Strapping device comprising ultrasonic sealer

Abstract

A strapping device comprising: an anvil (720) having teeth (734) in a plane angularly offset ([theta]) from a horizontal axis, i.e. A transverse direction of a strapping tape (S) in a strapping tape path; and an ultrasonic sealer (800) comprising a sonotrode (830) having teeth (834) in a plane angularly offset ([theta]) from the horizontal axis, and an ultrasonic transducer for transmitting mechanical vibrations to the sonotrode, the ultrasonic sealer extends longitudinally along an ultrasonic sealer axis and is movable along the ultrasonic sealer axis between a retracted position (depicted) and a sealing position, the ultrasonic sealer axis being angularly offset ([beta]) from a vertical axis (i.e., orthogonal to a transverse direction of the strapping tape (S) in the strapping tape path). Also described is a sonotrode (830) comprising teeth (834) extending substantially parallel to the strapping tape (S), where adjacent sonotrode teeth (834) define grooves, each having the same cross-section along their length.

Description

[0001] Priority This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 504,583, filed May 26, 2023, the entire contents of which are incorporated herein by reference. TECHNICAL FIELD

[0002] The present disclosure relates to a strapping device for strapping and unitizing a load of cargo, and more particularly to a strapping device including an ultrasonic sealer for attaching two overlapping strapping layers to one another to form a strapping joint. BACKGROUND

[0003] Strapping devices form a tensioned loop of plastic strapping, such as polyester or polypropylene strapping, metal strapping, such as steel strapping, or paper strapping around a load. A strapping machine is one type of strapping device. A typical strapping machine includes a support surface that supports the load, a strapping chute that loops around the support surface, a strapping head that forms a strapping loop, a controller that controls the strapping head to strap the load, and a frame that supports these components. A typical strapping head includes a strapping feed assembly for feeding strapping from a strapping supply into the strapping chute and around the strapping chute, and for retracting the strapping so that it moves away from the strapping chute and radially inward into contact with the load, a strapping tension assembly for tensioning the strapping around the load, and a strapping seal assembly for cutting the strapping from the strapping supply and attaching two regions of the strapping together to form the strapping loop. The strapping machine includes a number of guides that define strapping passages through which the strapping passes as it moves between the various components of the strapping head and the strapping chute. The strapping passages and the strapping chute together define a strapping path through which the strapping moves.

[0004] To bind a load, the binding machine performs a binding process that includes a binding tape feeding process, a binding tape retracting process, a binding tape tensioning process, and a binding tape sealing process. The binding machine first performs the binding tape feeding process during which the binding tape feeding assembly feeds the binding tape (first the binding tape leading end) from the binding tape supply through the binding tape tensioning assembly, through the binding tape sealing assembly, and into and around the binding tape chute until the binding tape leading end returns to the binding tape sealing assembly. The binding machine then performs the binding tape retracting process during which the binding tape sealing assembly holds the binding tape leading end while the binding tape feeding assembly retracts the binding tape to pull the binding tape out of the binding tape chute and onto and around the load. The binding machine then performs the binding tape tensioning process during which the binding tape tensioning assembly tensions the binding tape to a specified binding tape tension. The binding machine then performs the binding tape sealing process during which the binding tape sealing assembly attaches the binding tape leading end to another portion of the binding tape to form a binding tape joint and cuts the binding tape from the binding tape supply, thereby forming a tensioned binding tape loop around the load and completing the binding process. SUMMARY

[0005] Various embodiments of the present disclosure provide a binding apparatus including an ultrasonic sealer. BRIEF DESCRIPTION OF DRAWINGS

[0006] FIG. 1 is a perspective view of one example embodiment of a binding apparatus of the present disclosure.

[0007] FIG. 2A and FIG. 2B are, respectively, FIG. 1 are perspective and front elevational views of a binding head of the binding apparatus of

[0008] FIG. 3A and FIG. 3B are FIG. 2A and FIG. 2B are perspective views of a binding tape sealing assembly of the binding head of

[0009] FIG. 4A and FIG. 4B are FIG. 3A and FIG. 3B are perspective views of a sealing assembly frame, an anvil assembly, and an ultrasonic sealing assembly of the binding tape sealing assembly of

[0010] FIG. 5A and FIG. 5B are, respectively, FIG. 3A and FIG. 3B are perspective and side elevational views of an anvil of the anvil assembly of the binding tape sealing assembly of

[0011] FIG. 6A andFIG. 6B respectively FIG. 3A and FIG. 3B is a perspective view and front elevational view of an ultrasonic sealing assembly of a strap sealing assembly.

[0012] FIG. 6C is FIG. 6A and FIG. 6B is a perspective view of an ultrasonic sealer of an ultrasonic sealing assembly.

[0013] FIG. 6D is FIG. 6C is a side elevational view of a sonotrode head of a sonotrode of an ultrasonic sealer.

[0014] FIG. 7A is FIG. 3A and FIG. 3B is a side elevational view of a sealing assembly frame, an anvil assembly, and an ultrasonic sealing assembly of a strap sealing assembly, with the anvil assembly in its sealing position and the ultrasonic sealing assembly in its retracted position.

[0015] FIG. 7B is similar to FIG. 7A but shows the anvil assembly in its retracted position.

