterclockwise from the perspective shown in FIG. 3C). Accordingly, when the motor output shaft 712 is rotated in the second rotational direction, second belt 760 drives the anti-rotation gear 790 in rotation as it transmits the output of the motor output shaft 712 to the third transmission 750. Since the anti-rotation gear 790 cannot rotate in the first rotational direction and is engaged with the second belt 760, the anti-rotation gear 790 prevents the second belt 760 from rotating when the motor output shaft 712 is rotated in the first rotational direction.

The second transmission 730 is configured to transmit the output of the first transmission 720 to the tensioning assembly 400 to cause the tension wheel 440 to rotate. More particularly, the second transmission 730 is configured to transmit the output of the first transmission 720 to the tensioning-assembly gearing 420 of the tensioning assembly 400 to rotate the tension-wheel shaft 428b and the tension wheel 440 thereon. Accordingly, the motor 710 is operatively coupled to the tension wheel 440 (via the first transmission 720, the first belt 740, the second transmission 730, the tensioning-assembly gearing 420, and the tension-wheel shaft 428b) and configured to rotate the tension wheel 440. In this example embodiment, the second transmission 730 includes intermediary gearing (not labeled) rotatably mounted (via bearings or any other suitable components) to the tensioning-assembly-pivot shaft 405 and rotatable about the tensioning-assembly-pivot axis 405a such that to transmit the output of the motor 710 to the tensioning-assembly gearing 420 to rotate the tension wheel 440. The position of the intermediary gearing is such that the operative connection between the motor 710 and the tensioning assembly 400 is maintained as the tensioning assembly 400 pivots between its strap-tensioning and strap-insertion positions.

The third transmission 750 is configured to transmit the output of the first transmission 720 to the conversion assembly 800. The third transmission 750 may include any suitable components, such as one or more gears and one or more shafts arranged in any suitable manner. The conversion assembly 800 is configured to transmit the output of the third transmission 750 to the sealing assembly 500 to carry out the sealing cycle, which includes causing the jaws of the sealing assembly to move from their home positions to their sealing positions to cut notches in the seal element and the strap and then back to their home positions to release the notched seal element and strap. In doing so, in this embodiment the conversion assembly 800 is configured to convert rotational motion (the rotation of shafts and gears) to linear motion (the reciprocating translational movement of a coupler).

More specifically, rotation of the motor output shaft 712 of the motor 710 in the second rotational direction causes rotation of the second belt pulley 714b of the first transmission 720. The second belt 760 transmits the output of the first transmission 720 (in this instance, the rotation of the second belt pulley 714b) to the third transmission 750, which in turn transmits the output of the first transmission 720 to the conversion assembly 800.

The display assembly 1300 includes a suitable display screen 1310 with a touch panel 1320. The display screen 1310 is configured to display information regarding the strapping tool (at least in this embodiment), and the touch screen 1320 is configured to receive operator inputs such as a desired strap tension, desired weld cooling time, and the like as is known in the art. A display controller (not shown) may control the display screen 1310 and the touch panel 1320 and, in these embodiments, is communicatively connected to the controller 1300 to send signals to the controller 1300 and to receive signals from the controller 1300. Other embodiments of the strapping tool do not include a touch panel. Still other embodiments of the strapping tool do not include a display assembly.

The actuating assembly 1400 is configured to receive operator input to start operation of the tensioning and sealing cycles. In this example embodiment, the actuating assembly 1400 includes first and second pushbutton actuators 1410 and 1420 that, depending on the operating mode of the strapping tool 50, initiate the tensioning and/or sealing cycles as described below. Other embodiments of the strapping tool 50 do not have an actuating assembly 1400 and instead incorporate its functionality into the display assembly 1300. For instance, in one of these embodiments two areas of the touch panel define virtual buttons that have the same functionality as mechanical pushbutton actuators.

The controller 1600 includes a processing device (or devices) communicatively connected to a memory device (or devices). For instance, the controller may be a programmable logic controller. The processing device may include any suitable processing device such as, but not limited to, a general-purpose processor, a special-purpose processor, a digital-signal processor, one or more microprocessors, one or more microprocessors in association with a digital-signal processor core, one or more application-specific integrated circuits, one or more field-programmable gate array circuits, one or more integrated circuits, and/or a state machine. The memory device may include any suitable memory device such as, but not limited to, read-only memory, random-access memory, one or more digital registers, cache memory, one or more semiconductor memory devices, magnetic media such as integrated hard disks and/or removable memory, magneto-optical media, and/or optical media. The memory device stores instructions executable by the processing device to control operation of the strapping tool 50. The controller 1600 is communicatively and operably connected to the motor 710, the display assembly 1300, the actuating assembly 1400, and the sensor(s) 1700 and configured to receive signals from and to control those components. The controller 1600 may also be communicatively connectable (such as via Wi-Fi, Bluetooth, near-field communication, or other suitable wireless communications protocol) to an external device, such as a computing device, to send information to and receive information from that external device.

