Abstract:
A tote assembly to package, store, carry and/or dispense a length of flexible banding material coiled therein is provided. The tote assembly is fabricated from at least two pieces, of the same or different width, that are connected to form a cavity to house a banding material having a defined width. The tote assembly may be connected by one or more post and receptacle connectors and multiple tote assemblies may be stacked by a dimple and depression arrangement. The tote assembly further may include a removable buckle container and a removable cutting tool. Also provided is a method of inserting the banding material directly into a closed tote assembly through a band opening and winding the banding material therewithin.

Description:
FIELD OF INVENTION 
     This invention generally relates to tote assemblies used to house banding material and, more particularly, to tote assemblies fabricated from at least two pieces, having interior walls of the same or different height, that are connected to package, store, carry or dispense flexible banding material coiled therein. 
     BACKGROUND OF THE INVENTION 
     Band clamps are widely used in a variety of applications. The clamps generally include a flexible band that can be formed into a loop around an object, such as a telephone pole or signage pole, and a separate buckle that receives the opposing ends of the band and locks the ends in a fixed position. An example of a non-performed band clamp that is useful for outdoor applications is described in U.S. Pat. No. 4,765,032. Generally, banding material is manufactured in lengths of up to about one hundred feet or more, wound into circular coils for storage and transportation, and later partially unwound to cut off a desired length of band, as needed. 
     Various types of containers have been used to package, store, carry and dispense coils of flexible band. The band typically is wound into a spiral coil, before being placed into an open container. The open container receives the band and then is closed with a second piece, such as a lid. As such, prior containers require at least some assembly after the banding material is inserted. This can be cumbersome and expensive, often requiring significant manual assembly, in part due to the weight and the pressure of the coiled, flexible band against the container. 
     Containers are constructed in a variety of sizes to accommodate banding material of a variety of widths and lengths. Bands for these applications typically are manufactured in widths varying from about less than ¼ inch to a little over one inch and in lengths varying from several feet to several hundred feet. To securely hold the coiled banding material, the container must have side walls of sufficient height to house the banding material, without allowing it to partially or completely unwind. As such, such containers typically are constructed of two pieces to provide the desired side wall height for each different width of banding material, either 1) one piece having a side wall to accommodate the desired width of banding material and a second piece essentially being a lid, without a sidewall; or 2) two pieces having sidewalls of substantially the same height to combine to provide the desired height. In either event, a large number of separate pieces are required to construct such containers to accommodate a variety of widths of banding material. 
     Accordingly, it would be desirable to provide a tote assembly that incorporates additional advantages associated with assembling, packaging, storing, carrying and/or dispensing coiled, flexible banding material. 
     SUMMARY OF THE INVENTION 
     The present invention is directed to a band carrying device that includes a first tote assembly with a first tote member of a first width and a second tote member of the same or a second width, which is different from the first width, and a band held within the tote members. The first and second tote members may be connected by inserting at least one post on the periphery from one tote member into a corresponding receptacle of the other tote member. 
     A further embodiment of the invention is directed to a band carrying device that includes first and second tote assemblies, each with two tote members of the same or different widths, and a band held within the each tote assembly. The first and second tote assemblies may be stacked together by inserting at least one dimple of one tote member into a corresponding receptacle of the other tote member. 
     Yet another embodiment of the invention is directed to a method for assembling a band carrying device comprising inserting a tote assembly into a winding machine, locating a band through a band opening of the tote assembly, winding the band about a hub of the winding machine and removing the tote assembly from the winding machine. The band carrying device also may be provided with a band cutting insert tool and or may be printed with identifying indicia on a flat top surface. 
