Patent Publication Number: US-2018054033-A1

Title: Portable crimping tool for strap

Description:
CROSS-REFERENCE TO RELATED APPLICATION DATA 
     This application claims the benefit of and priority to Provisional U.S. patent application Ser. No. 62/377,039, filed August 19, 2016, the disclosure of which is incorporated herein in its entirety. 
    
    
     BACKGROUND 
     Hand-held, powered sealing tools are used to interlock overlapping courses of a strap into a high strength joint. One type of sealing tool is a crimp-type sealer that forms crimp-type deformations in a seal that is positioned over the overlapping course of strap. These crimp-type sealers press the edges of the strap and the seal into wavy crimps especially shaped to produce maximum frictional forces on the strap. 
     Unlike sealers that cut into the seal and strap, crimp-type sealers provide maximum strength of the joint without adversely affecting the overall strength of the strapping in that neither the strap nor the seal is cut to form the seal. As such, it will be appreciated that a large force is needed to form the seal, in that the seal as well as the strap must be bent to deform the seal and the overlapping course of strap material. 
     Pneumatic crimp sealers are known, and while such sealers function well, there are drawbacks. For example pneumatic sealers require a source of compressed air. This limits the mobility of the sealer in terms of location of use, e.g., within a facility, as well as the orientation of use, e.g., along the item to be strapped, due to the compressed air hose connection. In addition, such sealers are quite heavy in that they use air diaphragms or air drives, and require the valve systems necessary to port the compressed air into and out of the drives. 
     Portable sealers are also known, such as battery powered sealers. However, due to the forces required to form such seals, the power available from known battery operated sealers is limited at best. As such, battery life can be short. 
     Moreover, in order to form a seal that meets strength requirements it is necessary to properly position the seal within the sealer jaws so that a full and complete seal is made. Incomplete or improper seals due to, for example, the seal shifting sideways in the sealer, can affect seal strength and compromise the integrity of packaged load. 
     Accordingly, there is a need for a crimp-type sealing tool for strap. Desirably, such a sealing tool is portable to allow use in any location and in any orientation. More desirably, the tool is powered by an installed power source, and can be used on a wide variety of straps and seals in high strength applications, without undue power consumption. More desirably still, such a tool is effectively positioned the seal on the strap, within the tool to assure a complete and proper seal is made. 
     SUMMARY 
     A portable crimp-type sealing tool forms a crimp-type joint in a seal positioned on overlapping courses of strap. The tool includes a body, a motor and drive train housed, at least in part, in the body and a power supply, such as a battery. In an embodiment, the tool includes a controller. 
     The tool includes a crimping assembly mounted to the body and operably coupled to the motor through the drive train. The crimping assembly includes at least one pair of opposing jaw elements pivotable toward one another from an open position to a closed position, to contact and form crimps in the seal and the overlapping courses of strapping material. In an embodiment, a guide pin operably connects the drive train to the jaw elements. 
     A side plate encloses the jaw elements and the guide pin. In an embodiment the side plate includes an elongated, slotted opening. An embodiment of the tool includes a bearing element mounted to the guide pin and positioned in the elongated slotted opening. The bearing element facilitates movement of the guide pin as the guide pin moves through the elongated slotted opening to pivot the jaw elements from the open position to the closed position. 
     In an embodiment of the tool the crimping assembly includes two pairs of opposing jaw elements and a crimper positioned between and operably connecting the pairs of jaw elements. The crimper can include an anvil surface against which the seal is positioned as the jaw elements pivot toward one another. 
     In an embodiment, the bearing element has an outer diameter that is less than a transverse dimension across the slotted opening. A retaining ring or fastener can be positioned to retain the bearing element mounted to the guide pin. It will be appreciated that other ways in which to retain the bearing element mounted to the guide pin can be used. 
     An embodiment of the sealing tool includes an inertia storage element. The motor can include an output shaft operably connecting the motor to the drive train, and the inertia storage element can positioned on the motor output shaft. In an embodiment, the inertia storage element is a flywheel. The flywheel can be fixedly mounted to the motor output shaft. 
     In an embodiment the sealing tool includes a proximity sensor positioned between the opposing jaw elements. The proximity sensor can be operably connected to the controller. In an embodiment, the tool includes a seal edge positioning element. An embodiment of the seal edge positioning element is a lever mounted to the side plate. The lever provides tactile indication that the seal is properly positioned in the crimping assembly. An embodiment of the tool includes a switch and the lever is configured to move into and out of contact with the switch. 
     An embodiment of the sealing tool includes a proximity sensor configured to detect the presence or absence of the seal positioned in the crimping assembly, and the proximity sensor and the switch are operably connected to the controller such that the presence of a seal in the crimping assembly and proper position of the seal in the crimping assembly are required to actuate the motor. An embodiment of the tool includes a home position switch to sense a position of the jaw elements. In an embodiment, the home position switch senses when the jaw elements are in an open state. 
     Other objects, features, and advantages of the present disclosure will be apparent from the following description, taken in conjunction with the accompanying sheets of drawings, wherein like numerals refer to like parts, elements, components, steps, and processes. 
    
