Strapping tool

Abstract

A strapping tool is disclosed herein. In one or more embodiments, the strapping tool includes a motive power source; and a tensioning assembly operatively coupled to the motive power source, the tensioning assembly including a plurality of strapping foot members, the plurality of strapping foot members arranged side-by-side transversely across a strapping pass line, at least one of the plurality of strapping foot members being in a form of a tensioning foot member configured to apply tension to a piece of strapping while being driven in an oscillatory manner by the motive power source.

Description

Attorney Docket No.: 2012C05-SK-PCT5 PCT Patent Application Inventors: Joshua R. Sikora et al. SpecificationTITLE OF THE INVENTIONSTRAPPING TOOLCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This patent application claims priority to, and incorporates by reference in its entirety, U.S. Provisional Patent Application No. 63 / 682,753, entitled “Strapping Tool”, filed on August 13, 2024.STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

[0002] Not Applicable.NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT

[0003] Not Applicable.INCORPORATION BY REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISK

[0004] Not Applicable.BACKGROUND OF THE INVENTION1. Field of the Invention

[0005] The invention generally relates to a strapping tool. More particularly, the invention relates to a strapping tool that is configured to apply tension to a piece of strapping.2. Background

[0006] Various tools are known in the packaging art for performing numerous functions related to the manipulation of strapping, which is commonly used as a closing mechanism for packages, and as a convenient means for easily attaching two objects to one another (e.g., attaching a box to a pallet). Some tools are used to cut the seals on steel or poly strapping systems so that the strap is held tight in tension. Strapping often is used to consolidate several items for shipping purposes or holding positions of various components. Some of these conventional tools utilize a tensioning wheel to apply tension to a strap, which can require multi-Attorney Docket No.: 2012C05-SK-PCT5 PCT Patent Application Inventors: Joshua R. Sikora et al. Specification stage speed reduction and / or a complicated and space-consuming drivetrain. Also, these conventional tools are often overly heavy and cumbersome to use.

[0007] Therefore, what is needed is a strapping tool for tensioning a strap that addresses one or more deficiencies of conventional tools. In addition, there is a need for a strapping tool that utilizes fewer and simpler components than conventional tools so as to reduce the overall complexity and weight of the tool, and thereby provide a more cost effective alternative for performing strapping operations.BRIEF SUMMARY OF EMBODIMENTS OF THE INVENTION

[0008] Accordingly, the present invention is directed to a strapping tool that substantially obviates one or more problems resulting from the limitations and deficiencies of the related art.

[0009] In accordance with one or more embodiments of the present invention, there is provided a strapping tool. The strapping tool includes a motive power source; and a tensioning assembly operatively coupled to the motive power source, the tensioning assembly including a plurality of strapping foot members, the plurality of strapping foot members arranged side-by- side transversely across a strapping pass line, at least one of the plurality of strapping foot members being in a form of a tensioning foot member configured to apply tension to a piece of strapping while being driven in an oscillatory manner by the motive power source.

[0010] In a further embodiment of the present invention, the strapping tool further comprises at least one cam member, the at least one cam member operatively coupling the tensioning foot member to the motive power source.

[0011] In yet a further embodiment, the at least one cam member is in a form of an eccentric cam member.

[0012] In still a further embodiment, the at least one cam member is disposed on a drive shaft, the drive shaft operatively coupling the tensioning foot member to the motive power source by means of the at least one cam member.

[0013] In yet a further embodiment, at least another one of the plurality of strapping foot members is in a form of a holding foot member, the holding foot member being supported from the drive shaft that is operatively coupled to the tensioning foot member; and during the tensioning of the piece of strapping, the tensioning foot member continually grabs and appliesAttorney Docket No.: 2012C05-SK-PCT5 PCT Patent Application Inventors: Joshua R. Sikora et al. Specification tension to the piece of strapping, and the holding foot member prevents the piece of strapping from slipping back.

[0014] In still a further embodiment, strapping tool further comprises a tensioning leg operatively coupling the tensioning foot member to the at least one cam member, and a holding leg coupling the holding foot member to the drive shaft.

[0015] In yet a further embodiment, the strapping tool further comprising one or more oneway rotation restriction devices disposed on the drive shaft, the one or more one-way rotation restriction devices allowing the drive shaft to be rotated in a first rotational direction where the tensioning foot member applies tension to the piece of strapping, while preventing rotation of the drive shaft in a second rotational direction, which is opposite to the first rotational direction, so as to enable the tension to be maintained on the piece of strapping.

[0016] In still a further embodiment, the tensioning foot member is in a form of a first tensioning foot member, and at least another one of the plurality of strapping foot members comprises a second tensioning foot member configured to apply tension to the piece of strapping while being driven in an oscillatory manner by the motive power source.

[0017] In yet a further embodiment, the strapping tool further comprises at least a first cam member and a second cam member, the first cam member operatively coupling the first tensioning foot member to the motive power source, and the second cam member operatively coupling the second tensioning foot member to the motive power source.

[0018] In still a further embodiment, the first cam member and the second cam member are disposed on a drive shaft, the drive shaft operatively coupling the first tensioning foot member to the motive power source by means of the first cam member, and the drive shaft operatively coupling the second tensioning foot member to the motive power source by means of the second cam member.

[0019] In yet a further embodiment, the first cam member is in a form of a first eccentric cam member and the second cam member is in a form of a second eccentric cam member, the first eccentric cam member having a first lobe portion and the second eccentric cam member having a second lobe portion, and the first lobe portion of the first eccentric cam member being rotationally offset from the second lobe portion of the second eccentric cam member by approximately 180 degrees on the drive shaft.Attorney Docket No.: 2012C05-SK-PCT5 PCT Patent Application Inventors: Joshua R. Sikora et al. Specification

[0020] In still a further embodiment, the strapping tool further comprises a first tensioning leg operatively coupling the first tensioning foot member to the first cam member, and a second tensioning leg operatively coupling the second tensioning foot member to the second cam member.

[0021] In yet a further embodiment, the strapping tool further comprises one or more bearings disposed on the drive shaft.

