Strap Sealing Tool With Staggered Cuts for Lower Power 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 below the desired 75% of the strap's original cross-section.
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 by staggering cuts and maintaining at least 75% of the strap's width intact, thereby enhancing joint strength and mobility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high power is used to form seals quickly and strongly, then joint strength and sealing quality are improved, but battery life is reduced and power consumption increases
Solution Approach 1:
The sealing process is divided into two distinct phases: a first sealing phase that applies a first level of closing force to form an initial seal, and a second sealing phase that applies a second level of closing force to form a final strengthened seal. This segmentation allows the system to achieve high joint strength while managing power consumption by using lower force initially and building up to the required sealing force in stages, rather than applying maximum force throughout the entire sealing cycle.
2Duration of action of moving object
If battery capacity is increased to extend operating life, then duration of action is improved, but weight and device complexity increase
Solution Approach 1:
The sealing system dynamically adjusts the closing force applied during the sealing cycle by transitioning between two distinct force levels. The system applies a first level of closing force during the initial sealing phase, then transitions to a second level of closing force during the final sealing phase. This dynamic force adjustment allows the existing battery to provide sufficient power for extended operation while maintaining the ability to create strong seals, eliminating the need for larger battery capacity.
3Productivity
If a single sealing cycle is used to form the joint, then productivity is improved, but the complexity of achieving sufficient joint strength increases
Solution Approach 1:
The sealing process employs periodic action with two distinct sealing phases occurring within a single operational cycle. The first sealing phase applies a first level of closing force for a first duration to form an initial seal, then the second sealing phase applies a second level of closing force for a second duration to strengthen the seal. This periodic variation in force application within one cycle achieves high joint strength while maintaining high productivity, as the entire process completes in a single cycle without requiring multiple separate operations.
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.