[0016] FIG. 8A is FIG. 3A and FIG. 3B is a cross-sectional side elevational view of a sealing assembly frame, an anvil assembly, and an ultrasonic sealing assembly of a strap sealing assembly taken along line 8A-8A of FIG. 4A , with the anvil assembly in its sealing position and the ultrasonic sealing assembly in its retracted position.

[0017] FIG. 8B is similar to FIG. 8A but shows the ultrasonic sealing assembly in its sealing position.

[0018] FIG. 9A to FIG. 9C is a side elevational view of a sonotrode head, FIG. 6D and FIG. 5A is a side elevational view of an anvil, and an upper strap portion and a lower strap portion of a strap sealing assembly during a strap sealing cycle. FIG. 5B

[0019] is a top plan view of an example strap joint formed by a strapping head of FIG. 10 and FIG. 2A . FIG. 2B

[0020] is a cross-sectional front elevational view of a portion of a strap sealing assembly of FIG. 11A to FIG. 11E and FIG. 2A during a strapping process. FIG. 2B ​ DETAILED DESCRIPTION

[0021] While the systems, devices, and methods described herein can 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 or described in the specification can be necessary in every implementation, and some implementations can include additional, different or fewer components. The arrangement and type of components; the shape, size, and material of components; and the manner in which components are connected can be varied without departing from the spirit or scope of the claims. Unless otherwise stated, any direction mentioned in the specification reflects the orientation of the components shown in the corresponding drawing and does not limit the scope of the disclosure. Further, terms relating to methods of mounting, connecting, and the like are not intended to be limited to direct mounting, connecting, and the like, but should be interpreted broadly to include indirect and operatively mounting, connecting, and the like. The specification is intended to be considered as a whole and interpreted in accordance with the principles of the disclosure and as understood by those of ordinary skill in the art.

[0022] Various embodiments of the present disclosure provide a strapping device configured to perform a strapping process. FIG. 1 to FIG. 11E One example embodiment of a strapping device of the present disclosure, in the form of a strapping machine 10, and components thereof, is shown. The strapping machine 10 is configured to form a tensioned loop of strapping tape, drawn from a strapping tape supply (not shown), around a load 50, and includes a frame 100, a strapping tape chute 150, a load support 200, a strapping head 300, and a controller.

[0023] The frame 100 supports some (or all, depending on the embodiment) of the other components of the strapping machine 10, and can be formed of any suitable components arranged in any suitable configuration. The load support 200 is supported by the frame 100, and is sized, shaped, positioned, oriented, and otherwise configured to support a load (such as the load 50 shown) as it is strapped by the strapping machine 10 and as it moves through the strapping machine. FIG. 1 The load support 200 includes a support surface (not labeled) on which the load is positioned during the strapping process, and over which the load moves as it moves through the strapping machine 10. In this example embodiment, the support surface includes a plurality of rollers that facilitate movement of the load through the load support 200. The rollers can be driven or undriven. In other embodiments, the support surface includes any other suitable driven conveyor.

[0024] The strap chute 150 is supported by the frame 100 and encircles the support surface of the load support 200. The strap chute 150 defines a strap path along which the strap moves as it is fed through the strap chute 150 and from which the strap is removed as it is retracted. The strap chute 150 includes two spaced apart first and second upright legs (not labeled), an upper connecting portion (not labeled) that spans the first and second legs, a first lower connecting portion (not labeled) within or below the load support 200 that connects the strap head 300 with the first upright leg, and a second lower connecting portion (not labeled) within or below the load support 200 that connects the strap head 300 with the second upright leg. The radially inward wall of the strap chute 150 is formed by one or more gates that are biased to a closed position so that the strap can traverse the strap path as it is fed through the strap chute 150. During the strapping process (as described below), the gates are moved to an open position prior to the retraction cycle to enable the strap to be retracted from the strap chute 150 and moved radially inward to contact the load. A front end sensor communicatively connected to the controller is positioned and otherwise configured to detect the front end of the strap when it has traversed the strap chute 150 and back to the strap head 300 during the strap feeding process, as explained below.

[0025] The strap head 300 is configured to perform the strapping process and includes a head frame 305 that is mounted to the frame 100 and supports a strap feeding assembly 400, a strap tensioning assembly 500, a strap sealing assembly 600, and one or more guides configured to guide the strap between these assemblies and the strap chute 150. In this example embodiment, the strap head 300 is removably attached to the frame 100, but in other embodiments, the strap feeding assembly 400, the strap tensioning assembly 500, and / or the strap sealing assembly 600 are removably attached to the frame 100.

[0026] The strap feeding assembly 400 (in FIG. 2A and FIG. 2BThe strap feed assembly 400 includes a drive roller 410, a pinch roller 420, and a strap feed actuator 430. The drive roller 410 is cylindrical (here, disc-shaped) and is mounted to the head frame 305, so the drive roller 410 is rotatable relative to the head frame 305 about a drive roller rotation axis. The pinch roller 420 is cylindrical (here, disc-shaped) and is mounted to the head frame 305 so that the pinch roller 420 is freely rotatable relative to the head frame 305 about a pinch roller rotation axis. The drive roller 410 and the pinch roller 420 are sized, shaped, positioned, and oriented so that their respective rotation axes are generally parallel and coplanar. The pinch roller 420 is positioned adjacent to the drive roller 410 so that a roller gap is formed between the two rollers. The roller gap is sized so that a strap S can be received in the roller gap, and so that the drive roller 410 and the pinch roller 420 exert sufficient force on the strap S to enable the drive roller 410 to feed and retract the strap S. In certain embodiments, at least a portion of the cylindrical outer surface of the drive roller 410 and / or the pinch roller 420 is knurled or coated with a friction-enhancing material to facilitate engagement with the strap.