     Other objects and advantages of the invention will become apparent on reading the following detailed description and the appended claims, and also by referring to the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is an exploded view of a tote assembly having a first tote member and a second tote member, without a band installed; 
     FIG. 2 is a front plan view of a tote assembly, without a band installed; 
     FIG. 3 is a right side view of a tote assembly, without a band installed; 
     FIG. 4 is a cross sectional view of a tote assembly, with the interior spoke of the first tote member having a first height and the interior spoke of the second tote member having the same first height; 
     FIG. 5 is a cross sectional view of a tote assembly, with the interior spoke of the first tote member having a first height and the interior spoke of the second tote member having a second height; 
     FIG. 6 is a cross sectional view of a tote assembly, with the interior spoke of the first tote member having a second height and the interior spoke of the second tote member having the same second height; 
     FIG. 7 is a front plan view of a tote assembly, with a roll of band installed; 
     FIG. 8 is a front plan view of a tote assembly, with the first tote member removed to show roll of a band installed in the second tote member; 
     FIG. 9 is a exploded view of a tote assembly, with a band installed and with a buckle container; 
     FIG. 10 is a perspective view of a tote assembly, with a band installed and with a buckle container installed; 
     FIG. 11 is a bottom plan view of four tote assemblies, three of which are stacked together; 
     FIG. 12 is a exploded view of four tote assemblies, three of which are stacked together; 
     FIG. 13 is a exploded view of a tote assembly, with a band installed and with a buckle container and an insert cutting tool; 
     FIG. 14 is a exploded view of an insert cutting tool; 
     FIG. 15 is a front plan view of a winding machine; 
     FIG. 16 is a front plan view of the band winder component of a winding machine, showing a band entering the band winder and the direction of travel of the band and the band winder; 
     FIG. 17 is a top plan view of the band winder shown in FIG. 16; 
     FIGS. 18A-18F illustrate diagrammatically steps of winding a band inside a tote assembly using the band winder; 
     FIG. 19 is a front plan view of a vertical tote assembly feed of a winding machine, showing three tote assemblies; 
     FIG. 20 is a right side plan view of the vertical tote assembly feed shown in FIG. 19; 
     FIG. 21 is a top plan view of the vertical tote assembly feed shown in FIG. 19; 
     FIG. 22 is a front plan view of four tote assemblies in an assembly line, one of which is opposing a printer; and 
     FIG. 23 is a top plan view of four tote assemblies in an assembly line, two of which show printed text, with an exploded view of such printed text. 
    
    
     DETAILED DESCRIPTION 
     The relationship and workings of the various elements of the invention will be better understood by the following detailed description. However, the embodiments of the invention described below are by way of example only and the invention is not limited to the embodiments described. Furthermore, one should understand that the drawings are not to scale and that the embodiments are illustrated by graphic symbols and fragmentary views. In certain instances, details may have been omitted that are not necessary for an understanding of the present invention, such as conventional details of fabrication and assembly. 
     Referring to FIG. 1, one embodiment of the tote assembly  22  of the present invention is shown in an exploded view, without a band. A first tote member  12  comprises one or more posts  20  located around its periphery and a second tote member  14  comprises one or more corresponding receptacles  22  located around its periphery. Preferably, the first tote member  12  and the second tote member each contain at least one post  20  and at least one receptacle  22 . Most preferably, the first tote member  12  comprises about five posts  20  located around the periphery of the right half of the first tote member  12  and about five receptacles  22  located around the periphery of the left half of the first tote member  12 . Correspondingly, the second tote member  16  most preferably comprises about five receptacles  22  located around the periphery of the right half of the second tote member  16  and about five posts  20  located around the periphery of the left half of the second tote member  16 . To assemble the tote assembly  22 , a post  20  of one tote member is lined up with and inserted into the corresponding receptacle  22  of the other tote member. Preferably, the post  20  and receptacle  22  are fabricated of resilient material, such as molded plastic, to provide a snap fit connection, although various other common connecting mechanism or ways could be employed. 