[0022] In still a further embodiment, during the tensioning of the piece of strapping, the first tensioning foot member is displaced in a first direction for applying tension to the piece of strapping, while the second tensioning foot member is displaced in a second direction that is opposite to the first direction so as to grip the piece of strapping that is being tensioned; and during the tensioning of the piece of strapping, the second tensioning foot member is displaced in the first direction for applying tension to the piece of strapping, while the first tensioning foot member is displaced in the second direction that is opposite to the first direction so as to grip the piece of strapping that is being tensioned.

[0023] In yet a further embodiment, the plurality of strapping foot members further comprises one or more additional tensioning foot members configured to apply tension to the piece of strapping while being driven in an oscillatory manner by the motive power source such that the strapping tool comprises three or more tensioning foot members.

[0024] In still a further embodiment, the drive shaft has a linear configuration such that the first tensioning foot member and the second tensioning foot member have an aligned common driving axis.

[0025] In yet a further embodiment, the motive power source comprises one of: (i) an electric motor, (ii) a pneumatic motor, and (iii) a liquid fuel-based motor.

[0026] In still a further embodiment, the motive power source comprises a battery-powered motor.

[0027] In accordance with one or more embodiments of the present invention, there is provided a strapping tool. The strapping tool includes a motive power source; a drive shaft operatively coupled to the motive power source; and a tensioning assembly operatively coupled to the drive shaft, the tensioning assembly including a plurality of strapping foot members, each of the plurality of strapping foot members being arranged on the drive shaft, at least one of the plurality of strapping foot members being in a form of a tensioning foot member configured toAttorney Docket No.: 2012C05-SK-PCT5 PCT Patent Application Inventors: Joshua R. Sikora et al. Specification apply tension to a piece of strapping while being driven in an oscillatory manner by the drive shaft.

[0028] In a further embodiment of the present invention, the drive shaft has a linear configuration such that the plurality of strapping foot members has an aligned common rotational axis.

[0029] In yet a further embodiment, at least another one of the plurality of strapping foot members is in a form of a holding foot member, the holding foot member being supported from the drive shaft that is operatively coupled to the tensioning foot member; and during the tensioning of the piece of strapping, the tensioning foot member continually grabs and applies tension to the piece of strapping, and the holding foot member prevents the piece of strapping from slipping back.

[0030] In still a further embodiment, the strapping tool further comprises a tensioning leg operatively coupling the tensioning foot member to the drive shaft, and a holding leg coupling the holding foot member to the drive shaft.

[0031] In yet a further embodiment, the tensioning foot member is in a form of a first tensioning foot member, and at least another one of the plurality of strapping foot members comprises a second tensioning foot member configured to apply tension to the piece of strapping while being driven in an oscillatory manner by the motive power source.

[0032] In still a further embodiment, the strapping tool further comprises a first tensioning leg operatively coupling the first tensioning foot member to the drive shaft, and a second tensioning leg operatively coupling the second tensioning foot member to the drive shaft.

[0033] It is to be understood that the foregoing general description and the following detailed description of the present invention are merely exemplary and explanatory in nature. As such, the foregoing general description and the following detailed description of the invention should not be construed to limit the scope of the appended claims in any sense.BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0034] The invention will now be described, by way of example, with reference to the accompanying drawings, in which:

[0035] FIG. 1 is a perspective view of a strapping tool, according to a first illustrative embodiment of the invention;Attorney Docket No.: 2012C05-SK-PCT5 PCT Patent Application Inventors: Joshua R. Sikora et al. Specification

[0036] FIG. 2 is a front elevational view of the strapping tool of FIG. 1;

[0037] FIG. 3 is a rear elevational view of the strapping tool of FIG. 1;

[0038] FIG. 4 is a first side elevational view of the strapping tool of FIG. 1;

[0039] FIG. 5 is a second side elevational view of the strapping tool of FIG. 1;

[0040] FIG. 6 is a bottom plan view of the strapping tool of FIG. 1;

[0041] FIG. 7 is a top plan view of the strapping tool of FIG. 1;

[0042] FIG. 8 is a bottom perspective view of the strapping tool of FIG. 1, wherein the strapping tool is shown tensioning a piece of strapping that has been inserted in the strapping tool;

[0043] FIG. 9 is an exploded perspective view of the strapping tool of FIG. 1;

[0044] FIG. 10 is another perspective view of the strapping tool of FIG. 1, wherein a cover plate of the strapping tool has been removed in order to depict a one-way bearing at an outer end of a drive shaft;

[0045] FIG. 11 is an enlarged perspective view of a tensioning assembly of the strapping tool of FIG. 1;

[0046] FIG. 12 is an enlarged perspective view of a tensioning leg and foot member of the strapping tool of FIG. I ;

[0047] FIG. 13 is an enlarged perspective view of a holding leg and foot member of the strapping tool of FIG. 1;

[0048] FIG. 14 is an underside perspective view of a camshaft of the strapping tool of FIG. 1;

[0049] FIG. 15 is a top side perspective view of a camshaft of the strapping tool of FIG. 1;

[0050] FIG. 16 is a sectional side view cut through the strapping tool of FIG. 1, wherein the sectional view is cut along the cutting-plane line A-A in FIG. 2 through the holding leg and foot member of the strapping tool;

[0051] FIG. 17 is an enlarged partial side view of the leg and foot members of the strapping tool depicted in FIG. 16, wherein the leg and foot members are shown together with a piece of strapping (“Section A-A Detail”);

[0052] FIG. 18 is a sectional side view cut through the strapping tool of FIG. 1, wherein the sectional view is cut along the cutting -plane line B-B in FIG. 2 through the leg spacer on the camshaft of the strapping tool;Attorney Docket No.: 2012C05-SK-PCT5 PCT Patent Application Inventors: Joshua R. Sikora et al. Specification

[0053] FIG. 19A is an enlarged partial side view of the tensioning leg and foot member of the strapping tool of FIG. 1, wherein the tensioning leg and foot member is shown in a first position together with a piece of strapping;

[0054] FIG. 19B is another enlarged partial side view of the tensioning leg and foot member of the strapping tool of FIG. 1, wherein the tensioning leg and foot member is shown in a second position together with the piece of strapping;

