Patent Description:
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.

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: (<NUM>) a tensioning cycle during which a tensioning assembly tensions the strap around the load; and (<NUM>) 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). <CIT> discloses a tool for tensioning and sealing the overlapping ends of a loop of strap comprising a main frame over which the strap is passed, a tensioning wheel, an auxiliary frame mounting said tensioning wheel for movement toward and away from said main frame, a first latch operable between said main frame and said auxiliary frame for holding said tensioning wheel in a raised position away from said main frame, a first shear blade mounted on said main frame for movement toward and away from said main frame, a control lever pivotally mounted on said main frame for raising said shear blade, a second latch operable between said control lever and said auxiliary frame for holding said first shear blade in the raised position when said tensioning wheel is in its raised position, means on said auxiliary frame for selectively releasing the latches to permit movement of the first shear blade and tensioning wheel toward said main frame, a sealing head mounted on said main frame for movement toward and away from said main frame and including a second shear blade positioned to cooperate with said first shear blade to sever the supply end of the strap from the loop, and a motion transmitting connection between said auxiliary frame and said sealing head for raising said sealing head when said tensioning wheel is raised. Further, <CIT> relates to a strapping tool of a type having a gripping jaw for gripping one end of a strap loop encircled about a bundle and a rotary tensioning wheel for gripping and moving the other end of the strap loop to draw the strap loop taut about the bundle comprising a frame having a base for resting against a bundle being bound and having a pair of strap supports - one adjacent the gripping jaw and the other adjacent the rotary tensioning wheel, an auxiliary frame rotatably supporting the rotary tensioning wheel and pivotally mounted to the frame to permit movement of the rotary tensioning wheel toward and away from the strap support adjacent thereto, a first lever attached to the auxiliary frame for rocking the auxiliary frame to move the rotary tensioning wheel toward and away from its adjacent strap support, means on the first lever to cause rotation of the rotary tensioning wheel, a spring biased toggle mounted between the first lever and the frame for holding the rotary tensioning wheel either toward or away from its adjacent strap support, a shaft for pivoting the gripping jaw to the frame, a spring urging the gripping jaw toward its adjacent strap support, a second lever attached to the gripping jaw for rocking it toward and away from its adjacent strap support, a control lever pivotally connected at its far end to the second lever and having its inner end urged upward by means of a spring, the inner end engaging a projection on the first lever when both the rotary tensioning wheel and the gripping jaw are rotated away from their respective strap supports, the inner end disengaging the projection upon downward movement of the inner end of the control lever to thereby permit the gripping jaw to move toward its adjacent strap support under the force of said spring urging it in that direction, the inner end of the control lever extending in sufficient proximity to said first lever to permit one hand operation of the control lever and the first lever from the same approximate location on the tool without shifting the position of the operator's hand.

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.

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 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.

<FIG> and <FIG> show one example embodiment of the strapping tool <NUM> 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 <NUM> is configured to tension strap (metal strap in this example embodiment) 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 (referred to as "notching" in the strapping industry and in this Detailed Description) and cut the strap from the strap supply.

The strapping tool <NUM> includes a housing <NUM>, a working assembly <NUM>, a movable handle assembly <NUM>, a display assembly <NUM>, a controller <NUM> (not shown in the drawings but numbered for clarity), and a power supply <NUM>.

The housing <NUM>, which is best shown in <FIG> and <FIG>, at least partially encloses and/or supports some (or all) of the other assemblies and components of the strapping tool <NUM>. In this example embodiment, the housing <NUM> includes a front housing section <NUM> that at least partially encloses and/or supports at least some of the components of the working assembly <NUM> and the movable handle assembly <NUM>, a rear housing section <NUM> that at least partially encloses and/or supports the controller <NUM> and the power supply <NUM>, a connector housing section <NUM> that extends between and connects the bottoms of the front and rear housing sections <NUM> and <NUM>, and a stationary handle <NUM> that extends between and connects the tops of the front and rear housing sections <NUM> and <NUM>. The housing <NUM> may be formed from any suitable quantity of components joined together in any suitable manner. In this example embodiment, the housing <NUM> is formed from plastic, though it may be made from any other suitable material in other embodiments.

The working assembly <NUM>, the subassemblies and components of which are best shown in <FIG> and <FIG>, includes the majority of the components of the strapping tool <NUM> that are configured 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. The working assembly <NUM> includes a support <NUM>, a tensioning assembly <NUM>, a sealing assembly <NUM>, a drive assembly <NUM>, a rocker-lever assembly <NUM>, and a gate assembly <NUM>.

The support <NUM>, which is best shown in <FIG> and <FIG>, serves as a direct or indirect common mount for the tensioning assembly <NUM>, the sealing assembly <NUM>, the drive assembly <NUM>, the rocker-lever assembly <NUM>, and the gate assembly <NUM>. The support <NUM> includes a body <NUM>, a foot <NUM> extending transversely from a bottom of the body <NUM>, a tensioning-assembly-mounting element <NUM> extending rearward from the body <NUM>, and a drive-and-conversion-assembly-mounting element <NUM> extending upwardly from the body <NUM>. A front side of the body <NUM> defines a gate-receiving recess <NUM> sized, shaped, oriented, and otherwise configured to receive a gate <NUM> of the gate assembly <NUM> and to enable the gate <NUM> to move between a lower home position and an upper strap-insertion position (described below). The body <NUM> includes aligned first and second sealing-assembly-mounting tongues 372a and 372b on one side of the gate-receiving recess <NUM> and aligned third and fourth sealing-assembly-mounting tongues 374a and 374b on the other side of the gate-receiving recess <NUM>. A roller <NUM> is coupled to and freely rotatable relative to the foot <NUM>.

The tensioning assembly <NUM>, which is best shown in <FIG>, <FIG>, and <FIG>, is configured to tension the strap around the load. The tensioning assembly <NUM> includes a tension shaft (not shown), a tension wheel <NUM> (<FIG> and <FIG>) fixedly attached to the tension shaft to rotate therewith, tensioning-assembly gearing (not shown) operably connected to the tension shaft and configured to rotate the tension shaft (and the tension wheel <NUM> attached thereto), and a tensioning assembly housing <NUM> at least partially enclosing these components.

The tensioning assembly <NUM> is movably mounted to the tensioning-assembly-mounting element <NUM> of the support <NUM> and configured to pivot relative to the support <NUM>-and particularly relative to the foot <NUM> of the support <NUM>-under control of the rocker-lever assembly <NUM> (as described below) between a strap-tensioning position (<FIG> and <FIG>) and a strap-insertion position (<FIG> and <FIG>). When the tensioning assembly <NUM> is in the strap-tensioning position, the tension wheel <NUM> is adjacent to (and in this embodiment contacts) the roller <NUM> of the support <NUM> (or the upper surface of the strap if the strap has been inserted into the strapping tool <NUM>). When the tensioning assembly <NUM> is in the strap-insertion position, the tension wheel <NUM> is spaced-apart from the roller <NUM> to enable the top portion of the strap (described below) to be inserted between the tension wheel <NUM> and the roller <NUM>. A tensioning-assembly-biasing element (not shown) such as a torsion spring, a compression spring, or any other suitable type of spring biases the tensioning assembly <NUM> to the strap-tensioning position.