    
     
       DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a side view of an embodiment of a portable crimp-type sealing tool; 
         FIG. 2  illustrates an example of a crimp seal on overlapping courses of strapping material; 
         FIG. 3  is a partially exploded view of the sealing tool; 
         FIG. 4  is a perspective side view of an embodiment of the tool with portions of the outer case removed for ease of illustration; 
         FIG. 5  is partial perspective view of the crimping assembly 
         FIG. 6  is view similar to  FIG. 5  with a crimping assembly side plate removed for clarity of illustration; 
         FIG. 7  is another illustration of the crimping assembly; 
         FIG. 8  is a view of a portion of the crimping assembly; and 
         FIG. 9  is still another illustration of the crimping assembly showing an embodiment of the seal edge positioning element. 
     
    
    
     DETAILED DESCRIPTION 
     While the present disclosure is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described one or more embodiments with the understanding that the present disclosure is to be considered illustrative only and is not intended to limit the disclosure to any specific embodiment described or illustrated. 
       FIG. 1  illustrates an embodiment of a portable crimp-type sealing tool or sealer  10 . As illustrated in  FIG. 2 , the sealing tool  10  is used to form bends or crimps C in a seal S that is positioned on overlapping courses of strap material M. Crimp type seals S are used in applications that require high strength, high integrity joints, such as in securing loads in the holds of ships, to prevent the loads from shifting during transport. 
     The tool  10  includes generally a body  12 , a sealing or crimping head  14  and a power supply  16 , such as a battery. The battery  16  is positioned in a battery receiver  18  on the body  12 . A motor  20  and drive train  22  are mounted within the body  12 . The tool  10  includes an outer housing or case  24 . The drive train  22  includes a gear set  26  to convert the high speed output (e.g., about 28,000 rpm) of the motor  20  into increased output power or torque to drive the sealing components in the sealing head  14 . It will be appreciated that motor  20  speed can vary and that motors of such varied speeds can be used (for example, it is anticipated that motors with speeds as low as 6000 rpm can be used). In an embodiment, the motor  20  includes an output shaft  28  that is operably connected to the gear set  26  and an inertia storage element  30 . In an embodiment, the inertia storage element  30  is a flywheel that is mounted to the output shaft  28  to rotate with the shaft  28 . The gear set  26  can be, for example, a planetary gear set mounted to a linear output or worm gear  32 . 
     An embodiment of the tool  10  includes a controller  34 , an actuation switch  35  that is actuated by a trigger button  36  and one or more status indicators  38 , such as LED indicators to indicate the status of the tool. In an embodiment, the tool  10  includes a home position switch  39 . A cover  15  can be positioned over the sealing head  14 . 
     A crimper assembly  40  is operably connected to the gear set  26 , at the linear gear  32 . In an embodiment, the crimper assembly  40  includes a drive gear  42  that meshes with the linear gear  32 . A first link  44  is eccentrically mounted to the drive gear  42  by a first pin  46 . A pair of link arms  48   a,b  are pivotally mounted to the first link  44  by a second pin  50 . The assembly  40  includes at least one pair of jaw elements  52   a,b . In an embodiment, the assembly  40  includes multiple pairs, e.g., two pairs,  52   a,b  and  53   a,b , of jaw elements. Each pair  52 ,  53  of jaw element includes opposing or facing jaw elements  52   a ,  53   a  and  52   b ,  53   b  and each jaw element is pivotally mounted to a respective link arm  48   a,b  by respective third pins  54   a,b . Each pair of jaw elements  52   a,b  and  53   a,b  forms a pair of opposing bends or crimps C in the seal S and strap M. 
     The jaw elements  52   a,b  and  53   a,b  are mounted to, and operably connected to each other by one or more crimpers  56 . The crimper  56  include a pair of slopes faces  58 , a central region  60  between the sloped faces that includes an upstanding anvil surface  62  against which the seal S is bent during crimping. In an embodiment in which the assembly  40  includes two pairs of jaw elements  52 ,  53 , the assembly  40  includes a crimper  56  between and separating the jaw element pairs  52 ,  53 . 