[0027] The strap feed actuator 430 (which is an electric motor in this example embodiment, but can include any suitable actuator) is mounted to the head frame 305 and is operably connected to the drive roller 410, and is configured to drive the drive roller 410 in opposite feed and retract rotational directions. The strap feed actuator 430 can be operably connected to the drive roller 410 in any suitable manner, such as via a key or spline connection and / or via a suitable drive train.

[0028] The strap tension assembly 500 (which is a strap tensioner in this example embodiment, but can include any suitable strap tensioner) is mounted to the head frame 305 and is operably connected to the strap feed assembly 400, and is configured to apply a tension force to the strap S to maintain the strap S in tension as the strap S is fed and retracted by the strap feed assembly 400. The strap tension assembly 500 can be operably connected to the strap feed assembly 400 in any suitable manner, such as via a key or spline connection and / or via a suitable drive train. FIG. 2A and FIG. 2B(Best shown in the image) is configured to tension a strapping band around a load 50. The strapping band tensioning assembly 500 includes a drive roller 510, a clamping roller 520, and a strapping band tensioning actuator 530. The drive roller 510 is cylindrical (disc-shaped in this case) and mounted to the head frame 305, so that the drive roller 510 is rotatable relative to the head frame 305 about a drive roller rotation axis. The clamping roller 520 is cylindrical (disc-shaped in this case) and mounted to the head frame 505 such that the clamping roller 520 is freely rotatable relative to the head frame 305 about a clamping roller rotation axis. The drive roller 510 and the clamping roller 520 are sized, shaped, positioned, and oriented such that their respective rotation axes are substantially parallel and coplanar. The clamping roller 520 is positioned adjacent to the drive roller 510 such that a gap is formed between the two rollers. The roll gap is set such that the strapping band S can be received within the roll gap, and that the drive roller 510 and clamping roller 520 apply sufficient force to the strapping band S so that the drive roller 510 can tension the strapping band S around the load. In some embodiments, at least a portion of the cylindrical outer surface of the drive roller 510 and / or clamping roller 520 is knurled or coated with a friction-enhancing material to facilitate engagement of the strapping band.

[0029] A strapping tension actuator 530 (in this example embodiment, an electric motor, but may include any suitable actuator) is mounted to the head frame 305 and operatively connected to the drive roller 510, and configured to drive the drive roller 510 in the tensioning rotation direction (in this example embodiment, the same rotation direction as the retraction rotation direction). The strapping tension actuator 530 may be operatively connected to the drive roller 510 in any suitable manner (e.g., via a keyed or splined connection and / or via a suitable drivetrain).

[0030] Strapping tape sealing assembly 600 (in FIG. 3A and FIG. 3B (Best shown in the image) Supported by a head frame 305, and configured to attach two overlapping portions of the strapping to each other to form a strapping joint and to cut the strapping from the strapping feeder after the strapping tensioning assembly 500 tensions the strapping to a specified tension. The strapping sealing assembly 600 includes a sealing assembly frame 605, a drive assembly 610 including a strapping sealing actuator 615, a front guide 630, a first strapping clamp 640, a second strapping clamp 650, a strapping cutter 660, an anvil assembly 700, and an ultrasonic sealing assembly 800.

[0031] Sealing component frame 605 (in FIG. 3A to FIG. 4BSome (or all) of the other components that support the sealing assembly 600 (best shown) can be formed of any suitable components arranged in any suitable configuration. In this example embodiment, the sealing assembly frame 605 is mounted to the head frame 305 in any suitable manner, such as via fasteners, such that the sealing assembly frame is positioned below the work platform W.

[0032] The drive assembly 610 is operatively connected to various components of the strapping seal assembly 600, including the front end guide 630, the first strapping clamp 640, the second strapping clamp 650, the strapping cutter 660, the anvil assembly 700, and the ultrasonic seal assembly 800, to move these components as described below to perform the strapping process. In this example embodiment, the drive assembly 610 includes a cam shaft that includes a plurality of cams. The cams are shaped, positioned, oriented, and otherwise configured to drive the various components of the strapping seal assembly 600 during the strapping process as described below. The cam shaft is rotatably supported by the sealing assembly frame 605 via suitable bearings such that the cam shaft can rotate relative to the sealing assembly frame 605. A strapping seal actuator 615, which in this example embodiment is a motor, but which in other embodiments can be any other suitable actuator, is operatively connected to the cam shaft, such as via suitable couplings or spline or key connections, and is configured to rotate the cam shaft one full revolution (but can be more or less than one full revolution in other embodiments) to perform the strapping process. The cam shaft (and more particularly the cams that are fixed relative to the cam shaft with respect to rotation) control the movement of the various components of the strapping seal assembly 600 during the strapping process. Although not labeled or described in detail, the drive assembly 610 includes suitable actuators that operatively connect certain ones of the cams to the front end guide 630, the first strapping clamp 640, the second strapping clamp 650, the strapping cutter 660, the anvil assembly 700, and the ultrasonic seal assembly 800 to move these components as the cam shaft rotates during the strapping process as described below.