The controller 1600 is configured to operate the strapping tool in one of three operating modes: (1) a manual operating mode; (2) a semi-automatic operating mode; and (3) an automatic operating mode. In the manual operating mode, the controller 1600 operates the motor 710 to cause the tension wheel 440 to rotate responsive to the first pushbutton actuator 1410 being actuated and maintained in its actuated state. The controller 1600 operates the motor 710 to cause the sealing assembly 500 to carry out the sealing cycle responsive to the second pushbutton actuator 1420 being actuated. In the semi-automatic operating mode, the controller 1600 operates the motor 710 to cause the tension wheel 440 to rotate responsive to the first pushbutton actuator 1410 being actuated and maintained in its actuated state. Once the controller 1600 determines that the tension in the strap reaches the (preset) desired strap tension, the controller 1600 automatically operates the motor to cause the sealing assembly 500 to carry out the sealing cycle (without requiring additional input from the operator). In the automatic operating mode, the controller 1600 operates the motor 710 to cause the tension wheel 440 to rotate responsive to the first pushbutton actuator 1410 being actuated. Once the controller 1600 determines that the tension in the strap reaches the (preset) desired strap tension, the controller 1600 automatically operates the motor to cause the sealing assembly 500 to carry out the sealing cycle (without requiring additional input from the operator).

The power supply is electrically connected to (via suitable wiring and other components) and configured to power several components of the strapping tool 50, including the motor 710, the display assembly 1300, the actuating assembly 1400, the controller 1600, and the sensor(s) 1700. The power supply is a rechargeable battery (such as a lithium-ion or nickel cadmium battery) in this example embodiment, though it may be any other suitable electric power supply in other embodiments. The power supply is sized, shaped, and otherwise configured to be received in the receptacle 190 defined by the housing 100. The strapping tool 50 includes one or more battery-securing devices (not shown) to releasably lock the power supply in place upon receipt in the receptacle. Actuation of a release device of the strapping tool 50 or the power supply unlocks the power supply from the housing 100 and enables an operator to remove the power supply from the housing 100.

Use of the strapping tool 50 to carry out a strapping cycle including: (1) a tensioning cycle in which the strapping tool 50 tensions a strap S around a load L; and (2) a sealing cycle in which the strapping tool 50 notches both a seal element SE positioned around overlapping top and bottom portions of the strap S and the top and bottom portions of the straps themselves and cuts the strap from the strap supply is described below. Initially, the tensioning assembly 400 is in its strap-tensioning position, the jaws 536 and 538 of the sealing assembly 500 are in their respective home positions, and the trigger 910 is in its home position. The strapping tool 50 is in the automatic mode for the purposes of this example.

The operator pulls the strap S leading-end first from a strap supply (not shown) and threads the leading end of the strap S through the seal element SE. While holding the seal element SE, the operator wraps the strap around the load L and positions the leading end of the strap S below another portion of the strap S, and again threads the leading end of the strap S through the seal element SE. Afterwards, the seal element SE is positioned around overlapping top and bottom portions of the strap S. The operator then bends the leading end of the strap S backward and slides the seal element SE along the strap S until it meets the bend. FIG. 11 shows the position of the bend and the seal element SE at this point.

The operator then pulls the trigger 910 from its home position to its actuated position to move the tensioning assembly 400 from its strap-tensioning position to its strap-insertion position. While holding the trigger 910 in its actuated position, the operator introduces the top portion of the strap S rearward of the seal element SE into the strap-receiving opening so the top portion of the strap S is between the tension wheel 440 and the roller 380 of the foot 320 of the support 300. The operator then manually pulls the strap S to eliminate the slack and pushes the strapping tool 50 toward the seal element SE until the seal element SE is positioned between the jaws 536 and 538. At this point the bottom portion of the strap S is beneath the foot 320.