     The jaw elements  52   a,b  and  53   a,b  are mounted to the crimper  56  by respective fourth pins  64 . In this configuration, as the worm gear  32  rotates, it rotates the drive gear  42 . A first end  66  of the first link  44  rotates eccentrically with the drive gear  42  which in turn moves a second end  68  of the first link  44  in a generally reciprocating manner. The link arms  48   a,b , which are mounted pivotally to the second end  68  of the first link  44 , move in a generally downward and outward arc, which in turn open and close the jaws  52   a,b  and  53   a,b.    
     In an embodiment the tool  10  includes a proximity sensor  70 . The proximity sensor  70  senses the presence or absence of a seal S in the crimping assembly  40 . In an embodiment, the sensor  70  is positioned between the jaw elements  53   a,b  of one of the pairs of jaw elements and adjacent to the crimper  56 . Other locations or positions for the proximity sensor  70  will be recognized by those skilled in the art. 
     Referring to  FIGS. 5-7 , in an embodiment, the crimping assembly  40  includes a pair of side plates  72  that contain the drive gear  42 , the jaw elements  52 ,  53 , link  44  and link arms  48   a,b  and the crimper  56 . In an embodiment, the side plates  72  include an elongated slotted opening  74  and the second pin  50  extends through the opening  74  to guide the second end  68  of the first link  44  and the first ends  66  of the link arms  48   a,b  in a reciprocating path as the tool  10  moves through the crimping cycle. To reduce the losses due to friction and to ease or smooth the movement of the link arms  48   a,b  and the second pin  50 , in an embodiment, the second pin  50  includes a bearing element  76 . The bearing element  76  can be, for example, a guide roller or like bearing mounted to an end of the pin  50  or to the body of the pin near an end thereof In the illustrated embodiment, the bearing or guide roller  76  is retained in place by a fastener or retaining ring  78 . It will be appreciated that other ways in which to retain the bearing element  76  mounted to the guide pin  50  can be used. For example, although not shown, a cap can be positioned on the pin  50  to retain the bearing  76  in place a cap can be positioned on the side plate or plates  72  to retain the bearing  76  in place, or a closed side plate or plates  72  can be used to retain the bearing  76  in place. All such configurations are within the scope and spriti of the present disclosure. The guide roller  76  is sized so as to freely move through the side plate slotted opening  74 . In an embodiment, the slotted opening  74  is dimensioned, as shown generally at d 74  slightly larger than an outside diameter D 76  of the guide roller  76  so that the roller  76  moves freely through the opening  74 . 
     In an embodiment, the side plates include a cut-out or recess  80  at about the jaws  52   a,b  and  53   a,b . The cut-out  80  is configured to position the seal S and strap M relative to the jaws  52   a,b  and  53   a,b  and crimper  56  and to provide a seat for the seal S and strap M during the crimping cycle. However, as noted above, the seal S can be improperly positioned transverse to the jaws  52   a,b  and  53   a,b  and crimper  56  by sliding along the cut-out  80  in the side plates  72 . In order to assure proper transverse positioning of the seal S during the crimping cycle, the tool  10  can include a seal edge positioning element  82 . In an embodiment, the seal edge positioning element  82  includes a catch lever  84  mounted to the side plate  72  adjacent to the cut-out  80 . The catch lever  84  can be a mechanical catch that is configured such that the seal S abuts the lever  84  and provides tactile indication that the seal S is properly positioned in the cut-out  80 . The lever  84  can be, for example, a spring steel member mounted to the side plate  72 , or a steel element pivotally mounted to the side plate by a spring (not shown). In such a configuration, the user is assured of proper seal S position by abutting the edge of the seal S against the lever  84 . 
     Alternatively, the seal edge positioning element can include a switch  86 , such as an electro-mechanical switch that works in conjunction with, for example, a lever  84 , to provide positive indication that the seal S is properly positioned in the tool  10 . In such an embodiment, for example, the lever  84  can move into contact with the switch  86  when the seal S is pressed on the lever  84 , and the lever  84  can move away from the switch  86  when the lever  84  is abutting an edge of the seal S (similar to the mechanical tactile indicator configuration) to indicate that the seal S is properly positioned for the crimping cycle. In such an embodiment, the switch  86  may also be operably connected, for example, through the controller  34  or control circuitry, to the proximity sensor  70  to permit operation of the tool  10  when the sensor  70  senses the presence of a seal S in the crimping assembly  40  and when the switch  86  indicates that the seal S is properly positioned in the side plate cut outs  80 . 
