Strap Sealing Jaw Geometry for Lower-Power Double-Notch Seals
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Solution Overview
Problem
Existing powered strap sealers require high power to form seals, limiting their operating life and mobility due to battery capacity constraints, and often result in joint strengths that are less than the desired 75% of the strap's original cross-sectional strength.
Innovation Solution
A sealing tool with a motor and drive train that uses an over-run clutch and asymmetric cutting edges to form double-notch seals in a single cycle, reducing power consumption and maintaining at least 75% of the strap's cross-sectional strength by staggering cuts and using an elevated inboard notcher to distribute cutting forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high power is used to form seals quickly, then productivity is improved, but power consumption increases and battery life is reduced
Solution Approach 1:
The sealing process is divided into two sequential stages: first forming a preliminary seal with lower power consumption, then completing the final seal. This segmentation allows the tool to reduce peak power requirements while maintaining overall sealing effectiveness and productivity.
Solution Approach 2:
The sealing process uses periodic action by implementing a two-stage sealing cycle where the first stage creates an initial seal and the second stage completes the final seal. This periodic approach distributes power consumption over time rather than requiring sustained high power, extending battery life while maintaining sealing productivity.
2Strength
If deep cuts are made to form strong seals, then joint strength is improved, but power consumption increases
Solution Approach 1:
The cutting process is segmented into two stages: preliminary cuts that create initial tabs with sufficient strength, and final cuts that complete the seal. This segmentation achieves the required 75% joint strength while reducing peak power consumption by distributing the cutting workload over two separate sealing cycles.
Solution Approach 2:
The first sealing cycle performs partial cutting action to create preliminary tabs that provide sufficient initial strength. The second cycle completes the cutting to achieve full seal strength. This partial action approach maintains adequate joint strength while reducing the peak power requirements compared to completing all cuts in a single cycle.
3Use of energy by moving object
If single-notch seals are used, then power consumption is reduced, but joint strength falls below 75% of strap strength
Solution Approach 1:
The patent merges the benefits of single-notch seals (lower power consumption) with the strength requirements of double-notch seals by implementing a two-stage sealing process. The first cycle creates preliminary tabs similar to single-notch seals, and the second cycle completes the tabs to achieve double-notch strength, combining the advantages of both approaches.
Solution Approach 2:
The first sealing cycle performs preliminary action by creating initial tabs that provide sufficient strength for the first stage. The second cycle then completes the tab formation to achieve full double-notch strength. This preliminary action allows the system to maintain strength requirements while distributing power consumption across two cycles.
4Productivity
If double-notch seals are formed in a single cycle, then productivity is improved, but peak power requirements increase significantly
Solution Approach 1:
The double-notch sealing process is segmented into two separate sealing cycles rather than attempting to complete all cuts in a single cycle. This segmentation reduces peak power requirements by distributing the cutting workload, while still maintaining improved productivity compared to traditional single-cycle double-notch sealing.
Solution Approach 2:
The patent uses periodic action by implementing two sealing cycles: the first cycle creates preliminary tabs and the second cycle completes them. This periodic approach reduces peak power requirements while achieving double-notch seal strength, balancing power consumption with productivity requirements.
Data Source
AI summary
A sealing tool for forming a joint in a seal positioned on overlying courses of strap includes a body, a motor and drive train housed, at least in part, in the body, a power supply and a sealing assembly mounted to the body. The sealing assembly is operably coupled to the motor. The sealing assembly includes at least one jaw having a pair of opposing jaw elements. Each jaw element has two edges for cutting into the seal and the courses of strap and forming a bent tab. The jaw element edges are configured to cut into the seal and the courses of strap material at different distances into a width of the seal and strap material. A method for forming seal and a seal formed by the tool and method are disclosed.