The rocker-lever assembly <NUM>, which is best shown in <FIG>, is operably connected to the tensioning assembly <NUM> and configured to move the tensioning assembly <NUM> relative to the support <NUM> from the strap-tensioning position to the strap-insertion position. The rocker-lever assembly <NUM> includes a rocker lever <NUM>, rocker-lever gearing (not labeled), and a spring-clutch assembly <NUM>. The rocker-lever gearing operably connects the rocker lever <NUM> to the tensioning assembly <NUM> such that movement (here, pivoting) of the rocker lever <NUM> relative to the support <NUM> and the housing <NUM> from a home position (best shown in <FIG>) to an actuated position (not shown) causes the rocker-lever gearing to cause the tensioning assembly <NUM> to move from the strap-tensioning position to the strap-insertion position. Movement of the rocker lever <NUM> from the actuated position back to the home position (such as under control of the tensioning-assembly biasing element) causes the rocker-lever gearing to cause the tensioning assembly <NUM> to return to the strap-tensioning position. Put differently, the rocker lever <NUM> is movable between the home position and the actuated position to (via the rocker-lever gearing) cause the tensioning assembly <NUM> to move between the strap-tensioning position and the strap-insertion position, respectively. The spring-clutch assembly <NUM> is configured to act on a gear component of the tensioning-assembly gearing to facilitate a soft release of the strap after tensioning and sealing. Specifically, as the rocker lever <NUM> moves from its home position to its actuated position, the spring-clutch assembly <NUM> decouples the tensioning-assembly gearing from the tension wheel <NUM>. This enables the tensioning wheel <NUM> to, while decoupled from the tensioning-assembly gearing (and therefore the motor <NUM>), rotate in a direction opposite the tensioning direction. This facilitates removal of the tool <NUM> from the strap after the tensioning and sealing processes are complete.

The sealing assembly <NUM>, which is best shown in <FIG>, is configured to attach overlapping portions of the strap to one another to form a tensioned strap loop around the load 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 <NUM> includes a front cover <NUM>; a back cover <NUM>; connectors <NUM>, <NUM>, <NUM>, and <NUM>; a jaw assembly <NUM>; and an object-blocking assembly <NUM>.

The front cover <NUM> is generally U-shaped. The back cover <NUM> includes a generally planar base 506a, two mounting wings 506b and 506c extending rearward and inward from opposing lateral ends of the base 506a, and lips 506d extending forward from the base 506a (toward the jaw assembly <NUM>). As best shown in <FIG>, the front cover <NUM> and the back cover <NUM> are connected to one another via the connectors <NUM>, <NUM>, <NUM>, and <NUM> and suitable fasteners (not labeled) and cooperate to partially enclose the jaw assembly <NUM> and the object-blocking assembly <NUM>.

The sealing assembly <NUM> is movably (and more particularly, slidably) mounted to the support <NUM> via the back cover <NUM>. Specifically, the back cover <NUM> is positioned so the first and second sealing-assembly-mounting tongues 372a and 372b of the support <NUM> are received in a groove defined between the base 506a and the first mounting wing 506b and so the third and fourth sealing-assembly-mounting tongues 374a and 374b of the support <NUM> are received in a groove defined between the base 506a and the second mounting wing 506c. This mounting configuration enables the sealing assembly <NUM> to move vertically relative to the support <NUM> and prevents the sealing assembly <NUM> from moving side-to-side or forward and rearward relative to the support <NUM>. As best shown in <FIG>, laterally-spaced-apart first and second sealing-assembly-mounting elements 390a and 390b are fixedly attached to the body <NUM> of the support <NUM> and extend through respective vertically-extending slots (not labeled) defined through the base 506a of the back cover <NUM>. These slots and sealing-assembly-mounting elements 390a and 390b co-act to constrain the vertical movement of the sealing assembly <NUM> relative to the support <NUM> between an (upper) home position (<FIG> and <FIG>) at which the sealing-assembly-mounting elements 390a and 390b are at the lower ends of the slots and a (lower) sealing position (<FIG>, <FIG>, and <FIG>) at which the sealing-assembly-mounting elements 390a and 390b are at the upper ends of the slots. As explained below, the drive assembly <NUM> controls movement of the sealing assembly <NUM> between its home and sealing positions.

As best shown in <FIG> and <FIG>, the jaw assembly <NUM> includes a coupler <NUM>, a pivot pin <NUM>, first and second upper linkages <NUM> and <NUM>, first and second inner jaws <NUM> and <NUM>, first and second outer jaws <NUM> and <NUM>, an inner jaw connector <NUM>, a central jaw connector <NUM>, and an outer jaw connector <NUM>.

The pivot pin <NUM> is connected to the coupler <NUM> so the pivot pin <NUM> is rotatable relative to the coupler <NUM>. As best shown in <FIG> and <FIG>, the opposing ends of the pivot pin <NUM> are positioned in slots (not labeled) defined in the front and back covers <NUM> and <NUM> so the slots limit the pivot pin <NUM> to moving vertically between an upper and a lower position. The first and second upper linkages <NUM> and <NUM> are each pivotably connected to the pivot pin <NUM> near their respective upper ends. This pivotable connection enables the first and second upper linkages <NUM> and <NUM> to pivot relative to the coupler <NUM> and the pivot pin <NUM> about a longitudinal axis of the pivot pin <NUM> (not shown). The respective upper portions of each of the first and second inner jaws <NUM> and <NUM> are pivotably connected to the respective lower ends of the upper linkages <NUM> and <NUM> via pivot pins <NUM> and <NUM>, respectively. The respective upper portions of each of the first and second outer jaws <NUM> and <NUM> are pivotably connected to the respective lower ends of the upper linkages <NUM> and <NUM> via the pivot pins <NUM> and <NUM>. These pivotable connections enable the first inner and outer jaws <NUM> and <NUM> to pivot relative to the upper linkage <NUM> about a longitudinal axis of the pivot pin <NUM> (not shown) and the second inner and outer jaws <NUM> and <NUM> to pivot relative to the upper linkage <NUM> about a longitudinal axis (not shown) of the pivot pin <NUM>.

The respective lower portions of each of the first and second inner jaws <NUM> and <NUM> are pivotably connected by the connectors <NUM> and <NUM> to the front cover <NUM>, the back cover <NUM>, the inner jaw connector <NUM>, the central jaw connector <NUM>, and the outer jaw connector <NUM>. The respective lower portions of each of the first and second outer jaws <NUM> and <NUM> are pivotably connected by the connectors <NUM> and <NUM> to the front cover <NUM>, the back cover <NUM>, the inner jaw connector <NUM>, the central jaw connector <NUM>, and the outer jaw connector <NUM>. The pivotable connections enable the first inner and outer jaws <NUM> and <NUM> to pivot relative to the front and back covers <NUM> and <NUM> and the jaw connectors <NUM>, <NUM>, and <NUM> about longitudinal axis (not shown) of the connector <NUM> between respective home positions (<FIG>) and sealing positions (<FIG>). The pivotable connections enable the second inner and outer jaws <NUM> and <NUM> to pivot relative to the front and back covers <NUM> and <NUM> and the jaw connectors <NUM>, <NUM>, and <NUM> about a longitudinal axis (not shown) of the connector <NUM> between respective home positions (<FIG>) and sealing positions (<FIG>).