     The tote assembly  10  is shaped and sized to coaxially receive a coil of flexible band, which typically is wound into a spiral. Referring to FIGS. 1-2, the tote assembly  10  preferably is generally polygonal, with a generally octagonal shaped interior to house a spiral coil of flexible band  32 . The tote assembly  10  comprises an access window  28  that provides an opening to manually access the band  32 . For example, one may reach through the access window  28  to the interior of the tote assembly  10  and advance or retract the band  32  from its coiled state. When a strip of the band  32  is cut off for use, the remaining portion of the band  32  typically extends through the band opening  34 . The ability to manually retract the end of the band  32  back into the interior of the tote assembly  10  protects the band  32  from damage and protects the user from injury. Also, the access window  28  provides an opening to hold and carry the tote assembly  10 . Additional windows  30  may also be provided for a visual determination of the amount of band remaining in the tote assembly  10  and to reduce its cost and weight. 
     Referring to FIG. 3, a right side view of the tote assembly  10  is shown in FIGS. 1-2. The first tote member  12  and the second tote member  16  are connected to define a band opening  34 . The band opening  34  provides access to insert the band, as described in more detail below, and also provides an opening to selectively remove all or part of the band  32 , as desired in use. Also, to provide greater flexibility in inserting and removing the band  32 , as well as to reduce cost and weight, preferably both the right side and the left side of the tote assembly  10  have such a band opening  34 . 
     To securely hold the coiled, flexible band  32 , the tote assembly  10  must have a width sufficient to house the band  32 , without allowing it to partially or completely unwind. The tote assembly  10  provides a cavity that is greater than the width of the band  32  desired to be housed therein. Because the band  32  can be commercially available in various widths, it is preferred that a tote assembly  10  be available for each available width of band  32 . 
     To provide flexibility in manufacturing a tote assembly  10  to accommodate a desired width of band  32 , the first tote member  12  has a first interior spoke  14  and the second tote  16  has a second interior spoke  18 . The first interior spoke  14  and the second interior spoke  18  may be of the same or different dimensions to create a tote assembly  10  having a cavity of a desired width for a particular width of band  32 . Generally, a shorter interior spoke  14  or  18  will result in a larger cavity to house a larger width band  32 , while a taller spoke  14  or  18  will result in a smaller cavity to house a smaller width band  32 . For example, the first interior spoke  14  may be ¼ inch high and the second interior spoke may be {fraction (7/16)} inch high to create a tote assembly  10  having a interior width of about {fraction (11/16)} inch to house a band about ½ inch wide. 
     Referring again to FIG. 1, preferably the first tote member  12  comprises a circular rib  24  and the second tote member  16  comprises a circular rib  26 , each positioned at approximately the center of the tote assembly  10 . The circular ribs  24 ,  26  have the same diameter, which is sufficient to house the mandrel of the winding machine and allow its operation, as described below. Also, the circular ribs  24 ,  26  provide a rigid opening for the mandrel. Preferably, the diameter of the circular ribs  24 ,  26  is about four and one-half inches. 
     The first tote member  12  also comprises a series of interior spokes  14  emanating from the circular rib  24  to the exterior side wall  15 . Similarly, the second tote member  16  comprises a series of interior spokes  18  emanating from the circular rib  26  to the exterior side wall  19 . Preferably, the height of the circular ribs  24  of the first tote member  12  is about the same as the height of the interior spoke  14 , while the height of the circular ribs  26  of the second member  16  is about the same as the height of the interior spoke  18 . When the first tote member  12  and the second tote member  16  are connected, the combined height of the interior spokes  14 ,  18  defines the cavity in which the band is housed. By keeping the dimensions of the exterior side walls  15 ,  19  constant, the width of the cavity housing the band then may be selected by selecting the appropriate height of the interior spokes  14 ,  18 . 