[0033] FIG. 11A The illustrated front end guide 630 is configured to guide the front end of the strapping into the strapping chute 150 at the beginning of the strapping feed cycle. The front end guide 630 is movable via the drive assembly 610 between a guide position, in which the front end guide 630 is in the strapping path, FIG. 11A ), and a retracted position, in which the front end guide 630 is removed from the strapping path FIG. 11B to FIG. 11E The first strapping clamp 640 (in FIG. 11A to FIG. 11E(Best shown in the image) is configured to clamp a portion of the strapping tape against the anvil assembly 700 at certain moments during the strapping process. The first strapping tape clamp 640 includes a first strapping tape clamp body 640b that defines a strapping tape passage therethrough and includes clamping surfaces 640s. The first strapping tape clamp 640 is retracted in a position relative to the anvil assembly 700 via a drive assembly 610. FIG. 11A and FIG. 11E ) and clamping position ( FIG. 11B to FIG. 11D The second strapping clamp 650 moves between them. FIG. 11A to FIG. 11E (Best shown in the image) is also configured to clamp a portion of the strapping tape against the anvil assembly 700 at certain points during the strapping process. The second strapping tape clamp 650 includes a second strapping tape clamp body 650b, which includes clamping surfaces 650s. The second strapping tape clamp 650 is retracted in a position relative to the anvil assembly 700 via the drive assembly 610. FIG. 11A , FIG. 11B and FIG. 11E ) and clamping position ( FIG. 11C and FIG. 11D Move between ) strapping cutter 660 (in FIG. 11A to FIG. 11E (Best shown in the image) is configured to cut the strapping tape at certain points during the strapping process. The strapping tape cutter 660 includes a strapping tape cutter body 660b, which includes cutting surfaces 660s. The strapping tape cutter 660 can be moved to a retracted position via a drive assembly 610. FIG. 11A to FIG. 11C and FIG. 11E ) and cutting position ( FIG. 11D Move between ).

[0034] Anvil assembly 700 (in FIG. 4A to FIG. 5BThe anvil assembly 700 includes an anvil support 710 and an anvil 720. The anvil support 710 includes first and second curved arms 712 and 714 and a head 716. One end of each arm 712 and 714 of the anvil support 710 is attached to the head 716, and the other end of each arm 712 and 714 is pivotably attached to the seal assembly frame 605. The anvil 720 includes an anvil body 722 and a tooth support 724 extending at an angle from the anvil body 722. A plurality of elongate anvil teeth 734 having a triangular cross-section are formed on the underside of the tooth support 724. This example anvil 720 includes six teeth, but in other embodiments the anvil can include any other suitable number of teeth. Each anvil tooth 734 includes opposing planar angled side surfaces 734a and 734b and a generally planar contact surface 734c connecting the side surfaces 734a and 734b. The anvil teeth 734 together define an anvil contact plane that forms an angle Θ with respect to a horizontal plane when the anvil assembly 700 is in its sealing position (explained below). In this case, the horizontal plane corresponds to the transverse direction of the banding path (and of the banding tape in the banding path). In this example embodiment, the anvil contact plane is defined by the generally coplanar contact surfaces 734c of the anvil teeth 734. In this example embodiment, the angle Θ is between 0 and 60 degrees, and most preferably between 0 and 10 degrees. The side surfaces of adjacent anvil teeth are separated by an angle a (which in this example embodiment is 90 degrees, but in other embodiments can be any suitable angle) such that generally V-shaped grooves are formed between adjacent anvil teeth. The cross-section of these grooves (and thus the cross-section of the teeth forming the grooves) is generally constant along their entire length. The base of each anvil tooth 734 has a width D1, and the contact surface 734c of each anvil tooth 734 has a width D2 that is less than D1. Each anvil tooth 734 has a height D3. In this example embodiment, D1 is 0.5 mm, D2 is 2 mm, and D3 is 0.75 mm (but these dimensions can be different in other embodiments). The anvil teeth extend generally parallel to the longitudinal direction of the banding path and of the banding tape, and in this example embodiment have a length that is greater than or equal to the length (described below) of the sonotrode teeth.

[0035] Anvil 720 is attached to head 716 of anvil support 710 such that teeth 734 of anvil 720 face ultrasonic sealer 810 (described below). In this example embodiment, anvil 720 is removably attached to head 716 via fasteners to enable an operator to replace anvil 720 when teeth 734 are excessively worn to operate properly. Anvil support 710 (and thus the entire anvil assembly 700 including anvil 720 attached to anvil support 710) is pivotable about anvil assembly pivot axis A 700 FIG. 7A and FIG. 7B between a sealing position FIG. 4A , FIG. 7A , FIG. 8A and FIG. 11A to FIG. 11D and a retracted position FIG. 7B , FIG. 8B and FIG. 11E , in which anvil 720 is removed from the strapping tape path such that anvil assembly 700 does not interfere with removal of a load from strapping machine 10. Drive assembly 610 is configured to move anvil assembly 700 between the sealing position and the retracted position, as explained above.

[0036] Ultrasonic sealer assembly 800 (best shown in FIG. 6A to FIG. 6D ) is configured to apply ultrasonic vibrations to two overlapping portions of strapping tape to attach them to one another to form a strapping tape joint. Ultrasonic sealer assembly 800 includes ultrasonic sealer 810 and ultrasonic sealer support 850.