As best shown in <FIG> and <FIG>, each jaw has a lower tooth that cuts a notch in the seal element and the overlapping portions of the strap during the sealing cycle and an upper tooth that engages an object blocker <NUM> of the object-blocking assembly <NUM> (described below) if the object blocker <NUM> is in its blocking position (described below) at the start of the sealing cycle and moves the object blocker <NUM> toward its retracted position as the jaws move to their respective sealing positions. This prevents the jaws from damaging the object blocker <NUM>. More specifically, the first inner jaw <NUM> has a lower tooth 530a and an upper tooth 530b, the second inner jaw <NUM> has a lower tooth 534a and an upper tooth 534b, the first outer jaw <NUM> has a lower tooth 538a and an upper tooth 538b, and the second outer jaw <NUM> has a lower tooth 542a and an upper tooth 542b.

The object-blocking assembly <NUM> is mounted to the jaw assembly <NUM> (and more particularly, to the central jaw connector <NUM>) and configured to prevent objects from inadvertently entering the space between the first and second inner jaws <NUM> and <NUM> and the first and second outer jaws <NUM> and <NUM>, sometimes referred to herein as the sealing-element-receiving space. This reduces the possibility of an object interfering with the operation of the strapping tool. This also prevents the jaws of the strapping tool from damaging the object (or vice-versa). As best shown in <FIG> and <FIG>, the object-blocking assembly <NUM> includes an object blocker <NUM> formed from a first object blocker portion <NUM> and a second object blocker portion <NUM>; an object-blocker-lift element <NUM>; a lift-element-mounting pin <NUM>; an object-blocker fastener <NUM>; an object-blocker-mounting pin <NUM>; multiple biasing elements 670a, 670b, 670c, and 670d; a biasing-element retainer <NUM>; and fasteners <NUM>.

The object blocker <NUM> is best shown in <FIG> and is formed from the first object blocker portion <NUM> and the second object blocker portion <NUM> joined by the object-blocker-mounting pin <NUM> and the object-blocker fastener <NUM>. The first object blocker portion <NUM> includes a body <NUM> and a mating lug <NUM> extending from a rear surface of the body <NUM>. The body <NUM> defines cylindrical biasing-element-receiving bores 612a and 612b that extend downward from an upper surface of the body <NUM>. The biasing-element-receiving bores are sized, shaped, oriented, and otherwise configured to partially receive the biasing elements 670d and 670c, respectively. The underside of the body <NUM> includes a curved object-engaging surface 612c (though this surface may be planar in other embodiments). Opposing side surfaces of the body <NUM> define vertically extending slots 612d and 612e. Tooth-engaging pins 616a and 616b are received in bores defined in the body <NUM> from front to back and are positioned to extend across the slots 612d and 612e, respectively.

The second object blocker portion <NUM> includes a body <NUM> and a mating lug <NUM> extending from a front surface of the body <NUM>. The body <NUM> defines cylindrical biasing-element-receiving bores 622a and 622b that extend downward from an upper surface of the body <NUM>. The biasing-element-receiving bores are sized, shaped, oriented, and otherwise configured to partially receive the biasing elements 670b and 670a, respectively. The underside of the body <NUM> includes a curved object-engaging surface 622c (though this surface may be planar in other embodiments). Opposing side surfaces of the body <NUM> define vertically extending slots 622d and 622e. Tooth-engaging pins 626a and 626b are received in bores defined in the body <NUM> from front to back and are positioned to extend across the slots 622d and 622e, respectively.

The object blocker <NUM> is slidably mounted to the central jaw connector <NUM>. More specifically, as best shown in <FIG> and <FIG>, the central jaw connector <NUM> includes a body <NUM> and a neck <NUM> extending upward from a center of the body <NUM>. The body <NUM> and the neck <NUM> define an object-blocker-mounting slot <NUM> therethrough. The object blocker <NUM> is assembled such that the mounting elements <NUM> and <NUM>, the object-blocker fastener <NUM>, and the object-blocker-mounting pin <NUM> extend through the object-blocker-mounting slot <NUM>. After assembly, the object blocker <NUM> is vertically movable relative to the central jaw connector <NUM> (and constrained by the size of the object-blocker-mounting slot <NUM>) between a (upper) retracted position (<FIG>) and a (lower) blocking position (<FIG>). The biasing-element retainer <NUM> is attached to the neck <NUM> of the central jaw connector <NUM> via the fasteners <NUM> to constrain the biasing elements 670a, 670b, 670c, and 670d in place in their respective biasing-element-receiving bores 622b, 622a, 612b, and 612a in the object blocker <NUM>. The biasing elements <NUM> bias the object blocker <NUM> to its blocking position.

The object-blocker-lift element <NUM> is operably connected to the object blocker <NUM> to maintain the object blocker <NUM> in its retracted position when the sealing assembly <NUM> is in its home position to prevent the object blocker <NUM> from interfering with the seal element and the strap during strap insertion and strap tensioning. In this example embodiment and as best shown in <FIG> and <FIG>, the object-blocker-lift element <NUM> is a lever arm that includes a body having a first (attached) end 632a, a second (free) end 632b, and a camming surface 632c extending therebetween. The object-blocker-lift element <NUM> is pivotably mounted to the second object blocker portion <NUM> at the first end 632a by the lift-element-mounting pin <NUM>. The object-blocker-lift element <NUM> is pivotable relative to the object blocker <NUM> about a longitudinal axis of the lift-element-mounting pin <NUM> (not shown). As best shown in <FIG>, <FIG>, after being mounted to the object blocker <NUM>, the object-blocker-lift element <NUM> is positioned between the lips 506d of the back cover <NUM> of the sealing assembly <NUM> and the first sealing-assembly-mounting element 390a. The camming surface 632c of the object-blocker-lift element <NUM> engages and rests upon one of the lips 506d. The object-blocker-lift element <NUM> is pivotable relative to the remainder of the support assembly <NUM> between a home position (<FIG>) and a lifting position (<FIG>).

The object-blocker-lift element <NUM> is positioned and configured such that the position of the object-blocker-lift element <NUM> in part controls the position of the object blocker <NUM>. Specifically, when the object-blocker-lift element <NUM> is in the lifting position, the object-blocker-lift element <NUM> imparts a force on the object blocker <NUM> that overcomes the biasing force of the biasing elements <NUM> and maintains the object blocker <NUM> in its retracted position. Conversely, when the object-blocker-lift element <NUM> is in its home position, it does not impart this force on the object blocker <NUM>, and the object blocker <NUM> can move between its retracted and blocking positions. The biasing elements <NUM> bias the object-blocker-lift element <NUM> to its home position.

The position of the sealing assembly <NUM> controls the position of the object-blocker-lift element <NUM> (and therefore, in part, the position of the object blocker <NUM>). As best shown in <FIG>, when the sealing assembly <NUM> is in its home position, the first sealing-assembly-mounting element 390a engages the object-blocker-lift element <NUM> and forces the object-blocker-lift element <NUM> into its lifting position. This in turn (and as explained above) forces the object blocker <NUM> into its retracted position. As the sealing assembly <NUM> moves from its home position to its sealing position, space is created between the lips <NUM> and the first sealing-assembly-mounting element 390a. As this space is created, the biasing elements <NUM> force the object blocker <NUM> to move toward its blocking position. Due to its pinned connection to the object blocker <NUM>, this causes the object-blocker-lift element <NUM> to pivot so it remains in contact with the first sealing-assembly-mounting element 390a. <FIG> shows the object-blocker-lift element <NUM> and the object blocker <NUM> after they've reached their respective home position and blocking positions.