[0055] FIG. 19C is yet another enlarged partial side view of the tensioning leg and foot member of the strapping tool of FIG. 1, wherein the tensioning leg and foot member is shown in a third position together with the piece of strapping;

[0056] FIG. 20 is a perspective view of a strapping tool, according to a second illustrative embodiment of the invention, wherein a cover plate of the strapping tool has been removed in order to depict a bearing at an outer end of a drive shaft;

[0057] FIG. 21 is an enlarged perspective view of a tensioning assembly of the strapping tool of FIG. 20;

[0058] FIG. 22 is a first side perspective view of a camshaft of the strapping tool of FIG. 20;

[0059] FIG. 23 is a second side perspective view of a camshaft of the strapping tool of FIG. 20;

[0060] FIG. 24 is a sectional side view cut through the strapping tool of FIG. 20, wherein the sectional view is cut along the cutting-plane line C-C in FIG. 20 through the interior tensioning leg and foot member of the strapping tool;

[0061] FIG. 25A is an enlarged partial side view of the tensioning leg and foot members of the strapping tool of FIG. 20, wherein the tensioning leg and foot members are shown in a first position together with a piece of strapping;

[0062] FIG. 25B is another enlarged partial side view of the tensioning leg and foot members of the strapping tool of FIG. 20, wherein the tensioning leg and foot members are shown in a second position together with the piece of strapping; and

[0063] FIG. 25C is yet another enlarged partial side view of the tensioning leg and foot members of the strapping tool of FIG. 20, wherein the tensioning leg and foot members are shown in a third position together with the piece of strapping.

[0064] Throughout the figures, the same parts are always denoted using the same reference characters so that, as a general rule, they will only be described once.Attorney Docket No.: 2012C05-SK-PCT5 PCT Patent Application Inventors: Joshua R. Sikora et al. SpecificationDET AILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

[0065] A first illustrative embodiment of a strapping tool is illustrated in FIGS. 1-19C. An exploded perspective view of the components that form the strapping tool is depicted in FIG. 9. In the illustrative embodiment, the strapping tool is in a form of a strap tensioner with an external power source (e.g., a battery-powered drill). In particular', the strapping tool of the first illustrative embodiment is configured to apply tension to a piece of strapping being around a package or bundle of items. In particular, the first illustrated embodiment depicts an 18-volt battery-powered strap tensioner. While the external power source of the first embodiment is in a form of a battery-powered drill, those of ordinary skill in the art will appreciate that other suitable external power sources may be substituted for the drill. For example, an alternative external power source in the form of a 120- volt AC drill or pneumatic drill could be used. Also, a suitable circular saw or grinder could be used to power the strap tensioner. In general, the external power required to drive the strapping tool could be supplied by a variety of different sources including, but not limited to, battery, air, alternating-current (AC) electricity, hydraulic or fluid power.

[0066] Referring initially to FIGS. 1 and 9, the strapping tool of the first illustrative embodiment is seen generally at 100. Initially, with reference to FIGS. 1 and 9, it can be seen that the strapping tool 100 generally comprises a motive power source (e.g., electric motor 164); and a tensioning assembly operatively coupled to the motive power source 164, the tensioning assembly including a plurality of strapping foot members 142, 146, the plurality of strapping foot members 142, 146 arranged side-by-side transversely across a strapping pass line (see e.g., FIGS. 11, 16, and 17), at least one of the plurality of strapping foot members being in a form of a tensioning foot member 142 configured to apply tension to a piece of strapping 190 while being driven in an oscillatory manner by the motive power source 164. Referring to FIG. 8, a user utilizes the strapping tool 100 for tensioning the strap 190 (e.g., in the direction indicated by arrow 194). Then, after the strap is pulled tight using the strapping tool 100, another tool may be utilized to secure a sealing member 196 to the strap 190. As shown in FIG. 8, the free end 192 of the strap 190 may be folded over so as not to be pulled through the sealing member 196 when tension is being applied to the strap 190.Attorney Docket No.: 2012C05-SK-PCT5 PCT Patent Application Inventors: Joshua R. Sikora et al. Specification

[0067] In the illustrative embodiment, with reference to FIGS. 11-15, it can be seen that the tensioning assembly of the strapping tool 100 generally includes a dual leg camshaft 130 with an eccentric cam member 134, a tensioning leg 140 with tensioning foot member 142 disposed at the bottom end thereof, and a holding leg 144 with a holding foot member 146 disposed at the bottom end thereof. The eccentric cam member 134 operatively couples the tensioning leg and foot members 140, 142 to the motive power source 134 by means of the drive shaft portion of the camshaft 130. As will be described in detail hereinafter, the tensioning foot member 142 of the tensioning assembly is configured to apply tension to a piece of strapping 190 (see FIG. 8) while being driven in an oscillatory manner by the motive power source (e.g., motor 164). Like the tensioning leg 140, the holding leg 144 with holding foot member 146 is also supported from the dual leg camshaft 130 (see FIG. 11). More specifically, the holding leg 144 is supported on concentric shaft portion 132 of camshaft 130 so that the holding leg 144 does not oscillate when the camshaft 130 is rotated. During the tensioning of the piece of strapping 190, the tensioning foot member 142 continually grabs and applies tension to the piece of strapping 190, while the holding foot member 146 prevents the piece of strapping 190 from slipping back. As shown in FIGS. 14 and 15, in the illustrative embodiment, the camshaft 130 of the strapping tool 100 further comprises outer concentric shaft portion 131 extending to cover plate 1 15, spacer wall 135, bearing zone portion 136, and a keyed end 139 that fits into planetary gear plate 151. When the piece of strapping 190 is being tensioned (as shown in FIG. 8), the holding leg 144 with associated foot member 146 holds the strap 190 in place so that the strap is unable to slide in a direction opposite to the tensioning direction. In the illustrative embodiment, the holding leg 144 is pivotally coupled to the concentric shaft portion 132 of camshaft 130 by means of roller bearing 145. During the tensioning of the strap 190, the holding leg 144 is not driven by the motor 164, but rather is manually pivotable about the camshaft 130. In the illustrative embodiment, the holding foot 146, which is disposed at the bottom of the holding leg 144, may be formed from a suitable metallic material, such as carbide, so that the foot 146 is able to frictionally engage, and hold the strap 190 in place as it is being tensioned. The tensioning foot member 142, which is driven by the motor 164 during the tensioning of the strap 190, also may be formed from a suitable metallic material, such as carbide.Attorney Docket No.: 2012C05-SK-PCT5 PCT Patent Application Inventors: Joshua R. Sikora et al. Specification

[0068] In the illustrative embodiment, with reference to FIGS. 9-11, it can be seen that the cam drive shaft of the camshaft 130 has a linear configuration such that the tensioning foot member 142 and the holding foot member 146 have an aligned central axis.