[0037] Ultrasonic sealer 810 includes ultrasonic horn 815 and ultrasonic transducer 840, and extends longitudinally along ultrasonic sealer axis A 810 Ultrasonic horn 815 includes ultrasonic horn body 820, ultrasonic horn neck 825 connected to (and integrally formed with) ultrasonic horn body 820, and ultrasonic horn head 830 connected to (and integrally formed with) ultrasonic horn neck 825. As FIG. 6D best shown, ultrasonic horn head 830 includes tooth support 832. A plurality of elongate ultrasonic horn teeth 834 having triangular cross-sections are formed on a top surface of tooth support 824. This example ultrasonic horn includes seven teeth, but in other embodiments, the ultrasonic horn can include any other suitable number of teeth. Each ultrasonic horn tooth 834 includes opposing planar angled side surfaces 834a and 834b and a generally planar contact surface 834c connecting side surfaces 834a and 834b. Ultrasonic horn teeth 834 together define a generally triangular cross-section transverse to ultrasonic sealer axis A 810 ​The ultrasonic horn contact plane is defined by the substantially coplanar contact surfaces 834c of the ultrasonic horn teeth 834 in this example embodiment. The side surfaces of adjacent ultrasonic horn teeth are separated by an angle a, such that substantially V-shaped grooves are formed between adjacent ultrasonic horn teeth. The cross-section of these grooves (and thus the cross-section of the teeth forming the grooves) is substantially constant along their entire length. The base of each ultrasonic horn tooth 834 has a width Dl, and the contact surface 834c of each ultrasonic horn tooth 834 has a width D2. Each ultrasonic horn tooth 734 has a height D3. In this example embodiment, the ultrasonic horn teeth extend substantially parallel to the strap path and the longitudinal direction of the strap (as well as the anvil teeth), and have a length that is less than or equal to the length of the anvil teeth. In other words, the ultrasonic horn teeth 834 are sized, shaped, oriented, and otherwise configured to be substantially the same as the anvil teeth 734 (although they can differ in other embodiments).

[0038] The ultrasonic transducer 840 is powered by a suitable power source, and is configured to convert high frequency electrical signals received from the power source into high frequency mechanical vibrations within the ultrasonic range, such as 20-100 kilohertz. Preferably, the ultrasonic transducer 840 is configured to produce vibrations within the 20 kilohertz to 40 kilohertz range. More preferably, the ultrasonic transducer 840 is configured to produce vibrations within the 34 kilohertz to 36 kilohertz range. Most preferably, the ultrasonic transducer is configured to produce vibrations within the 35 kilohertz range. The ultrasonic transducer 840 is connected to the ultrasonic horn body 820 of the ultrasonic horn 810, such that the mechanical vibrations produced by the ultrasonic transducer 840 are transmitted to the ultrasonic horn 810, and the ultrasonic horn 810 is sized, shaped, oriented, and otherwise configured such that these vibrations are transmitted to the ultrasonic horn head 830, including the ultrasonic horn teeth 834. Accordingly, the ultrasonic transducer 840 is configured to convert high frequency electrical signals into mechanical vibrations of the ultrasonic horn teeth 834 at ultrasonic frequencies.

[0039] The ultrasonic sealer support 850 is configured to support the ultrasonic sealer 810 and includes a lower support 860, an upper support 870, and first and second support biasing elements 880a and 880b. The ultrasonic transducer 840 is mounted to the lower support 860, such as via suitable fasteners or retainers. The upper support 870 is movably attached to the lower support 860, such as via suitable fasteners, such that the upper support 870 can be translated toward and away from the lower support 860 relative to the ultrasonic sealer 810. The support biasing elements 880a and 880b, which in this example embodiment are compression springs but in other embodiments can be any other suitable biasing elements, are configured to bias the upper support 870 away from the lower support 860. The ability of the upper and lower supports 860 and 870 to move relative to one another compensates for varying strap thicknesses. In other words, the lower and upper supports have a first configuration in which the lower and upper supports are separated by a first distance and a second configuration in which the lower and upper supports are separated by a second, smaller distance, and the biasing elements bias the supports to the first configuration.

[0040] The ultrasonic sealing assembly 800 is mounted to the sealing assembly frame 605, such as via suitable brackets and fasteners, such that the ultrasonic horn contact plane forms an angle Θ relative to a horizontal plane, and such that the ultrasonic sealer axis A 810 forms an angle β relative to a vertical axis, as FIG. 8A and FIG. 8B are best shown. In this case, the horizontal plane corresponds to the transverse direction of the strap path (and the strap in the strap path). Thus, the contact surface 834c of the ultrasonic horn tooth 834 is generally parallel to the contact surface 734c of the anvil tooth 734 (and the anvil and horn contact planes are generally parallel). The ultrasonic sealing assembly 800, and in particular the ultrasonic sealer 810, is movable relative to the sealing assembly frame 605 and the anvil assembly 700 along the ultrasonic sealer axis A FIG. 8A between a retracted position ( FIG. 8B ) and a sealing position ( ) via the drive assembly 610. The ultrasonic horn tooth 834 is movable relative to the anvil tooth 734 along the ultrasonic horn axis H 810 . The angle Θ formed by the ultrasonic horn tooth 834 does not change as the ultrasonic sealing assembly 800 is moved between its retracted and sealing positions. In this example embodiment, the angle β is between 0 and 60 degrees, and most preferably between 0 and 10 degrees. In certain embodiments, the angle Θ and the angle β are the same, such that the ultrasonic horn contact plane formed by the ultrasonic horn tooth 834 is generally perpendicular to the ultrasonic sealer axis A 810 .