When the object blocker <NUM> is in its blocking position and the jaws <NUM>, <NUM>, <NUM>, and <NUM> are in their home positions, the object blocker <NUM> and the jaws are in a blocking configuration. When these components are in the blocking configuration, the object blocker <NUM> occupies most of the seal-element-receiving space (not labeled) defined between the pair of jaws <NUM> and <NUM> and the pair of jaws <NUM> and <NUM> and below the jaw connectors <NUM>, <NUM>, and <NUM>. As described in detail below, responsive to application of a force sufficient to overcome the biasing force of the biasing elements <NUM>, the object blocker <NUM> moves from its blocking position to its retracted position and remains there until the force is removed. When in the retracted position, the object blocker <NUM> is not positioned in the seal-element-receiving space such that a seal element and strap can be positioned there for sealing.

If the sealing cycle (described below) is initiated with the object blocker <NUM> and the jaws <NUM>, <NUM>, <NUM>, and <NUM> in the blocking configuration, the jaws are configured to move the object blocker <NUM> toward its retracted position to avoid damaging the jaw assembly <NUM> or any other component of the strapping tool <NUM> during the sealing cycle. Specifically, when the object blocker <NUM> is in its extended position, the upper teeth 530b, 534b, 538b, and 542b of the jaws <NUM>, <NUM>, <NUM>, and <NUM> are adjacent to the pins 626b, 626a, 616b, and 616a of the object blocker <NUM>, respectively. As the jaws begin pivoting from their respective home positions to their respective sealing positions, the upper teeth engage their respective pins. Continued movement of the jaws to their respective sealing positions causes the upper teeth to apply sufficient force to the pins to overcome the biasing force of the biasing elements <NUM> and move the object blocker <NUM> toward its retracted position. As this occurs, the lower teeth enter the slots defined in the sides of the object blocker <NUM>.

One issue with certain known strapping tools that use jaws to crimp or notch the strap and (if applicable) the seal element is that a foreign object may (inadvertently) enter the space between the jaws instead of or in addition to the strap and (if applicable) the seal element. This is problematic for several reasons. The object may interfere with the operation of the strapping tool and cause the joint formed via the attachment of the overlapped strap portions to one another to have suboptimal strength, which could lead to unexpected joint failure and product loss. Additionally, the object could damage the jaws and/or other components of the sealing assembly during the sealing process, which would require tool repairs and cause downtime. Further, the sealing assembly could damage or destroy the object.

The object-blocking assembly <NUM> solves this problem by ejecting foreign objects from and by preventing foreign objects from inadvertently entering the seal-element-receiving space between the jaws. Specifically, if a loose foreign object-such as the shaft of a screwdriver-is in the seal-element-receiving space between the jaws as the sealing assembly <NUM> reaches its sealing position, the object blocker <NUM> will force that object out of the seal-element-receiving space as the object blocker <NUM> moves from its retracted position to its blocking position. Once the object blocker <NUM> reaches its blocking position, minimal space exists between the object blocker <NUM> and the lower teeth of the jaws, thereby preventing foreign objects from entering the seal-element-receiving space between the jaws.

Although not shown here, a cutter is positioned in and movable within the recess in the back cover <NUM> (best shown in <FIG>) and mounted to the pivot pin <NUM>. Movement of the pivot pin <NUM> downwards causes the pivot pin <NUM> to force the cutter downward to cut the strap from the strap supply, and movement of the pivot pin <NUM> back upward causes the cutter to move back upward.

The drive assembly <NUM>, which is best shown in <FIG> and 12A-<NUM>, is operably connected to and configured to rotate the tension wheel <NUM> to tension the strap and is operably connected to the sealing assembly <NUM> to attach the overlapping portions of the strap to one another. The drive assembly <NUM> includes an actuator <NUM>, a first transmission <NUM>, a second transmission <NUM>, a first belt <NUM>, a third transmission <NUM>, a second belt <NUM>, and a conversion assembly <NUM>.

In this example embodiment, the actuator <NUM> is a motor (and referred to herein as the motor <NUM>), and particularly a brushless direct-current motor that includes a motor output shaft (not labeled) (though the motor <NUM> may be any other suitable type of motor in other embodiments). The motor <NUM> is operably connected to (via the motor output shaft) and configured to drive the first transmission <NUM>, which (as described below) is configured to selectively transmit the output of the motor <NUM> to either the tensioning assembly <NUM> or the sealing assembly <NUM>. 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 <NUM> includes any suitable gearing and/or other components that are configured to selectively transmit the output of the motor <NUM> to the second transmission <NUM> via the first belt <NUM> and to the third transmission <NUM> via the second belt <NUM>. More specifically, the first transmission <NUM> is configured such that: (<NUM>) rotation of the motor output shaft in a first rotational direction causes the first transmission <NUM> to transmit the output of the motor <NUM> to the second transmission <NUM> via the first belt <NUM> and not to the third transmission <NUM>; and (<NUM>) rotation of the motor output shaft in a second rotational direction opposite the first rotational direction causes the first transmission <NUM> to transmit the output of the motor <NUM> to the third transmission <NUM> via the second belt <NUM> and not to the second transmission <NUM>. Thus, in this embodiment, a single motor (the motor <NUM>) is configured to actuate both the tensioning and sealing assemblies <NUM> and <NUM>.

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

The second transmission <NUM> is configured to transmit the output of the first transmission <NUM> to the tensioning assembly <NUM> to cause the tensioning wheel <NUM> to rotate. More particularly, the second transmission <NUM> is configured to transmit the output of the first transmission <NUM> to the tensioning-assembly gearing of the tensioning assembly <NUM> to rotate the tension shaft and the tension wheel <NUM> thereon. Accordingly, the motor <NUM> is operatively coupled to the tension wheel <NUM> (via the first transmission <NUM>, the first belt <NUM>, the second transmission <NUM>, the tensioning-assembly gearing, and the tension shaft) and configured to rotate the tension wheel <NUM>. The second transmission <NUM> may include any suitable components arranged in any suitable manner.

The third transmission <NUM> is configured to transmit the output of the first transmission <NUM> to the conversion assembly <NUM>. The third transmission <NUM> may include any suitable components, such as one or more gears and one or more shafts arranged in any suitable manner.

The conversion assembly <NUM> is configured to transmit the output of the third transmission <NUM> to the sealing assembly <NUM> to carry out the sealing cycle, which includes: moving the sealing assembly from its home position to its sealing position, 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, causing the jaws to move back to their home positions to release the notched seal element and strap, and moving the sealing assembly back to its home position. In doing so, in this embodiment the conversion assembly <NUM> is configured to convert rotational output (the rotation of shafts and gears) to linear output (the reciprocating translational movement of a coupler).

The conversion assembly <NUM> is best shown in <FIG> and includes a drive wheel <NUM>, a bearing <NUM>, a tubular shaft <NUM>, a linkage mount <NUM>, a retaining ring <NUM>, a conversion-assembly linkage <NUM>, and an effective-length-changing device <NUM>.