[0069] Now, with reference primarily to FIGS. 9 and 19A-19C, the functionality of the strapping tool 100 will be described. Initially, the camshaft 130 is rotated by the motor 164 by means of the gearbox reducer assembly 151-163. When the camshaft 130 is driven in a tensioning direction by the motor 164, the eccentric cam member 134 disposed on the drive shaft of the camshaft 130 is rotated. As the eccentric cam member 134 rotates through its cycle, the tensioning leg 140 oscillates forwards and backwards so as to apply tension to the strap 190. In particular, referring to FIG. 19A, it can be seen that the tensioning foot member 142 is shown at a first position (e.g., a rearmost position) in the beginning of the tensioning cycle with reference point 172 diagrammatically denoting the rotational position of the eccentric cam member 134. Then, turning to FIG. 19B, as tension is being applied to the strap 190 during the tensioning cycle by the tensioning foot 142 on the end of the tensioning leg member 140, the eccentric cam member 134 has rotated approximately 180 degrees as indicated by the reference point 172. Finally, referring to FIG. 19C, after tension has been applied to the strap 190 during the tensioning cycle by the tensioning foot 142, the tensioning foot 142 is shown back in its original position (e.g., its rearmost position) with the reference point 172 on the eccentric cam member 134 being in approximately the same location as in FIG. 19A. In the illustrative embodiment, as shown in FIGS. 11 and 19A-19C, tensioning leg 140 with tensioning foot 142 is held down against the strap 190 by a spring 174 (i.e., a downward spring force is applied to the leg 140 to maintain the foot 142 in contact with the strap 190 during the resetting thereof). Similarly, referring again to FIGS. 11 and 19A-19C, in the illustrative embodiment, the holding leg 144 with holding foot 146 is held down against the strap 190 by a spring 150 (i.e., a downward spring force is applied to the leg 144 to maintain the foot 146 in contact with the strap 190). In the illustrative embodiment, during the tensioning operation of the strapping tool 100, the tensioning foot 142 advances the tensioned strap 190 a predetermined amount (e.g., one-eighth of an inch) during each cycle. During the tensioning operation, the tensioning foot 142 continually grabs and pulls a predetermined amount of strapping 190 through the seal member and the holding foot 146 prevents the strapping 190 from slipping back. During each tensioning cycle, the foot 142 resets and grabs another predetermined amount of strap 190 (e.g., one-eighth of an inch) as it isAttorney Docket No.: 2012C05-SK-PCT5 PCT Patent Application Inventors: Joshua R. Sikora et al. Specification forced back and forth in the tool 100. After sufficient tension is applied to the strap 190, the tensioning operation is concluded. In the tensioning cycle, on the return stroke of the powered tensioning leg 140, the static holding leg 144 stops the strap 190 from releasing tension. If the static leg 144 were not there, the strap 190 would move back, and then forward as long as there was power. The static leg 144 is like a one-way stop, the strap 190 can move in tension and then hold for powered leg 140 to reverse. In the first illustrative embodiment, the outer holding foot 146 essentially operates as a friction brake to keep the strap 190 from slipping.

[0070] In the illustrative embodiment, referring again to the exploded view of FIG. 9, it can be seen that the tensioning assembly may further include housing portions 102, 110 and a removable side cover 115 so as to cover portions of the tensioning assembly components.

[0071] Referring again to FIGS. 9, 11, 14, and 15, in the illustrative embodiment, the motor 164 supplies power to the tensioning assembly by means of the camshaft 130, which includes a central drive shaft portion with eccentric cam member 134. In the illustrative embodiment, with reference to the tensioning assembly depicted in FIG. 11, the strapping tool 100 further comprises one or more one-way rotation restriction devices (e.g., one-way bearings 114) disposed on the central drive shaft portion of the camshaft 130 so as to allow the cam drive shaft to be rotated in a first rotational direction where the tensioning foot member 142 applies tension to the piece of strapping 190, while preventing rotation of the cam drive shaft in a second rotational direction (i.e. , the drive shaft is prevented from twisting backwards), which is opposite to the first rotational direction, so as to enable the tension to be maintained on the piece of strapping 190. In the first illustrative embodiment, one-way bearings 114 further prevent the strapping 190 from slipping back at the end of the tensioning cycle by keeping the cam 134 from reversing under the significant strain of a tensioned strap 190.

[0072] While one-way bearings 114, 116 are utilized in the illustrative embodiment for regulating the tensioning operations of the strapping tool 100, other means for controlling the directional rotation of the cam drive shaft may be used. For example, in one or more alternative embodiments, a clutch subassembly may be operatively coupled to the cam drive shaft, rather than the one or more one-way bearings 114. As another example, in one or more other alternative embodiments, a one-way ratchet subassembly or one-way indexing subassembly may be operatively coupled to the cam drive shaft, rather than the one or more one-way bearings 114.Attorney Docket No.: 2012C05-SK-PCT5 PCT Patent Application Inventors: Joshua R. Sikora et al. Specification

[0073] In the illustrative embodiment, the motive power source 164 is in the form of an electric motor powered by the battery pack 106. However, in other embodiments, other types of motive power sources may be used, such as pneumatic motors, liquid fuel-based motors (e.g., gasoline-powered motors), motors driven by mechanical spring assemblies, and manually- actuated power sources (e.g., a power source driven by the turning of a crank by user, etc.).