[0041] When the ultrasonic sealer 810 is in the retracted position, it is spaced apart from the anvil 720 and removed from the strapping path, as shown in FIG. 9A In FIG. 9A to FIG. 9C , the strapping path extends into and out of the page. For clarity, the space between the anvil teeth and the strapping and the ultrasonic horn teeth and the strapping is exaggerated in FIG. 9A . The ultrasonic horn head 830 of the ultrasonic horn 810 is removed from the strapping path to enable other components of the strapping head 300 to manipulate the strapping S to move through the strapping path so that the upper strapping portion UP and the lower strapping portion LP are positioned between the ultrasonic horn head 830 and the anvil 720, respectively. As the ultrasonic sealer 810 moves from the retracted position to the sealing position, the ultrasonic sealer moves toward the anvil 720 and through the strapping path. FIG. 9B The ultrasonic sealing assembly is shown after the ultrasonic sealing assembly has begun to move from the retracted position to the sealing position. Here, the contact surfaces 834c of the ultrasonic horn teeth 834 contact the underside of the lower strapping portion LP and cause the upper strapping portion UP and the lower strapping portion LP to rotate so that they also form the angle Θ with respect to the horizontal axis. FIG. 9C The ultrasonic sealing assembly is shown after the ultrasonic sealing assembly has reached the sealing position. Here, the ultrasonic horn 810 causes the upper surface of the upper strapping portion UP to abut against the contact surfaces 734c of the anvil teeth 734. Because the anvil teeth 734 and the ultrasonic horn teeth 834 are in meshing arrangement with one another (i.e., the teeth of one component are positioned opposite the corresponding grooves between the teeth of the other component), the upper strapping portion UP and the lower strapping portion LP are bent and exhibit a generally wavy profile in the lateral direction (including alternating peaks and valleys), as shown in FIG. 9C .

[0042] The ultrasonic transducer 840 is activated for a specified period of time while the ultrasonic sealer 810 causes the upper strapping portion UP and the lower strapping portion LP to abut against the anvil 720. As described above, this causes the ultrasonic horn teeth 834 to vibrate at ultrasonic frequencies, causing the upper strapping portion UP and the lower strapping portion LP to locally melt together to form a strapping joint. FIG. 10 Such a strapping joint SJ is shown having a width D4 (corresponding to the length of the ultrasonic horn teeth) that extends in the longitudinal direction of the strapping (which is horizontal when viewed from the perspective shown in FIG. 10 ) that is perpendicular to the lateral direction of the strapping (which is vertical when viewed from the perspective shown in FIG. 10 ). In this example embodiment, the width D4 is 14 millimeters, but in other embodiments, the width can be any other suitable value. As FIG. 9CAs shown, the cross-section of the strap joint SJ has a wavy profile with several alternating peaks WP and valleys WV formed by the offset anvil teeth and the ultrasonic horn teeth.

[0043] In general, the strap feed assembly 400, the strap tension assembly 500, and the strap seal assembly 600 together are configured to form a tensioned strap loop around a load 50 by feeding the strap S through the strap chute 150 in the feed direction, holding the strap front end while retracting the strap S in the retraction direction to remove it from the strap chute 150 to contact the load 50, tensioning the strap S around the load 50 to a specified tension, attaching the two overlapping portions of the strap S to each other to form a strap joint, and cutting the strap S from the strap supply. In this example embodiment, the strapping machine 10 is a "tabletop" strapping machine in which the frame 100 supports the strap feed assembly 400, the strap tension assembly 500, and the strap seal assembly 600. In other embodiments, one or more of these assemblies are not supported by the frame 100. For example, in certain embodiments in which the strapping machine is configured to strap large loads such as pallet loads, lumber loads, or corrugated cardboard loads, these assemblies are different, independently replaceable modules supported by different parts of the strapping machine.

[0044] The controller includes a processing device (or devices) communicatively connected to a memory device (or devices). For example, the controller can be a programmable logic controller. The processing device can 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 digital signal processor cores, one or more application-specific integrated circuits, one or more field programmable gate array circuits, one or more integrated circuits, and / or state machines. The memory device can 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 machine 10, such as to perform the strapping process described below.

[0045] In this example embodiment, the controller is operatively connected to the strap feed actuator 430, the strap tension actuator 530, and the strap seal actuator 615, and is configured to control the output of these actuators. The controller is operatively connected to the ultrasonic transducer 840 and is configured to operate the ultrasonic transducer. The controller is communicatively connected to the front-end sensor and is configured to receive signals from and send signals to the front-end sensor.

[0046] The operation of the strapping machine 10 to perform the strapping process is now described. During the strapping process, the strapping machine is configured to perform: a strapping tape feeding process by feeding strapping tape from the strapping tape supply through the strapping tape chute around the load; a strapping tape retraction process by pulling the strapping tape out of the strapping tape chute and onto and around the load; a strapping tape tensioning process by tensioning the strapping tape around the load to a specified strapping tape tension; and a strapping tape sealing process by attaching two portions of the strapping tape to each other to form a strapping tape joint.