As best shown in <FIG>, the drive wheel <NUM> includes a cylindrical base <NUM> and a disc-shaped head <NUM> centered at one end of the base <NUM>. A linkage-drive shaft <NUM> extends from the head <NUM> near the perimeter of the head <NUM> (i.e., radially spaced from the longitudinal axis of the head <NUM>). The linkage mount <NUM> includes a disc-shaped base <NUM> including a radially-outwardly extending first finger 832a. A disc-shaped head <NUM> is centered on one end of the base <NUM>. A drive-shaft-mounting opening (not labeled) is defined through the base <NUM> and the head <NUM>, and is radially spaced from the common longitudinal axis of the base <NUM> and the head <NUM>. A radially-inwardly extending second finger 834a extends in front of the drive-shaft-mounting opening. The linkage <NUM> includes a body <NUM> with an annular head <NUM> at one end and a foot <NUM> at the other end. A stop tab 844a extends radially outwardly from the head <NUM>.

As best shown in <FIG>, the base <NUM> of the drive wheel <NUM> is journaled in the drive-and-conversion-assembly-mounting element <NUM> of the support <NUM> via the bearing <NUM>, which is a roller bearing in this example embodiment, so the drive wheel <NUM> can rotate relative to the support <NUM> about a drive-wheel rotational axis (not shown). As best shown in <FIG>, the tubular shaft <NUM> is positioned on the linkage-drive shaft <NUM>, and the tubular shaft <NUM> is received in the drive-shaft-mounting opening in the linkage mount <NUM> to mount the linkage mount <NUM> to the drive wheel <NUM>. The retaining ring <NUM> is inserted into a groove (not labeled) defined around the perimeter of the linkage-drive shaft <NUM> to retain these components in place. Once mounted, the linkage mount <NUM> is rotatable relative to the drive wheel <NUM> about a rotational axis AU (<FIG>), which is coaxial with the longitudinal axis of the linkage-drive shaft <NUM>. The head <NUM> of the linkage mount <NUM> is received in the head <NUM> of the linkage <NUM> to mount the linkage <NUM> to the linkage mount <NUM>. Once mounted, the linkage <NUM> is rotatable relative to the linkage mount <NUM> about a central axis (not shown) of the head <NUM>.

As best shown in <FIG> and <FIG>, the effective-length-changing device <NUM> includes a mounting bracket <NUM>, a first stationary finger <NUM>, and a second stationary finger <NUM>. As best shown in <FIG>, the effective-length-changing device <NUM> is fixedly connected to the drive-and-conversion-assembly-mounting element <NUM> of the support <NUM> so the effective-length-changing device <NUM> (and particularly the first and second stationary fingers <NUM> and <NUM>) is stationary relative to the drive wheel <NUM>, the linkage mount <NUM>, and the linkage <NUM>.

Although not shown, the third transmission <NUM> is operably connected to the drive wheel <NUM> (such as via a shaft and suitable gearing) and configured to rotate the drive wheel <NUM> about the drive-wheel rotational axis. The foot <NUM> of the linkage <NUM> is pivotably connected to the coupler <NUM> of the sealing assembly <NUM>, as best shown in <FIG>, <FIG>, so the linkage <NUM> is pivotable relative to the coupler <NUM> about an axis AL (<FIG>). Accordingly, the motor <NUM> is operatively coupled to the sealing assembly <NUM> (via the third transmission <NUM>, the second belt <NUM>, and the conversion assembly <NUM>) and configured to control the sealing assembly <NUM> to carry out a sealing cycle, as described below.

More specifically, rotation of the motor output shaft of the motor <NUM> in the second rotational direction causes rotation of the second belt pulley of the first transmission <NUM>. The second belt <NUM> transmits the output of the first transmission <NUM> (in this instance, the rotation of the second belt pulley) to the third transmission <NUM>, which in turn transmits the output of the first transmission <NUM> to the conversion assembly <NUM>. More specifically, the third transmission <NUM> transmits the output of the first transmission <NUM> to the drive wheel <NUM> of the conversion assembly <NUM>, which causes the drive wheel <NUM> to rotate about the drive-wheel rotational axis, carrying the head <NUM> of the linkage <NUM> with it.

The drive wheel <NUM> has a home position (and may be detected at that home position by a home position sensor that communicates this to the controller <NUM>). As best shown in <FIG>, when the drive wheel <NUM> is in the home position: the foot <NUM> of the linkage <NUM> is at its home position (which is its uppermost position in this example embodiment), the sealing assembly <NUM> is in its home position, and the jaws <NUM>, <NUM>, <NUM>, and <NUM> are in their respective home positions in preparation for sealing. Upon initiation of the sealing cycle, the drive wheel <NUM> begins rotating (counter-clockwise in this example embodiment) from its home position to its sealing position (shown in <FIG>). As the drive wheel <NUM> rotates, the linkage <NUM> imparts a force on the coupler <NUM> that moves the sealing assembly <NUM> toward its sealing position. After the sealing assembly <NUM> reaches its sealing position, continued rotation of the drive wheel <NUM> causes the link <NUM> to force the coupler <NUM> to move toward the jaws relative to the front and back plates <NUM> and <NUM> of the sealing assembly <NUM> (guided by the pivot pin <NUM> received in the slots defined in the front and back plates). This causes downward movement of the upper ends of first and second upper linkages <NUM> and <NUM>, which causes outward movement of the lower ends of the first and second upper linkages <NUM> and <NUM>. This causes outward movement of the upper portions of the jaws. This causes inward movement of the lower portions of the jaws. In other words, this causes the jaws to pivot from their respective home positions to their respective sealing positions. The jaws are in their respective sealing positions when the foot <NUM> of the linkage <NUM> reaches its sealing position (which is its lowermost position in this example embodiment). Continued rotation of the drive wheel <NUM> back to its home position reverses the above movements: the jaws move from their sealing positions back to their home positions, and afterwards the sealing assembly moves back to its home position.

The components of the conversion assembly <NUM> are sized, shaped, positioned, oriented, and otherwise configured to change the effective length of the linkage <NUM>-which is the distance D between the axes AU and AL-during the sealing cycle to rapidly move the sealing assembly <NUM> toward its sealing position (by increasing the effective length of the linkage <NUM>) and, after notching, back toward its home position (by decreasing the effective length of the linkage <NUM>). The minimum effective length of the linkage <NUM> is DMIN, and the maximum effective length of the linkage <NUM> is DMAX, as shown in <FIG>.

<FIG> illustrate how the components of the conversion assembly <NUM> cooperate to change the effective length of the linkage <NUM> during the sealing cycle. At the start of the sealing cycle, the drive wheel <NUM> and the foot <NUM> of the linkage <NUM> are at their respective home positions, as shown in <FIG>. The drive wheel <NUM> begins rotating from its home position to its sealing position, causing the second finger 834a of the head <NUM> of the linkage mount <NUM> to contact the second stationary finger <NUM> of the effective-length-changing device <NUM>. As the drive wheel <NUM> continues to rotate, the engagement between the second finger 834a and the second stationary finger <NUM> causes the linkage mount <NUM> to remain stationary as the drive wheel <NUM> and the linkage <NUM> continue to rotate relative to the linkage mount <NUM>. As shown in <FIG>, as this occurs it causes the first finger 832a to rotate relative to the linkage <NUM> toward the stop tab 844a of the head <NUM> of the linkage <NUM>. This relative rotation of the linkage mount <NUM> relative to the linkage <NUM> combined with the eccentric mounting of the linkage mount <NUM> to the drive wheel <NUM> causes the effective length of the linkage <NUM> to increase from DMIN. As shown in <FIG>, just as the effective length of the linkage <NUM> reaches its maximum DMAX and the first finger 832a reaches the stop tab 844a, the second finger 834a disengages the second stationary finger <NUM>. In this example embodiment, the sealing assembly <NUM> reaches its sealing position just as the effective length of the linkage <NUM> reaches its maximum DMAX.