     More particularly, and as shown in more detail in FIGS. 4-6, a tote assembly  10  comprises a first tote member  12  and a second tote member  16  that are snapped together by inserting posts  20  into corresponding receptacles  22 . The first tote member  12  and second tote member  16  combine to define a cavity  21  to house the band. As shown in FIG. 4, the height of the first interior spoke  14  and of the second interior spoke  18  are about the same and combine to define the cavity  21 A. As shown in FIG. 5, the height of interior spoke  14  remains the same as in FIG.4, but a shorter height of interior spoke  18  results in a larger cavity  21 B, to house a wider band. Finally, as shown in FIG. 6, the shorter height of both interior spokes  14 ,  18  results in an even larger cavity  21 C, to house an even wider band. Meanwhile, in each of the examples shown in FIGS. 4-6, the outside width of the tote assembly  10  remains the same. 
     Referring now to FIG. 8, the second tote member  16  is shown with the first tote member  12  removed to show a band  32  installed therein. Contact nubs  33  are provided at selected intervals around the periphery of the interior of the second tote member  16 . Preferably, the contact nubs  33  are positioned at approximately the midpoint of each straight side of the generally polygonal shaped interior surface of the second tote member  16 . The contact nubs  33  provide selected points of contact between the coiled band  32  and the second tote member  15 . The pressure exerted by the coiled band  32  against the interior of the tote member  12  is thereby directed primarily to the contact nubs  33 , which are preferably cylindrical to present a rounded surface to the coiled band  32 . The contact nubs  33  facilitate the retrieving and removal of the band  32 , while reducing the likelihood and severity of the coiled band  32  binding on the interior of the second tote member  16 . Preferably, the first tote member  12  comprises similar contact nubs  33 . 
     As shown in FIGS. 9-10, a buckle container  40  may be provided for insertion into the central opening formed by the circular ribs  24 ,  26 . Preferably, the buckle container  40  is formed of resilient material, such as plastic, to allow a snap fit with the circular ribs  24 ,  26 . In use, a portion of the band  32  is drawn out of the tote assembly  10  and cut to a strip of a desired length. The strip of cut band  32  is typically wound about an object and then secured by a separate buckle. These buckles are needed with each application of a band and have relatively short dimensions. Buckle container  40  houses a supply of buckles, preferably at least one for each length of band  32  contained within the tote assembly  10 . A closable lid  41  keeps the buckles secure, while allowing ready access when desired. 
     It may be desirable to stack two or more tote assemblies  10  for shipping, storage or the like. As shown in FIGS. and  11 , to facilitate such stacking, a tote assembly  10  may comprise one or more dimples  36  and depressions  38 , which match with corresponding depressions  38  and dimples  36  of a second tote assembly  10 . Preferably, the first tote member  12  and the second tote member  16  each comprise two dimples  36  spaced apart on one side of the front outside surface of the first tote member  12  and two depressions  38  spaced apart on the other side of the front outside surface of the first tote member  12 . As shown in FIG. 11, when the first tote member  12  and the second tote member  16  are connected, the two dimples  36  of the first tote member  12  are located directly in line with the two depressions  38  of the second tote member  16 . Similarly, the two dimples  36  of the second tote assembly  16  are located directly in line with the two depressions  38  of the first tote assembly  12 . In this fashion, two or more tote assemblies  10  may be stacked, as shown in FIGS. 11-12. 
     Referring to FIGS. 13-14, the tote assembly  10  may further comprise an insert cutting tool  42  to cut off a desired length of band  32 . The insert cutting tool  42  preferably is connected with assembly screws  44  to the tote assembly  10  near the band opening  34 . The insert cutting tool  42  preferably comprises a screw  46  connecting a knob  48  to a threaded insert key  50 , which in turn is connected to a cutter bar  52  with a cutting edge  53 , a cutter block insert  54  with a cutting edge  55 , a retaining ring  56  and a cutter head  58 . 
     As shown in FIGS. 22-23, the tote assembly  10  comprises a top surface that is flat for at least a portion thereof to allow the printing or other marking of indicia, such as the size, length and manufacturer of the band contained within the tote assembly  10 . Because this indicia is located on the top surface, it may be seen even when the tote assemblies  10  are stacked. 