The operator then releases the trigger 910. This causes the tensioning-assembly-biasing element 400s to force the tensioning assembly 400 back to its strap-tensioning position, which causes the tension wheel 440 to engage the top portion of the strap S and pinch it against the roller 380. The trigger-biasing element 910s forces the trigger 910 back to its home position. At this point the bottom portion of the strap S is beneath the foot 320. The operator then actuates the first pushbutton actuator 1410 to initiate the strapping cycle. In response the controller 1600 starts the tensioning cycle by controlling the motor 710 to begin rotating the motor output shaft 712 in the first rotational direction, which causes the tension-wheel shaft 428b and tension wheel 440 thereon to begin rotating. As the tension wheel 440 rotates, it pulls on the top portion of the strap S, thereby tensioning the strap S around the load L. Throughout the tensioning cycle, the controller 1600 monitors the current drawn by the motor 710. When this current reaches a preset value that is correlated with the (preset) desired strap tension for this strapping cycle, the controller 1600 stops the motor 710, thereby terminating the tensioning cycle.

The controller 1600 then automatically starts the sealing cycle by controlling the motor 710 to begin rotating the motor output shaft 712 in the second rotational direction. This causes the jaws 536 and 538 to: (1) pivot from their respective home positions to their respective sealing positions to cut notches in the seal element SE and the top and bottom portions of the strap S within the seal element SE; and then (2) pivot from their respective sealing positions back to their respective home positions to enable the strapping tool 50 to be removed from the strap S. FIG. 12 shows the notched seal element SE and strap S.

Although the sealing assembly comprises jaws configured to cut into seal elements to attach two portions of the strap to itself, the sealing assembly may comprise other sealing mechanisms in other embodiments, such as a friction-welding assembly or a sealless-attachment assembly.

Other embodiments of the strapping tool may include fewer assemblies, components, and/or features than those included in the strapping tool 50 described above and shown in the Figures. For instance, other strapping tools may include fewer than all of (including only one of) the double-pivoting trigger, the decoupling assembly, and the anti-rotation gear. In other words, while the strapping tool 50 includes all of these assemblies, components, and feature, they are independent of one another and may be independently included in other strapping tools.

Claims

1. A strapping tool comprising: a support;a tensioning assembly mounted to the support and pivotable relative to the support between a strap-tensioning position and a strap-insertion position; anda trigger assembly comprising: a trigger comprising a trigger body and a trigger head extending from the trigger body, wherein the trigger head defines a curved slot, wherein the trigger is mounted to the tensioning assembly via a trigger pivot pin and is pivotable relative to the tensioning assembly and about the trigger pivot pin between a home position and an intermediate position and is pivotable relative to the support and about the tensioning-assembly pivot axis from the intermediate position to an actuated position to move the tensioning assembly from the strap-tensioning position to the strap-insertion position;a travel pin mounted to the tensioning assembly and extending through the slot of the trigger head to constrain pivoting of the trigger relative to the tensioning assembly between the home and intermediate positions; anda trigger gear comprising a trigger-gear head defining a stop surface, a trigger-gear arm extending from the trigger-gear head, and a trigger-gear foot connected to the trigger-gear arm and including trigger-gear teeth, wherein the trigger-gear head is rotatably mounted to the travel pin.

2. The strapping tool of claim 1, wherein the tensioning-assembly pivot axis and the trigger pivot axis are different and parallel to one another.

3. The strapping tool of claim 1, wherein the travel pin is at a first end of the slot when the trigger is in the home position and an opposing second end of the slot when the trigger is in the intermediate position.

4. The strapping tool of claim 3, wherein the travel pin is at the second end of the slot when the trigger is in the actuated position.

5. The strapping tool of claim 1, wherein the trigger assembly further comprises a trigger biasing element biasing the trigger to the home position.

6. The strapping tool of claim 5, wherein the trigger biasing element comprises a torsion spring.

7. The strapping tool of claim 1, wherein the trigger assembly further comprises a trigger-gear-engaging component fixedly attached to the trigger and a trigger-gear biasing element biasing the stop surface of the trigger-gear head into contact with the trigger-gear-engaging component.