After the effective length of the linkage <NUM> reaches DMAX, as the drive wheel <NUM> continues to rotate toward its sealing position, the linkage <NUM> remains the same effective length and the jaws begin moving from their home positions to their sealing positions, as shown in <FIG>. <FIG> shows the drive wheel <NUM> at its sealing position, at which point the jaws have also reached their sealing positions and notched the seal element and the strap. Afterwards, continued rotation of the drive wheel <NUM> brings the first finger 832a into contact with the first stationary finger <NUM> of the effective-length-changing device <NUM>, as shown in <FIG>. As the drive wheel <NUM> continues to rotate back to its home position, the engagement between the first finger 832a and the first stationary finger 856a causes the linkage mount <NUM> to remain stationary as the drive wheel <NUM> and the linkage <NUM> continue to rotate relative to the linkage mount <NUM>. As shown in <FIG>, as this occurs it causes the first finger 832a to rotate relative to the linkage <NUM> away from the stop tab 844a of the head <NUM> of the linkage <NUM>. This relative rotation of the linkage mount <NUM> relative to the linkage <NUM> combined with the eccentric mounting of the linkage mount <NUM> to the drive wheel <NUM> causes the effective length of the linkage <NUM> to decrease from DMAX. As shown in <FIG>, just as the effective length of the linkage <NUM> reaches its minimum DMIN, the first finger 832a disengages the first stationary finger <NUM>. In this example embodiment, the sealing assembly <NUM> reaches its home position just as the effective length of the linkage <NUM> reaches its minimum DMIN.

Varying the effective length of the linkage <NUM> during the sealing cycle provides several benefits compared to prior art tools with linkages having a fixed effective length. Since the sealing assembly <NUM> reaches its sealing position shortly after the start of the sealing cycle, more of the travel of the linkage-drive shaft <NUM> as it rotates from its home position to its sealing position is used to cut the notches in the seal element and the strap (as compared to prior art tools). This means that less force is required to cut the notches. In turn, the components of the jaws assembly <NUM>-such as the jaws, gears, links, and the like-are lighter (and in some instances smaller) than those of prior art tools, rendering this tool lighter (and in some instances more compact) and therefore easier to handle. Since less force is required to cut the notches, the amount of torque the motor must provide is less than in prior art tools, meaning that the motor draws less current than in prior art tools and is more efficient. And this also allows the motor to run faster and therefore increase the speed of the sealing cycle as compared to prior art tools.

The gate assembly <NUM>, which is best shown in <FIG>, is configured to facilitate easy insertion of the strap and is adjustable to accommodate straps of differing thicknesses. The gate assembly <NUM> includes a gate <NUM> and multiple linkages <NUM>, <NUM>, and <NUM>.

The gate <NUM> is slidably received in the gate-receiving recess <NUM> of the body <NUM> of the support <NUM> and retained in that recess via a retaining bracket (not shown for clarity). A strap-receiving opening (not labeled) is defined between the bottom of the gate <NUM> and the top surface of the foot <NUM> of the support <NUM>. The gate <NUM> is movable relative to the support <NUM> between a home position (<FIG> and <FIG>) and a retracted position (<FIG> and <FIG>). When in the home position, the gate <NUM> is positioned relative to the foot <NUM> so the height H<NUM> of the strap-receiving opening is equal to or just larger than the thickness of the particular strap to-be-tensioned and sealed. When in the retracted position, the gate <NUM> is positioned relative to the foot <NUM> so the height H<NUM> of the strap-receiving opening larger than the height H<NUM>. The position of the tensioning assembly <NUM> controls the position of the gate <NUM>.

The linkage <NUM> is fixedly connected at one end to the tensioning assembly <NUM> and pivotably connected at the other end to one end of the linkage <NUM>. The other end of the linkage <NUM> is pivotably connected to one end of the linkage <NUM>. The other end of the linkage <NUM> is fixedly connected to the gate <NUM>. The linkages <NUM>, <NUM>, and <NUM> are sized, shaped, positioned, oriented, and otherwise configured such that: (<NUM>) when the tensioning assembly <NUM> is in the strap-tensioning position, the gate <NUM> is in its home position (and the strap-receiving opening has the height H<NUM>); and (<NUM>) when the tensioning assembly <NUM> is in its strap-insertion position, the gate <NUM> is in its retracted position (and the strap-receiving opening has the height H<NUM>). More specifically, when the tensioning assembly <NUM> is pivoted from the strap-tensioning position to the strap-insertion position, the linkage <NUM> is pivoted counter-clockwise. This causes the linkage <NUM> to pivot clockwise, which forces the linkage <NUM> to move upward and carry the gate <NUM> with it.

One issue with certain known strapping tools is that it is difficult to insert the strap into the strapping tools. These known strapping tools include a gate positioned forward of the tensioning wheel so the seal engages the gate during the tensioning cycle and so the gate prevents the seal from contacting the tensioning wheel. The gate is fixed in place and positioned so the strap-receiving opening defined between the bottom of the gate the top of the foot of the strapping tool (on which the strap is positioned during operation) has the same height as or a height slightly larger than the thickness of the strap. This prevents the strap from moving up and down during operation of the strapping tool. The problem is that it is difficult and time-consuming for operators to align the strap with the strap-receiving opening to insert the strap into the strap-receiving opening that has a height that at best is slightly larger than the strap is thick.

The gate assembly <NUM> of the present disclosure solves this problem by increasing the height of the strap-receiving opening when the tensioning assembly <NUM> is moved to its strap-insertion position. In other words, the tensioning assembly <NUM> is coupled to the gate <NUM> (via the linkages) so movement of the tensioning assembly <NUM> from the strap-tensioning position to the strap-insertion position causes the gate <NUM> to move from its home position to its retracted position to enlarge the strap-receiving opening. This makes it easier for the operator to insert the strap into the strap-receiving opening, which streamlines operation of the strapping tool.

The position of the gate <NUM> relative to the foot <NUM> is also variable. Specifically, the gate <NUM> can be fixed to the linkage <NUM> in any of several different vertical positions. By changing the vertical position of the gate <NUM> relative to the linkage <NUM>, the operator can vary the height H<NUM> of the strap-receiving opening when the gate <NUM> is in the home position. For instance, in this embodiment, the linkage <NUM> is connected to the gate <NUM> via one or more screws. The screws extend through elongated slots that extend along the length of the gate <NUM>. To change the height H<NUM> of the strap-receiving opening when the gate <NUM> is in its home position, the operator loosens the screws, slides the gate <NUM> up or down relative to the linkage <NUM> (taking advantage of the slots), and re-tightens the screws.