[0047] After the strapping process is initiated, the controller initiates the strapping tape feeding process and drives the strapping tape feeding actuator 430 to drive the drive roller 410 in the feeding rotational direction to feed the strapping tape S in the feeding direction from the strapping tape supply through the various guides, through the strapping tape passage of the first strapping tape clamp 640, through the front end guide 630 and into and around the strapping tape chute 150. The leading end LE of the strapping tape S eventually reaches the front end stop of the head 716 of the anvil support 710, at which point the front end sensor senses the leading end LE and sends an appropriate signal to the controller. In response, the controller stops driving the strapping tape feeding actuator 430 to stop the drive roller 410 and complete the strapping tape feeding process. FIG. 11A The configuration of the strapping tape S and the strapping tape sealing assembly 600 at this time is shown.

[0048] After the strapping tape feeding process is completed, the controller initiates the strapping tape retraction process and drives the strapping tape sealing actuator 615 to move the front end guide 630 to its retracted position and to move the first strapping tape clamp 640 to its clamping position such that the clamping surface 640s of the first strapping tape clamp 640 clamps a portion of the strapping tape S spaced apart from the leading end LE of the strapping tape S against the underside of the head 716 of the anvil support 710. The controller drives the strapping tape feeding actuator 430 to drive the drive roller 410 in the retraction rotational direction to pull the strapping tape S in the retraction direction and out of the strapping tape chute 150 and onto and around the load, at which point the controller stops driving the strapping tape feeding actuator 430 to stop the drive roller 410 and complete the strapping tape retraction process. FIG. 11B The configuration of the strapping tape S and the strapping tape sealing assembly 600 at this time is shown.

[0049] After the strapping tape retraction process is completed, the controller initiates the strapping tape tensioning process and drives the strapping tape tensioning actuator 530 to drive the drive roller 510 in the tensioning rotational direction to pull the strapping tape S in the retraction direction and to tension the strapping tape S around the load. As this occurs, the controller monitors the current drawn by the strapping tape tensioning actuator 530. Once the current draw reaches a predetermined amount related to a predetermined strapping tape tension, the controller stops driving the strapping tape tensioning actuator 530 to stop the drive roller 510 and complete the strapping tape tensioning process.FIG. 11B The configuration of the strapping band S and the strapping band sealing assembly 600 at this time is shown.

[0050] After the strapping band tensioning process is completed, the controller initiates the strapping band sealing process and drives the strapping band sealing actuator 615 to move the second strapping band clamp 650 to its clamping position, such that the clamping surface 650s of the second strapping band clamp 650 clamps a portion of the strapping band S against the underside of the head 716 of the anvil support 710, as shown. FIG. 11C Continued drive of the strapping band sealing actuator 615 moves the ultrasonic sealing assembly 800, in particular the horn head 830 of the ultrasonic sealer 810, to its sealing position, such that the horn teeth 834 press the upper strapping band portion UP and the lower strapping band portion LP against the anvil teeth 734, as described above. At the same time, the strapping band sealing actuator 615 moves the strapping band cutter to its cutting position to cut the strapping band S from the strapping band supply. FIG. 11D The configuration of the strapping band S and the strapping band sealing assembly 600 at this time is shown. The controller activates the ultrasonic transducer 840 to form the sealed joint SJ, as described above.

[0051] Continued drive of the strapping band sealing actuator 615 moves the ultrasonic sealing assembly 800, the anvil assembly 700, the first strapping band clamp 640 and the second strapping band clamp 650, and the strapping band cutter 660 to their respective retracted positions, as shown. FIG. 11E This releases the strapping band S from the strapping head 300, thereby enabling the now strapped load 50 to be removed from the strapping device 10.

[0052] While the ultrasonic sealing assembly and the ultrasonic sealer are described above as part of a strapping machine, the ultrasonic sealing assembly and in particular the ultrasonic sealer can be used in any other suitable strapping device, such as a handheld strapping tool or a modular strapping head.

Claims

1. A banding apparatus comprising: an anvil comprising a plurality of anvil teeth, the plurality of anvil teeth defining an anvil contact plane that is angularly offset from a horizontal axis by a first non-zero angle; and an ultrasonic sealer comprising: an ultrasonic horn comprising a plurality of ultrasonic horn teeth, the plurality of ultrasonic horn teeth defining an ultrasonic horn contact plane that is angularly offset from the horizontal axis by the first non-zero angle; and an ultrasonic transducer configured to produce mechanical vibrations at an ultrasonic frequency and transmit the mechanical vibrations to the ultrasonic horn, wherein the ultrasonic sealer extends longitudinally along an ultrasonic sealer axis that is angularly offset from a vertical axis by a second non-zero angle, and wherein the ultrasonic sealer is movable along the ultrasonic sealer axis between a retracted position in which the ultrasonic horn teeth are spaced apart from the anvil teeth and a sealing position in which the ultrasonic horn teeth are in an engaged arrangement with the anvil teeth. each of the ultrasonic horn teeth comprises a contact surface, wherein the contact surfaces of the ultrasonic horn teeth define the ultrasonic horn contact plane.