8. The strapping tool of claim 7, wherein the trigger-gear biasing element comprises a torsion spring.

9. The strapping tool of claim 7, wherein the trigger-gear-engaging component comprises a pin.

10. The strapping tool of claim 1, wherein the tensioning assembly comprises a tension wheel and tensioning-assembly gearing operably connected to a tension wheel to rotate the tension wheel about a tension-wheel rotational axis in a tensioning rotational direction, the strapping tool further comprising: a motor operably connected to the tensioning-assembly gearing to drive the tensioning-assembly gearing; anda decoupling assembly actuatable to enable the tension wheel to rotate about the tension-wheel rotational axis in a direction opposite the tensioning rotational direction, wherein the trigger is operably connected to the decoupling assembly to actuate the decoupling assembly when pivoted from the home position to the intermediate position.

11. The strapping tool of claim 10, wherein the decoupling assembly comprises a decoupling-assembly housing having a tubular body mounted to and rotatable relative to the tensioning assembly, the body comprising teeth extending around an outer circumference of the body.

12. The strapping tool of claim 11, wherein the trigger assembly further comprises a trigger-gear-engaging component fixedly attached to the trigger and a trigger-gear biasing element biasing the stop surface of the trigger-gear head into contact with the trigger-gear-engaging component such that pivoting of the trigger from the home position to the actuated position causes the trigger-gear teeth to engage the teeth of the body of the decoupling-assembly housing and rotate the decoupling-assembly housing relative to the tensioning assembly.

13. The strapping tool of claim 11, wherein the decoupling assembly further comprises: a decoupling-assembly shaft at least partially disposed within the decoupling-assembly housing;a first engageable element at least partially disposed within the decoupling-assembly housing and mounted to the decoupling-assembly shaft for rotation therewith;a second engageable element at least partially disposed within the decoupling-assembly housing and fixed in rotation relative to the tensioning assembly; andan expandable element at least partially disposed within the decoupling-assembly housing and circumscribing at least part of the first engageable element and at least part of the second engageable element and having a first end fixed to the second engageable element and a second end fixed to the decoupling-assembly housing, wherein a the expandable element is dimensioned so when at rest the expandable element applies a compression force on the first and second engageable elements that prevents the first and second engageable elements from rotating relative to one another.

14. The strapping tool of claim 13, wherein rotation of the decoupling-assembly housing via movement of the trigger from the home position to the intermediate position causes the second end of the expandable element to rotate relative to the first end of the expandable element, thereby causing an inner diameter of the expandable element to expand and enable the first engageable element to rotate relative to the second engageable element.

15. The strapping tool of claim 14, wherein the expandable element comprises a torsion spring.

16. The strapping tool of claim 13, wherein the tensioning-assembly gearing comprises a ring gear comprising external teeth, wherein the decoupling-assembly shaft comprises teeth, wherein the strapping tool further comprises intermediary gearing operably connecting the external teeth of the ring gear with the teeth of the decoupling assembly shaft, wherein the decoupling-assembly shaft and the intermediary gearing prevent rotation of the ring gear unless the decoupling assembly is actuated.

17. A strapping tool comprising: a support;a sealing assembly mounted to the support and comprising multiple jaws movable from respective jaw home positions to respective jaw sealing positions;a motor comprising a motor output shaft;a first freewheel mounted to the motor output shaft, wherein the first freewheel is configured to rotate with the motor output shaft when the motor output shaft rotates in a first rotational direction and not to rotate with the motor output shaft when the motor output shaft rotates in a second rotational direction opposite the first rotational direction;a belt pulley mounted to the first freewheel;a belt operably connecting the belt pulley to the sealing assembly,a second freewheel mounted to the support; andan anti-rotation gear mounted to the second freewheel and drivingly engaged by the belt, wherein the second freewheel is configured to enable the belt to drive the anti-rotation gear to rotate in the first rotational direction and to prevent the belt from driving the anti-rotation gear to rotate in the second rotational direction.

18. The strapping tool of claim 17, further comprising a tensioning assembly mounted to the support and pivotable relative to the support between a strap-tensioning position and a strap-insertion position, wherein the tensioning assembly comprises a tension wheel and tensioning-assembly gearing operably connected to a tension wheel to rotate the tension wheel, wherein the motor is operably connected to the tensioning-assembly gearing to drive the tensioning-assembly gearing.

19. The strapping tool of claim 18, further comprising: a third freewheel mounted to the motor output shaft, wherein the third freewheel is configured to rotate with the motor output shaft when the motor output shaft rotates in the second rotational direction and not to rotate with the motor output shaft when the motor output shaft rotates in the first rotational direction;a second belt pulley mounted to the third freewheel; anda second belt operably connecting the second belt pulley to the tensioning-assembly gearing.