One issue with certain known strapping tools is that it is time-consuming to reconfigure the strapping tools for use with straps of different thicknesses. To reconfigure a strapping tool for use with a strap having a different thickness, the operator must replace the existing gate with another gate sized for use with the new strap (e.g., a gate that is longer (for thinner strap) or shorter (for thicker strap)). This requires the operator to partially disassemble the strapping tool, which not only causes downtime but also requires operators to keep the different gates on hand, recognize when a different gate is needed, and properly match the gates to the different strap thicknesses. Using the incorrect gate could result in a failed or suboptimal strapping operation (and in the latter case, suboptimal joint strength).

The gate assembly <NUM> of the present disclosure solves this problem by enabling the operator to vary the position of the gate <NUM> relative to the linkage <NUM> and therefore the height H<NUM> of the strap-receiving opening when the gate <NUM> is in its home position. This improves upon prior art strapping tools by enabling the operator to quickly and easily move the gate to accommodate straps of different thicknesses without having to swap out one gate for another.

The second handle assembly <NUM> of the strapping tool <NUM> is movably mounted to the support <NUM>. In this example, the second handle assembly <NUM> includes a second handle (not labeled) pivotably mounted to the support <NUM> by a pivot assembly <NUM> shown in <FIG>. The pivot assembly <NUM> includes a pivot-positioning-wheel with radially extending bores along its circumference and a spring-loaded ball assembly. The spring forces the ball into one of the bores to hold the handle in place. An operator can reposition the handle by pivoting the handle with enough force to force the ball to move against the spring force and out of the bore. Continued pivoting of the handle eventually causes the spring to force the ball into another one of the bores. The spring force can be adjusted with a screw plug or other suitable component.

The display assembly <NUM> includes a suitable display screen with a touch panel. The display screen is configured to display information regarding the strapping tool (at least in this embodiment), and the touch screen is configured to receive operator inputs. A display controller may control the display screen and the touch panel and, in these embodiments, is communicatively connected to the controller <NUM> to send signals to the controller <NUM> and to receive signals from the controller <NUM>.

The controller <NUM> 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 <NUM>. The controller <NUM> is communicatively and operably connected to the motor <NUM> and the display assembly <NUM> and configured to receive signals from and to control those components. The controller <NUM> may also be communicatively connectable (such as via WiFi, 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 power supply <NUM> is electrically connected to (via suitable wiring and other components) and configured to power several components of the strapping tool <NUM>, including the motor <NUM>, the display assembly <NUM>, and the controller <NUM>. The power supply <NUM> 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 <NUM> is sized, shaped, and otherwise configured to be received in a receptacle (not labeled) defined by the rear housing portion <NUM> of the housing <NUM>. The strapping tool includes one or more battery-securing devices (not shown) to releasably lock the power supply <NUM> in place upon receipt in the receptacle. Actuation of a release device of the strapping tool <NUM> or the power supply <NUM> unlocks the power supply <NUM> from the rear housing portion <NUM> and enables an operator to remove the power supply <NUM> from the rear housing portion <NUM>.

Use of the strapping tool <NUM> to carry out a strapping cycle including: (<NUM>) a tensioning cycle in which the strapping tool <NUM> tensions a strap S around a load L; and (<NUM>) a sealing cycle in which the strapping tool <NUM> 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 in accordance with <FIG>. Initially: the tensioning assembly <NUM> is in its strap-tensioning position; the sealing assembly <NUM> is in its home position; the jaws are in their respective home positions; the object blocker <NUM> is in its retracted position; the drive wheel <NUM> is in its home position; the rocker lever <NUM> is in its home position; and the gate <NUM> is in its home position.

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> shows the position of the bend and the seal element SE at this point.

The operator then pulls the rocker lever <NUM> from its home position to its actuated position, which causes the tensioning assembly <NUM> to move from its strap-tensioning position to its strap-insertion position and the gate <NUM> to move from its home position to its strap-insertion position, thereby enlarging the strap-receiving opening to the height H<NUM>. The operator then 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 <NUM> and the roller <NUM> of the foot <NUM> of the support <NUM>. The operator then manually pulls the strap S to eliminate the slack and pushes the strapping tool <NUM> toward the seal element SE until the seal element SE engages the gate <NUM> and is trapped between the bend in the bottom portion of the strap S and the gate <NUM>. As shown in <FIG>, at this point the seal element SE is below the object blocker <NUM>.

The operator then releases the rocker lever <NUM>, which enables the tensioning-assembly-biasing element to bias the tensioning assembly <NUM> back to the strap-tensioning position. This causes the tension wheel <NUM> to engage the top portion of the strap S and pinch it against the roller <NUM>. At this point the bottom portion of the strap S is beneath the foot <NUM>. Movement of the tensioning assembly <NUM> back to the strap-tensioning position causes the gate <NUM> to return to its home position in which the gate <NUM> barely contacts or is just above the top portion of the strap.

The operator then actuates an input device (which may be a mechanical pushbutton, which is not shown, or a particular area of the touchscreen of the display assembly <NUM> that defines a virtual button) to initiate the strapping cycle. Upon receipt of that operator input, the controller <NUM> starts the tensioning cycle by controlling the motor <NUM> to begin rotating the motor output shaft in the first rotational direction, which causes the tension wheel <NUM> to begin rotating. As the tension wheel <NUM> 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 <NUM> monitors the current drawn by the motor <NUM>. When this current reaches a preset value that is correlated with the preset tension level set for this strapping cycle, the controller <NUM> stops the motor <NUM>, thereby terminating the tensioning cycle. The preset tension level may be set by the operator via an input device of the tool <NUM>.

The controller <NUM> then automatically starts the sealing cycle by controlling the motor <NUM> to begin rotating the motor output shaft in the second rotational direction. As described in detail above, this causes the sealing assembly <NUM> to move to its sealing position. As the sealing assembly <NUM> moves to its sealing position, the object-blocker-lift element <NUM> frees the object blocker <NUM> to move toward its blocking position. The object blocker <NUM> contacts the seal element SE and is forced to remain in place by the seal element SE, as shown in <FIG>. The sealing assembly <NUM> is positioned relative to the seal element SE so the seal element SE is within the seal-element-receiving space of the sealing assembly <NUM> when in its sealing position. After the sealing assembly <NUM> reaches its sealing position, the jaws: (<NUM>) 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, as shown in <FIG>; and then (<NUM>) pivot from their respective sealing positions back to their respective home positions to enable the strapping tool <NUM> to be removed from the strap S. <FIG> 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 than those included in the strapping tool <NUM> described above and shown in the Figures. For instance, other strapping tools may include only one of the conversion assembly, the object-blocking assembly, and the gate assembly. Further strapping tools may include only two of the conversion assembly, the object-blocking assembly, and the gate assembly. In other words, while the strapping tool <NUM> includes all three of these assemblies, these assemblies are independent of one another and may be independently included in other strapping tools.

In various embodiments, a strapping tool of the present disclosure comprises a support; a tensioning assembly mounted to the support and movable relative to the support between a tensioning assembly strap-tensioning position and a tensioning assembly strap-insertion position; and a gate movable relative to the support between a gate home position and a gate strap-insertion position. A height of a strap-receiving opening defined between the gate and the support is a first height when the gate is in the gate home position and a second height greater than the first height when the gate is in the gate strap-insertion position. The tensioning assembly is operably connected to the gate so movement of the tensioning assembly from the tensioning assembly strap-tensioning position to the tensioning assembly strap-insertion position causes the gate to move from the gate home position to the gate strap-insertion position.

In certain such embodiments, the gate is mounted to the support.