[0074] In the first illustrative embodiment, the strapping tool 100 uses two side-by-side legs 140, 144 with respective feet 142, 146, one leg 144 to hold (i.e., the static / non-moving leg 144), and another leg 140 (i.e., the active / moving leg 140) to pull tension. The advantage of putting the legs 140, 144 with feet 142, 146 beside each other are several. Using the same shaft cuts the part quantity and required space in half. This gives the advantage of a simpler and lighter tool. In the illustrative embodiment, each foot 142, 146 has a knurled bottom surface for better gripping of the strapping (see e.g., FIGS. 12 and 13).

[0075] A second illustrative embodiment of a strapping tool is illustrated in FIGS. 20-25C. Referring to these figures, it can be seen that, in many respects, the second illustrative embodiment of the strapping tool is similar to that of the first illustrative embodiment.Moreover, many elements are common to both such embodiments. For the sake of brevity, the elements that the second embodiment of the strapping tool has in common with the first embodiment will not be discussed because these components have already been described above.

[0076] Unlike the first illustrative embodiment described above, the second illustrative embodiment of a strapping tool utilizes a plurality of driven tensioning foot members (e.g., two or more driven tensioning foot members in contact with the strapping), rather than just a single driven tensioning foot member.

[0077] Referring initially to FIGS. 20 and 21, the strapping tool of the second illustrative embodiment is seen generally at 200. Initially, with reference to FIGS. 20 and 21, it can be seen that the strapping tool 200 generally comprises a motive power source (e.g., electric motor); and a tensioning assembly operatively coupled to the motive power source, the tensioning assembly including a plurality of strapping foot members 242, 246, the plurality of strapping foot members 242, 246 arranged side-by-side transversely across a strapping pass line (see e.g., FIGS. 25A- 25C), at least two of the plurality of strapping foot members comprising first and second tensioning foot members 242, 246 configured to apply tension to a piece of strapping 190 while being driven in an oscillatory manner by the motive power source. Similar to the first illustrativeAttorney Docket No.: 2012C05-SK-PCT5 PCT Patent Application Inventors: Joshua R. Sikora et al. Specification embodiment, a user utilizes the strapping tool 200 for tensioning the strap 190. Then, after the strap is pulled tight using the strapping tool 200, another tool may be utilized to secure a sealing member to the strap 190.

[0078] In the illustrative embodiment, with reference to FIGS. 21-23, it can be seen that the tensioning assembly of the strapping tool 200 generally includes a dual leg camshaft 230 with a first eccentric cam member 234 and a second eccentric cam member 232, a first tensioning leg 240 with tensioning foot member 242 disposed at the bottom end thereof, and a second tensioning leg 244 with tensioning foot member 246 disposed at the bottom end thereof. The first eccentric cam member 234 operatively couples the first tensioning leg and foot members 240, 242 to the motive power source by means of the drive shaft portion of the camshaft 230, while the second eccentric cam member 232 operatively couples the second tensioning leg and foot members 244, 246 to the motive power source by means of the drive shaft portion of the camshaft 230. In the illustrative embodiment, the first eccentric cam member 234 has a first lobe portion and the second eccentric cam member 232 has a second lobe portion, and the first lobe portion of the first eccentric cam member 234 is rotationally offset from the second lobe portion of the second eccentric cam member 232 by approximately 180 degrees on the cam drive shaft. As will be described in detail hereinafter, the tensioning foot members 242, 246 of the tensioning assembly arc configured to apply tension to a piece of strapping 190 while being driven in an oscillatory manner by the motive power source (e.g., electric motor). During the tensioning of the piece of strapping 190, the tensioning foot members 242, 246 continually grab and apply tension to the piece of strapping 190. As shown in FIGS. 22 and 23, in the illustrative embodiment, the camshaft 230 of the strapping tool 200 further comprises outer concentric shaft portion 231 extending to cover plate 215, spacer wall 235, bearing zone portion 236, and a keyed end 239 that fits into a planetary gear plate. When the piece of strapping 190 is being tensioned, the first tensioning foot member 242 is displaced in a first direction for applying tension to the piece of strapping 190, while the second tensioning foot member 246 is displaced in a second direction that is opposite to the first direction so as to grip the piece of strapping 190 that is being tensioned. Then, when the piece of strapping 190 is being tensioned, the second tensioning foot member 246 is displaced in the first direction for applying tension to the piece of strapping 190, while the first tensioning foot 242 member is displaced in the second direction that is opposite to the first direction so as to grip the piece of strapping 190 that is being tensioned. In theAttorney Docket No.: 2012C05-SK-PCT5 PCT Patent Application Inventors: Joshua R. Sikora et al. Specification illustrative embodiment, the first tensioning leg 240 is operatively coupled to the first eccentric cam member 234 by a bearing ring 241, and the second tensioning leg 244 is operatively coupled to the second eccentric cam member 232 by a bearing ring 245. During the tensioning of the strap 190, in the second illustrative embodiment, both tensioning legs 240, 244 are driven by the motor. In the illustrative embodiment, the first tensioning foot member 242, which is driven by the motor during the tensioning of the strap 190, may be formed from a suitable metallic material, such as carbide. Similarly, the second tensioning foot member 246, which is driven by the motor during the tensioning of the strap 190, also may be formed from a suitable metallic material, such as carbide.

[0079] In the illustrative embodiment, with reference to FIGS. 20-23, it can be seen that the cam drive shaft of the camshaft 230 has a linear configuration such that the first tensioning foot member 242 and the second tensioning foot member 246 have an aligned common driving axis.