2. The bundling apparatus of claim 1, wherein, the contact surfaces are planar.

3. The bundling apparatus of claim 2, wherein, the ultrasonic horn contact plane is generally perpendicular to the ultrasonic sealer axis.

4. The bundling apparatus of claim 1, wherein, the first non-zero angle and the second non-zero angle are generally the same.

5. The bundling device of claim 1, wherein, the first non-zero angle and the second non-zero angle are each approximately 20 degrees.

6. The bundling apparatus of claim 5, wherein, the anvil teeth and the ultrasonic horn teeth extend generally parallel to a banding path defined through the banding apparatus.

7. The bundling device of claim 1, wherein, each of the ultrasonic horn teeth comprises a contact surface, wherein the contact surfaces of the ultrasonic horn teeth define the ultrasonic horn contact plane.

8. The bundling apparatus of claim 7, wherein, the contact surfaces are planar.

9. The bundling apparatus of claim 8, wherein, 10. The banding apparatus of claim 1, further comprising an ultrasonic sealer support comprising: a first support to which the ultrasonic transducer is mounted; a second support; and a biasing element, wherein the first support and the second support have a first configuration in which the first support and the second support are separated by a first distance and a second configuration in which the first support and the second support are separated by a second distance, wherein the first distance is greater than the second distance, wherein the biasing element is configured to bias the first support and the second support to the first configuration. the anvil teeth and the ultrasonic horn teeth extend generally parallel to a banding path defined through the banding apparatus. the first support is movable relative to the second support along the ultrasonic sealer axis.

11. The bundling apparatus of claim 10, wherein, the ultrasonic transducer is configured to produce the mechanical vibrations at an ultrasonic frequency of approximately 35 kilohertz.

12. The bundling apparatus of claim 10, wherein, the first non-zero angle and the second non-zero angle are each approximately 20 degrees.

13. The bundling device of claim 1, wherein, the anvil teeth and the ultrasonic horn teeth extend generally parallel to a banding path defined through the banding apparatus.

14. The bundling device of claim 13, wherein, 16. A banding apparatus comprising:

15. The bundling device of claim 14, wherein, ​ ​ an anvil comprising a plurality of anvil teeth extending generally parallel to a banding path defined through the banding device; and an ultrasonic sealer comprising: an ultrasonic horn comprising a plurality of ultrasonic horn teeth extending generally parallel to the banding path, wherein each ultrasonic horn tooth comprises opposing angled side surfaces defining a groove between adjacent ultrasonic horn teeth, wherein a cross-section of each groove is generally the same along a length of the groove; and an ultrasonic transducer configured to produce mechanical vibrations at an ultrasonic frequency and transmit ultrasonic mechanical vibrations to the ultrasonic horn, wherein the ultrasonic sealer is movable along the ultrasonic sealer axis between a retracted position in which the ultrasonic horn teeth are spaced apart from the anvil teeth and a sealing position in which the ultrasonic horn teeth are in an engaged arrangement with the anvil teeth.

17. The bundling device of claim 16, wherein, The angled side surfaces of each pair of adjacent ultrasonic horn teeth diverge at a first angle, wherein the first angle is between 60 degrees and 120 degrees.

18. The bundling device of claim 17, wherein, The first angle is about 90 degrees.

19. The bundling device of claim 16, wherein, Each ultrasonic horn tooth comprises a contact surface extending between the two opposing angled side surfaces of the ultrasonic horn tooth.

20. The bundling device of claim 19, wherein, The contact surface of each ultrasonic horn tooth is planar.

21. The bundling device of claim 20, wherein, The angled side surfaces of each ultrasonic horn tooth are planar such that the groove has a generally V-shaped cross-section.

22. The bundling device of claim 21, wherein, The angled side surfaces of each pair of adjacent ultrasonic horn teeth diverge at a first angle, wherein the first angle is about 90 degrees.

23. The bundling device of claim 16, wherein, Each anvil tooth comprises opposing angled side surfaces defining a groove between adjacent anvil teeth, wherein each groove of the anvil is sized and shaped to receive one of the ultrasonic horn teeth when the ultrasonic horn teeth are in the engaged arrangement with the anvil teeth.

24. The bundling device of claim 23, wherein, The angled side surfaces of each pair of adjacent ultrasonic horn teeth diverge at a first angle, wherein the angled side surfaces of each pair of adjacent anvil teeth diverge at the first angle, wherein the first angle is between 60 degrees and 120 degrees.

25. The bundling device of claim 24, wherein, The first angle is about 90 degrees.

26. The bundling device of claim 23, wherein, Each ultrasonic horn tooth comprises a contact surface extending between the two opposing angled side surfaces of the ultrasonic horn tooth, wherein each anvil tooth comprises a contact surface extending between the two opposing angled side surfaces of the anvil tooth.

27. The bundling device of claim 26, wherein, The contact surface of each ultrasonic horn tooth and each anvil tooth is planar.

28. The bundling device of claim 27, wherein, The angled side surfaces of each ultrasonic horn tooth and each anvil tooth are planar such that the grooves of the anvil and the ultrasonic horn have a generally V-shaped cross-section.

29. The bundling device of claim 28, wherein, The angled side surfaces of each pair of adjacent ultrasonic horn teeth diverge at a first angle, wherein the angled side surfaces of each pair of adjacent anvil teeth diverge at the first angle, wherein the first angle is about 90 degrees.

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