In certain such embodiments, the support defines a gate-receiving recess in which at least part of the gate is positioned.

In certain such embodiments, the strapping tool further comprises one or more linkages operably connecting the tensioning assembly to the gate.

In certain such embodiments, the one or more linkages comprise a first linkage, a second linkage, and a third linkage. The first linkage is fixedly connected at a first end to the tensioning assembly and pivotably connected at a second end to a first end of the second linkage. A second end of the second linkage is pivotably connected to a first end of the third linkage. A second end of the third linkage is fixedly connected to the gate.

In certain such embodiments,, moving the tensioning assembly from the tensioning assembly strap-tensioning position to the tensioning assembly strap-insertion position causes the second linkage to rotate, thereby forcing the gate to move to the gate strap-insertion position.

In certain such embodiments, the tensioning assembly is pivotable relative to the support between the tensioning assembly strap-tensioning position and the tensioning assembly strap-insertion position.

In certain such embodiments, the gate is repositionable relative to the one or more linkages to vary the first height.

In other embodiments, the strapping tool of the present disclosure comprises a support; a sealing assembly mounted to the support, the sealing assembly comprising multiple jaws and an object blocker between the jaws and movable relative to the jaws between an object blocker blocking position and an object blocker retracted position; and a drive assembly operably coupled to the sealing assembly to pivot the jaws from respective jaw home positions to respective jaw sealing positions. The jaws define a seal-element-receiving space therebetween. The object blocker is within the seal-element-receiving space when in the object blocker blocking position. The object blocker is removed from the seal-element-receiving space when in the object blocker retracted position.

In certain such embodiments, the sealing assembly further comprises a biasing element that biases the object blocker to the object blocker blocking position.

In certain such embodiments, the object blocker defines a biasing-element-receiving opening in which at least part of the biasing element is received.

In certain such embodiments, the sealing assembly further comprises a biasing-element retainer that retains the biasing element in the biasing-element-receiving opening.

In certain such embodiments, when the object blocker is in the object blocker blocking position and the jaws move from their jaw home positions to their jaw sealing positions, at least one of the jaws engages the object blocker and drives the object blocker toward the object blocker retracted position.

In certain such embodiments, the sealing assembly further comprises an object-blocker-lift element operably connected to the object blocker and movable relative to the object blocker between a lift element home position and a lift element lifting position. The object blocker is in the object blocker retracted position when the object-blocker-lift element is in the lift element lifting position.

In certain such embodiments, the object blocker is movable between the object blocker retracted and object blocker blocking positions when the object-blocker-lift element is in the lift element home position.

In certain such embodiments, the sealing assembly is movable relative to the support between a sealing assembly home position and a sealing assembly sealing position. The object-blocker-lift element is in the lift element lifting position when the sealing assembly is in the sealing assembly home position. The object-blocker-lift element is biased to the lift element home position when the sealing assembly is in the sealing assembly sealing position.

In certain such embodiments, the sealing assembly further comprises a biasing element that biases the object blocker to the object blocker blocking position and the object-blocker-lift element to the lift element home position.

In certain such embodiments, the sealing assembly is mounted to the support by a sealing assembly mounting element. The sealing assembly comprises a cover comprising a lip. The object-blocker-lift element comprises a camming surface. The camming surface engages the lip so the object-blocker lift element is constrained between the lip and the sealing assembly mounting element.

In certain such embodiments, the sealing assembly further comprises a central jaw connector. The jaws comprise a first pair of jaws and a second pair of jaws. The jaws of the first and second pairs of jaws are pivotably mounted to the central jaw connector. The central jaw connector is positioned between the first and second pairs of jaws.

In certain such embodiments, the object blocker is movably mounted to the central jaw connector.

Other embodiments of the strapping tool of the present disclosure comprise a support; a sealing assembly mounted to the support and movable relative to the support between a sealing assembly home position and a sealing assembly sealing position, the sealing assembly comprising multiple jaws pivotable from respective jaw home positions to respective jaw sealing positions, a conversion assembly comprising a linkage operably connected to the sealing assembly and configured to move the sealing assembly between the sealing assembly home position and the sealing assembly sealing position and configured to move the jaws between their jaw home positions and their jaw sealing positions, wherein the conversion assembly is configured to change an effective length of the linkage while moving the sealing assembly from the sealing assembly home position and the sealing assembly sealing position; and a drive assembly operably connected to the conversion assembly and configured to drive the linkage.

In certain such embodiments, the conversion assembly further comprises a drive wheel comprising a drive shaft radially spaced from a rotational axis of the drive wheel. The drive assembly is operably connected to the drive wheel and configured to rotate the drive wheel. The linkage is mounted to the drive shaft.

In certain such embodiments, the conversion assembly further comprises a linkage mount mounted to and rotatable relative to the drive shaft. The linkage is mounted to and rotatable relative to the linkage mount.

In certain such embodiments, the effective length of the linkage is a minimum effective length when the linkage mount is in a first rotational position relative to the linkage and a maximum effective length when the linkage mount is in a second different rotational position relative to the linkage.

In certain such embodiments, the linkage mount further comprises first and second fingers. The conversion assembly further comprises an effective-length-changing device fixed relative to the drive wheel, the linkage, and the linkage mount. The effective-length-changing device comprises first and second stationary fingers.

In certain such embodiments, the effective-length-changing device is mounted to the support.

In certain such embodiments, the first and second stationary fingers are positioned such that, during rotation of the drive wheel from a drive wheel home position to a drive wheel sealing position, the second finger engages the second stationary finger and causes the linkage mount to rotate relative to the linkage to increase the effective length of the linkage.

In certain such embodiments, the first and second stationary fingers are positioned such that, during rotation of the drive wheel from the drive wheel sealing position to the drive wheel home position, the first finger engages the first stationary finger and causes the linkage mount to rotate relative to the linkage to decrease the effective length of the linkage.

In certain such embodiments, the sealing assembly is in the sealing assembly home position and the jaws are in the jaw home positions when the effective length of the linkage is the minimum effective length.

Claim 1:
A strapping tool (<NUM>) comprising:
a support (<NUM>);
a sealing assembly (<NUM>) mounted to the support (<NUM>), the sealing assembly (<NUM>) comprising multiple jaws (<NUM>, <NUM>, <NUM>, <NUM>) and an object blocker (<NUM>) between the jaws (<NUM>, <NUM>, <NUM>, <NUM>) and movable relative to the jaws (<NUM>, <NUM>, <NUM>, <NUM>) between an object blocker blocking position and an object blocker retracted position; and
a drive assembly (<NUM>) operably coupled to the sealing assembly (<NUM>) to pivot the jaws (<NUM>, <NUM>, <NUM>, <NUM>) from respective jaw home positions to respective jaw sealing positions,
wherein the jaws (<NUM>, <NUM>, <NUM>, <NUM>) define a seal-element-receiving space therebetween,
wherein the object blocker (<NUM>) is within the seal-element-receiving space when in the object blocker blocking position preventing foreign objects from entering the seal-element-receiving space,
wherein the object blocker (<NUM>) is removed from the seal-element-receiving space when in the object blocker retracted position,
characterized in that the sealing assembly (<NUM>) further comprises a biasing element (670a, 670b, 670c, 670d) configured to bias the object blocker (<NUM>) to the object blocker blocking position.