[0080] Now, with reference primarily to FIGS. 21 and 25A-25C, the functionality of the strapping tool 200 will be described. Initially, the camshaft 230 is rotated by the motor by means of the gearbox reducer assembly (e.g., similar to gearbox reducer assembly 151-163 of the first embodiment). When the camshaft 230 is driven in a tensioning direction by the motor, the first and second eccentric cam members 234, 232 disposed on the drive shaft of the camshaft 230 are rotated. As the first eccentric cam member 234 rotates through its cycle, the first tensioning leg 240 oscillates forwards and backwards so as to apply tension to the strap 190. Similarly, as the second eccentric cam member 232 rotates through its cycle, the second tensioning leg 244 oscillates forwards and backwards so as to apply tension to the strap 190. In particular, referring to FIG. 25 A, it can be seen that the second tensioning foot 246 (i.e., outer foot 246) is shown at a start position and is ready to tension strap 190, while the first tensioning foot 242 (i.e., inner foot 242) is shown is in a return position (e.g., a rearmost position) in the beginning of the tensioning cycle with reference point 272 diagrammatically denoting the rotational position of the camshaft 230. Then, turning to FIG. 25B, it can be seen that the second tensioning foot 246 (i.e., outer foot 246) is shown at a return position (end of tension stroke), while the first tensioning foot 242 (i.e., inner foot 242) has moved to a ready position to start a tension stroke. In FIG. 25B, camshaft 230 has rotated approximately 180 degrees as indicated by the reference point 272. Finally, referring to FIG. 25C, it can be seen that the second tensioning foot 246 (i.e., outer foot 246) has returned to the start position and is ready for a new tensioning cycle, while the firstAttorney Docket No.: 2012C05-SK-PCT5 PCT Patent Application Inventors: Joshua R. Sikora et al. Specification tensioning foot 242 (i.e., inner foot 242) has tensioned strap 190 and is ready to return to the tension position. In FIG. 25C, the reference point 272 on the camshaft 230 is in approximately the same location as in FIG. 25A. In the illustrative embodiment, as shown in FIGS. 24 and 25A-25C, the tensioning legs 240, 244 with tensioning feet 242, 246 are held down against the strap 190 by respective springs 250 (i.e., a downward spring force is applied to the legs 240, 244 to maintain the feet 242, 246 in contact with the strap 190). In the illustrative embodiment, during the tensioning operation of the strapping tool 200, the tensioning feet 242, 246 advance the tensioned strap 190 a predetermined amount (e.g., one -eighth of an inch) during each cycle. During the tensioning operation, the tensioning feet 242, 246 grab and pull a predetermined amount of strapping 190 through the seal member. During each tensioning cycle, the feet 242, 246 reset and grab another predetermined amount of strap 190 (e.g., one-eighth of an inch) as they are forced back and forth in the tool 200. After sufficient tension is applied to the strap 190, the tensioning operation is concluded.

[0081] Next, referring to FIGS. 20-24, the functionality of the strapping tool 200 will be further described. In the illustrative embodiment, when the trigger 205 is pulled, the motor rotates. Then, the motor shaft goes through a planetary gear set to reduce the speed and increase the power. The final planetary gear set attaches to the keyed end 239 of camshaft 230. In the second illustrative embodiment, the camshaft 230 comprises dual offset cams 232, 234. In an alternative embodiment, more than two offset cams could be provided, which would result in more than two legs and grippers. In the second illustrative embodiment, as the leg / gripper 240, 242 or 244, 246 pushes to the rear of the tool, the strapping is pulled tight. The leg works for one-half of the stroke (or more accurately 1 over number of lobes (i.e., a 3 lobe tool = 1 / 3)). During half of the stroke the leg moves toward the front of the tool 200 and the opposite leg takes over and tensions the strapping 190. The wedge angle of the leg 240, 244 lets it pull tension in one direction. In the other direction, the gripper lets go and drags barely on the strapping 190 to return home. In a reverse direction, the only pressure is from the spring 250. The lobes of the cams 232, 234 push the legs 240, 244, which push the grippers 242, 246. As such, the strapping tool 200 has a generally linear drivetrain configuration.

[0082] In the illustrative embodiment, referring again to the perspective view of FIG. 20, it can be seen that the tensioning assembly may further include housing portions 202, 210 and a removable side cover 215 so as to cover portions of the tensioning assembly components. In theAttorney Docket No.: 2012C05-SK-PCT5 PCT Patent Application Inventors: Joshua R. Sikora et al. Specification illustrative embodiment, each foot 242, 246 has a knurled bottom surface for better gripping of the strapping (see e.g., FIGS. 25A-25C).

[0083] Referring again to FIGS. 20-24, in the illustrative embodiment, a motor supplies power to the tensioning assembly by means of the camshaft 230, which includes a central drive shaft portion with eccentric cam members 232, 234. In the illustrative embodiment, with reference to the tensioning assembly depicted in FIG. 21, the strapping tool 200 further comprises one or more bearings 214, 248 disposed on the central drive shaft portion of the camshaft 230 so as to facilitate the rotation of the cam drive shaft.

[0084] In the illustrative embodiment, the motive power source is in the form of electric motor powered by the battery pack 206. However, in other embodiments, other types of motive power sources may be used, such as pneumatic motors, liquid fuel-based motors (e.g., gasoline- powered motors), motors driven by mechanical spring assemblies, and manually-actuated power sources (e.g., a power source driven by the turning of a crank by user, etc.).

[0085] In one or more further embodiments, the strapping tool further comprises one or more additional tensioning foot members configured to apply tension to the piece of strapping while being driven in an oscillatory manner by the motive power source such that the strapping tool comprises three, four, five, or more tensioning foot members.