     In use, the tool  10  is in a home or open state, with the jaw elements  52   a,b  and  53   a,b  open or rotated outwardly, ready to receive a seal S and strapping material M (the jaws  52 ,  53  are positioned so that a seal can be positioned in the tool  10 ). The seal S is positioned in the tool  10  in the side plate cut outs  80 . In an embodiment in which the tool  10  includes the seal edge positioning element  82 , the seal S edge is positioned against the positioning element  82 . The trigger button  36  is depressed, which actuates or closes the trigger switch  35 , which in turn sends a signal to the control to provide power to the motor  20 . The motor  20  actuates to drive the worm gear  32 , which in turn rotates the drive gear  42 . Rotation of the drive gear  42  in turn reciprocates the first link  44  and link arms  48   a,b , which pivot the jaw elements  52   a,b  and  53   a,b  inwardly onto and crimping the crimp seal S against the anvil surface  62 . 
     In an embodiment in which the tool  10  includes a proximity sensor  70 , the sensor  70  sends a signal to the controller  34  to indicate the presence or absence of a seal S in the tool  10  against the crimper anvil surface  62 . In the absence of a signal or in the absence of a seal on the crimper anvil surface, the controller  34  will not allow motor  20  to actuate. And, in an embodiment in which the seal edge positioning element  82  includes a switch  86 , the switch  86  generates a signal to the controller  34  to allow operation only when the switch  86  senses that the seal S is properly positioned relative to the side plates  72 . The seal edge positioning element switch  86  and the proximity sensor  70  may be used in conjunction with one another to assure both the presence of a seal S on the crimper anvil surface  62  and the proper positioning of the seal S relative to the side plates  72 . In such an embodiment both signals, that is presence of a seal S and proper position of the seal S, must be indicated for the motor  20  to actuate. 
     In an embodiment in which the tool  10  includes a home position switch  39 , the switch  39  senses when the jaw elements  52   a,b  and  53   a,b  are in the home or open state and sends a signal to the controller  34  to allow the tool  10  to operate (to move through a sealing cycle) when the jaw elements  52   a,b  and  53   a,b  open or rotated outwardly, ready to receive a seal S and strapping material M. 
     The tool  10  may also include wireless communication protocols to control and/or monitor the functions and operations of the tool  10 . In addition, in an embodiment, the tool  10  includes electronic controls, such as an electronic brake that is used to, for example, isolate power from the motor  20 . It will be appreciated that all or individually and independently, any of the sensing and control features may be included in an embodiment of the tool  10 . 
     As noted above, the inertia storage element  30 , which in an embodiment is a weighted flywheel, is mounted to the motor output shaft  28  to rotate with the shaft  28 . The flywheel  30  stores energy from the initial tool  10  start up to use during the crimping cycle. That is, the flywheel  30  provides momentum, e.g., an inertial force, to the gear set  26 . In this manner, power from the battery  16  can be isolated prior to the end of the crimping cycle, to reserve battery  16  power, while the momentum of the flywheel  30  continues to transfer power to the gear set  26  and ultimately to the jaw elements  52   a,b  and  53   a,b  to form the seal. The flywheel  30  also increases the overall power/torque of the tool  10  at output. 
     It will be appreciated by those skilled in the art that the relative directional terms such as sides, upper, lower, rearward, forward and the like are for explanatory purposes only and are not intended to limit the scope of the disclosure. 
     All patents referred to herein, are hereby incorporated herein by reference, whether or not specifically done so within the text of this disclosure. 
     In the present disclosure, the words “a” or “an” are to be taken to include both the singular and the plural. Conversely, any reference to plural items shall, where appropriate, include the singular. 
     From the foregoing it will be observed that numerous modifications and variations can be effectuated without departing from the true spirit and scope of the novel concepts of the present disclosure. It is to be understood that no limitation with respect to the specific embodiments illustrated is intended or should be inferred. The disclosure is intended to cover all such modifications as fall within the scope of the claims.