     Now referring to FIGS. 15-21, an apparatus for and method of inserting a length of band into a tote assembly are illustrated. A winding machine  60  comprises a band inlet guide  62 , straightening rolls  64 , a niproll  66 , a punch press  68 , a band cutter  70  with a band cutter blade  72 , a band bender  74  and a band winder  78 . A supply of band  32  is provided, which typically is in the form of coiled lengths of at least about 500 feet of band that are unwound with an unwind reel (not shown). A roll edger is used to round the edges of the band  32  (not shown). One end of the band  32  is then fed into the band inlet guide  32 , which includes a slot to direct the band  32  to the straightening rolls  64  to straighten or flatten the band  32 . The end of the band  32  is then fed into a niproll  66 , which uses a servo motor to feed the band forward into the winding machine  60  and which accurately measures the band as it passes through to the optional punch press  68 . The band bender  74  bends the band  32  to enter the band winder  78  at the appropriate angle. The band winder  78  winds the band  32  within the closed, assembled tote assembly  10 . The band cutter blade  72  of the band cutter  70  cuts off the band when the desired length of band has been inserted into the tote assembly  10 , typically about one hundred feet. 
     As shown in FIGS. 15,  16 ,  17  and  18 A- 18 F, a tote assembly  10  is inserted into a tote assembly support  80  for insertion of the band  32 . A mandrel  82  is pushed into the center opening of the tote assembly  10 . The mandrel  82  comprises a mechanism, such as a hook and dog, to secure the end of the band  32 , which has been either manually or automatically fed through the band opening  34  of the tote assembly  10  into the band winder  78 . As shown in FIGS. 18A-18F, the mandrel  82  spins, typically in a clockwise direction, to wind the band  32  into the tote assembly  10 . Meanwhile, the tote assembly  10  itself is not rotating, but is held relatively stationary by the tote assembly support  80 . After the desired length of band  32  has been inserted into the tote assembly  10 , the band  32  must be kept still and tight while it is cut by the band cutter blade  72 . Preferably, the mandrel  82  comprises a motor with a clutch that will wind faster than the niproll  66  will feed. When the niproll  66  stops feeding additional band  32  into the tote assembly  10 , the mandrel thereby will hold the band  32  under tension to allow it to be cut. After the band  32  is cut, the mandrel  82  retracts and the tote assembly  10  drops to a position for removal from the winding machine  60 . In the embodiment shown in FIG. 15, tote assembly  10 A is ready to drop into position for band winding, tote assembly  10  is in position for band winding, and tote assembly  10 B has dropped out for removal from the winding machine  60 . 
     Preferably, the tote assembly support  80  comprises a horizontal support for additional tote assemblies to line up behind tote assembly  10 A for automatic placement with the band winder  78 . Similarly, the tote assembly support  80  preferably comprises a horizontal support to automatically remove tote assembly  10 B after band winding. 
     The tote assembly  10  may be marked with indicia of its length, width, intended use, model number, or other relevant information. As shown in FIGS. 22-23, this marking is preferably performed automatically with an ink jet printer  90  onto the top, relatively flat surface of the tote assembly  10 . Preferably, this printing step is performed after insertion of the band  32 , although it could be done at any time. 
     The foregoing description of the present invention has been presented for purposes of illustration and description. The fact that the present invention has been described with reference to particular embodiments does not mean that other embodiments do not exist. It should be appreciated that many other embodiments can be provided within the spirit and scope of this invention. The embodiments described herein are further intended to explain the best mode known for practicing the invention and to enable others skilled in the art to utilize the invention in such, or other, embodiments and with various modifications required by the particular applications or uses of the present invention. It is intended that the appended claims be construed to include alternative embodiments to the extent permitted by the prior art.