[0086] The following is a list of reference characters that arc utilized in the drawings of this application together with the components that they are used to represent:100 Strapping Tool (First Embodiment)102 Main Housing for Motor and Planetary Gears104 Handle105 Trigger106 Battery Pack110 Cam Housing Cover111 Base Plate of Cam Housing Cover112 Nose Piece of Base (Seal Member Stops Against Nose Piece)114 One- W ay Bearing115 Side Cover116 One-Way Bearing Cavity on Side Cover117 Dowel Pin Between Cover Plate and Cam HousingAttorney Docket No.: 2012C05-SK-PCT5 PCT Patent Application Inventors: Joshua R. Sikora et al. Specification118 Cover Plate Screws120 Deck Surface to Rest Strap On130 Dual Leg One Cam Camshaft131 Centered Shaft of Cam that fits inside Front Cover132 Centered Shaft of Cam Area for Exterior Leg134 Eccentric Cam Member for Interior Leg135 Spacer Between Feet136 Shaft Zone For Bearing139 Keyed End that fits into Planetary Gear Plate140 Interior Tensioning Leg141 Needle Roller Bearing142 Tensioning Foot of Interior Leg143 Needle Roller Bearing that sits on Cam Shaft to Align and Support144 Exterior Holding Leg145 Needle Roller Bearing146 Holding Foot of Exterior Leg148 Needle Roller Bearing150 Holding Leg Spring151 Planetary Gear Plate152 Gear153 Planetary Gear Pins154 Planetary Gears155 Large Washer156 Cap157 Cap Screws158 Shifter Ring159 Second Drive Plate160 Planetary Gears - Middle Gears162 Reducer Housing163 Ball Bearing164 MotorAttorney Docket No.: 2012C05-SK-PCT5 PCT Patent Application Inventors: Joshua R. Sikora et al. Specification165 Ball Bearing166 Outer Housing Plate170 Center of the Outermost Extrusion of the Dual Leg One Cam Camshaft172 Cam Shaft Rotational Reference Point174 Tensioning Leg Spring190 Strap192 Polded End Portion of Strap194 Strap Tensioning Direction196 Seal Member200 Strapping Tool (Second Embodiment)202 Motor Housing204 Handle205 Trigger206 Battery Pack210 Cam / Leg Housing211 Base Plate of Cam Housing Cover214 Bearing for Cam to Cover Plate Connection215 Side Cover216 Aperture in Cover Plate218 Screws for Cover Plate220 Strap Slot230 Dual Leg Dual Cam Camshaft231 Outer End of Camshaft232 Eccentric Cam Portion for Exterior Tensioning Leg234 Eccentric Cam Portion for Interior Tensioning Leg235 Spacer Wall of Camshaft236 Bearing Shaft Area of Camshaft239 Keyed End of Cam Shaft that fits into Planetary Gear Plate240 Interior Tensioning Leg241 Bearing Ring for Interior Tensioning Leg242 Foot of Interior Tensioning LegAttorney Docket No.: 2012C05-SK-PCT5 PCT Patent Application Inventors: Joshua R. Sikora et al. Specification244 Exterior Tensioning Leg245 Bearing Ring for Exterior Tensioning Leg246 Foot of Exterior Tensioning Leg248 Roller Bearing250 Tensioning Leg Spring270 Center of the Dual Leg Dual Cam Camshaft 272 Cam Shaft Rotational Reference Point

[0087] In one or more further embodiments, the motor turns the drive shaft (or gearbox that turns the drive shaft). In these one or more further embodiments, the drive shaft is concentric in the bearing(s), but not necessarily concentric with the motor. The legs hang off the drive shaft. The leg(s) can be on a concentric shaft, or on an offset portion of the shaft. The leg(s) hang down and come in contact with a strap. The end of the leg can have a foot or gripper, or the foot or gripper can be incorporated into the leg. If the leg is on a concentric drive shaft, when the drive shaft spins, the leg will not rotate and stay static. If the leg(s) is on an offset, the leg will move with the cam lobe on the shaft. If the legs are on offsets at 180 degrees apart, one leg will be moving forward as the other moves backward. The legs work like a wedge or a dog. The legs let the strap move / slide through in one direction, and in the other direction the strap is stopped, which pushes the strap tight with the movement. For example, in these one or more further embodiments, if there are five (5) non-concentric shafts, two (2) shafts are pushing, two (2) shafts are holding, and the first shaft could be in either direction. With one leg on concentric, and one on an offset, the offset leg will push the strap in roughly one-half the stroke, and when it retracts, the concentric leg will stop the strap.

[0088] One important advantage of the strapping tool configurations described above is how few parts are needed to make the strapping work. Traditionally tensioners use gearboxes with big reductions to get the power they need. There may be a multi-stage planetary gearbox, sometimes also in combination with a worm or right angle gear. With the strapping tools 100, 200 described herein, part of the speed reduction is done with an offset. When the shaft of tools 100, 200 rotates the cam will move the leg a certain amount. With a conventional tool, the motor spins at a very fast rate. The gearbox might reduce the speed / increase the torque 30 times. In a conventional tool, one turn of the motor accomplishes a certain distance of strapping calculated by figuring out the circumference, and distance traveled by each motor rotation. This also givesAttorney Docket No.: 2012C05-SK-PCT5 PCT Patent Application Inventors: Joshua R. Sikora et al. Specification the tool total tension, also referred to as power. The offset of the strapping tools 100, 200 described herein has a huge advantage of using far fewer components, which is also an advantage for little weight. Advantageously, the side-by-side arrangement of the legs and associated feet of the strapping tools 100, 200 described herein allows a single drive shaft to be used, which results in a substantial reduction in the number of components and a significant reduction in both the size and weight of the strapping tool.

[0089] It is readily apparent that the aforedescribed embodiments of the strapping tool offer numerous advantages. The strapping tools described herein are lighter, smaller in size, and simpler in design than conventional tools used to tension steel or poly strapping systems. The abovedescribed strapping tools may use a packaged drill as the external power source, and modify the operation of the drill controls to perform the strap tensioning operation in a novel manner.

[0090] Although the invention has been shown and described with respect to a certain embodiment, it is apparent that this invention can be embodied in many different forms and that many other modifications and variations are possible without departing from the spirit and scope of this invention.

[0091] Moreover, any of the features or attributes of the above-described embodiments and variations can be used in combination with any of the other features and attributes of the abovedescribed embodiments and variations as desired.

[0092] Furthermore, while exemplary embodiments have been described herein, one of ordinary skill in the art will readily appreciate that the exemplary embodiments set forth above are merely illustrative in nature and should not be construed as to limit the claims in any manner. Rather, the scope of the invention is defined only by the appended claims and their equivalents, and not, by the preceding description.

[0093] The invention claimed is:

Claims

Attorney Docket No.: 2012C05-SK-PCT5 PCT Patent Application Inventors: Joshua R. Sikora et al. ClaimsCLAIMS1. A strapping tool, comprising: a motive power source; and a tensioning assembly operatively coupled to the motive power source, the tensioning assembly including a plurality of strapping foot members, the plurality of strapping foot members arranged side-by-side transversely across a strapping pass line, at least one of the plurality of strapping foot members being in a form of a tensioning foot member configured to apply tension to a piece of strapping while being driven in an oscillatory manner by the motive power source.

2. The strapping tool according to claim 1, further comprising at least one cam member, the at least one cam member operatively coupling the tensioning foot member to the motive power source.

3. The strapping tool according to claim 2, wherein the at least one cam member is in a form of an eccentric cam member.

4. The strapping tool according to claim 2, wherein the at least one cam member is disposed on a drive shaft, the drive shaft operatively coupling the tensioning foot member to the motive power source by means of the at least one cam member.

5. The strapping tool according to claim 4, wherein at least another one of the plurality of strapping foot members is in a form of a holding foot member, the holding foot member being supported from the drive shaft that is operatively coupled to the tensioning foot member; wherein, during the tensioning of the piece of strapping, the tensioning foot member continually grabs and applies tension to the piece of strapping, and the holding foot member prevents the piece of strapping from slipping back.Attorney Docket No.: 2012C05-SK-PCT5 PCT Patent Application Inventors: Joshua R. Sikora et al. Claims6. The strapping tool according to claim 5, further comprising a tensioning leg operatively coupling the tensioning foot member to the at least one cam member, and a holding leg coupling the holding foot member to the drive shaft.

7. The strapping tool according to claim 4, further comprising one or more one-way rotation restriction devices disposed on the drive shaft, the one or more one-way rotation restriction devices allowing the drive shaft to be rotated in a first rotational direction where the tensioning foot member applies tension to the piece of strapping, while preventing rotation of the drive shaft in a second rotational direction, which is opposite to the first rotational direction, so as to enable the tension to be maintained on the piece of strapping.

8. The strapping tool according to claim 1, wherein the tensioning foot member is in a form of a first tensioning foot member, and at least another one of the plurality of strapping foot members comprises a second tensioning foot member configured to apply tension to the piece of strapping while being driven in an oscillatory manner by the motive power source.

9. The strapping tool according to claim 8, further comprising at least a first cam member and a second cam member, the first cam member operatively coupling the first tensioning foot member to the motive power source, and the second cam member operatively coupling the second tensioning foot member to the motive power source.

10. The strapping tool according to claim 9, wherein the first cam member and the second cam member are disposed on a drive shaft, the drive shaft operatively coupling the first tensioning foot member to the motive power source by means of the first cam member, and the drive shaft operatively coupling the second tensioning foot member to the motive power source by means of the second cam member.

11. The strapping tool according to claim 10, wherein the first cam member is in a form of a first eccentric cam member and the second cam member is in a form of a second eccentric cam member, the first eccentric cam member having a first lobe portion and the second eccentric cam member having a second lobe portion, and the first lobe portion of the first eccentric camAttorney Docket No.: 2012C05-SK-PCT5 PCT Patent Application Inventors: Joshua R. Sikora et al. Claims member being rotationally offset from the second lobe portion of the second eccentric cam member by approximately 180 degrees on the drive shaft.

12. The strapping tool according to claim 10, further comprising a first tensioning leg operatively coupling the first tensioning foot member to the first cam member, and a second tensioning leg operatively coupling the second tensioning foot member to the second cam member.

13. The strapping tool according to claim 10, further comprising one or more bearings disposed on the drive shaft.

14. The strapping tool according to claim 8, wherein, during the tensioning of the piece of strapping, the first tensioning foot member is displaced in a first direction for applying tension to the piece of strapping, while the second tensioning foot member is displaced in a second direction that is opposite to the first direction so as to grip the piece of strapping that is being tensioned; and wherein, during the tensioning of the piece of strapping, the second tensioning foot member is displaced in the first direction for applying tension to the piece of strapping, while the first tensioning foot member is displaced in the second direction that is opposite to the first direction so as to grip the piece of strapping that is being tensioned.

15. The strapping tool according to claim 8, wherein the plurality of strapping foot members further comprises one or more additional tensioning foot members configured to apply tension to the piece of strapping while being driven in an oscillatory manner by the motive power source such that the strapping tool comprises three or more tensioning foot members.

16. The strapping tool according to claim 8, wherein the drive shaft has a linear configuration such that the first tensioning foot member and the second tensioning foot member have an aligned common driving axis.Attorney Docket No.: 2012C05-SK-PCT5 PCT Patent Application Inventors: Joshua R. Sikora et al. Claims17. The strapping tool according to claim 1, wherein the motive power source comprises one of: (i) an electric motor, (ii) a pneumatic motor, and (iii) a liquid fuel-based motor.

18. The strapping tool according to claim 1, wherein the motive power source comprises a battery-powered motor.

19. A strapping tool, comprising: a motive power source; a drive shaft operatively coupled to the motive power source; and a tensioning assembly operatively coupled to the drive shaft, the tensioning assembly including a plurality of strapping foot members, each of the plurality of strapping foot members being arranged on the drive shaft, at least one of the plurality of strapping foot members being in a form of a tensioning foot member configured to apply tension to a piece of strapping while being driven in an oscillatory manner by the drive shaft.

20. The strapping tool according to claim 19, wherein the drive shaft has a linear configuration such that the plurality of strapping foot members has an aligned common rotational axis.

21. The strapping tool according to claim 19, wherein at least another one of the plurality of strapping foot members is in a form of a holding foot member, the holding foot member being supported from the drive shaft that is operatively coupled to the tensioning foot member; wherein, during the tensioning of the piece of strapping, the tensioning foot member continually grabs and applies tension to the piece of strapping, and the holding foot member prevents the piece of strapping from slipping back.

22. The strapping tool according to claim 21, further comprising a tensioning leg operatively coupling the tensioning foot member to the drive shaft, and a holding leg coupling the holding foot member to the drive shaft.

23. The strapping tool according to claim 19, wherein the tensioning foot member is in a form of a first tensioning foot member, and at least another one of the plurality of strapping footAttorney Docket No.: 2012C05-SK-PCT5 PCT Patent Application Inventors: Joshua R. Sikora et al. Claims members comprises a second tensioning foot member configured to apply tension to the piece of strapping while being driven in an oscillatory manner by the motive power source.

24. The strapping tool according to claim 23, further comprising a first tensioning leg operatively coupling the first tensioning foot member to the drive shaft, and a second tensioning leg operatively coupling the second tensioning foot member to the drive shaft.

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