Strapping Tool

This application is a continuation application U.S. patent application Ser. No. 18/151,739, filed on Jan. 9, 2023, which is a continuation application of U.S. patent application Ser. No. 18/003,366, having a 371(c) filing date of Dec. 27, 2022, and which is a national phase application of PCT/US2021/040834, filed on Jul. 8, 2021, which claims priority to and the benefit of U.S. Provisional Patent Application No. 63/050,965, filed Jul. 13, 2020, and U.S. Provisional Patent Application No. 63/196,391, filed Jun. 3, 2021, the entire contents of each of which are incorporated herein by reference.

The present disclosure relates to strapping tools, and more particularly to strapping tools configured to tension strap around a load and to attach overlapping portions of the strap to one another to form a tensioned strap loop around the load.

Battery-powered strapping tools are configured to tension strap around a load and to attach overlapping portions of the strap to one another to form a tensioned strap loop around the load. To use one of these strapping tools to form a tensioned strap loop around a load, an operator pulls strap leading end first from a strap supply, wraps the strap around the load, and positions the leading end of the strap below another portion of the strap. The operator then introduces one or more (depending on the type of strapping tool) of these overlapped strap portions into the strapping tool and actuates one or more buttons to initiate: (1) a tensioning cycle during which a tensioning assembly tensions the strap around the load; and (2) after completion of the tensioning cycle, a sealing cycle during which a sealing assembly attaches the overlapped strap portions to one another (thereby forming a tensioned strap loop around the load) and during which a cutting assembly cuts the strap from the strap supply.

How the strapping tool attaches overlapping portions of the strap to one another during the sealing cycle depends on the type of strapping tool and the type of strap. Certain strapping tools configured for plastic strap (such as polypropylene strap or polyester strap) include friction welders, heated blades, or ultrasonic welders configured to attach the overlapping portions of the strap to one another. Some strapping tools configured for plastic strap or metal strap (such as steel strap) include jaws that mechanically deform (referred to as “crimping” in the strapping industry) or cut notches into (referred to as “notching” in the strapping industry) a seal element positioned around the overlapping portions of the strap to attach them to one another. Other strapping tools configured for metal strap include punches and dies configured to form a set of mechanically interlocking cuts in the overlapping portions of the strap to attach them to one another (referred to in the strapping industry as a “sealless” attachment).

Various embodiments of the present disclosure provide a strapping tool configured to tension metal strap around a load and, after tensioning, attach overlapping portions of the strap to one another by cutting notches into a seal element positioned around the overlapping portions of the strap and into the overlapping portions of the strap themselves.

While the systems, devices, and methods described herein may be embodied in various forms, the drawings show and the specification describes certain exemplary and non-limiting embodiments. Not all of the components shown in the drawings and described in the specification may be required, and certain implementations may include additional, different, or fewer components. Variations in the arrangement and type of the components; the shapes, sizes, and materials of the components; and the manners of connections of the components may be made without departing from the spirit or scope of the claims. Unless otherwise indicated, any directions referred to in the specification reflect the orientations of the components shown in the corresponding drawings and do not limit the scope of the present disclosure. Further, terms that refer to mounting methods, such as mounted, connected, etc., are not intended to be limited to direct mounting methods but should be interpreted broadly to include indirect and operably mounted, connected, and like mounting methods. This specification is intended to be taken as a whole and interpreted in accordance with the principles of the present disclosure and as understood by one of ordinary skill in the art.

show one example embodiment of the strapping toolof the present disclosure (sometimes referred to as the “tool” in the Detailed Description for brevity) and certain assemblies and components thereof. The strapping toolis configured to carry out a strapping cycle including: (1) a tensioning cycle during which the strapping tool tensions strap (metal strap in this example embodiment) around a load; and (2) a sealing cycle during which the strapping tool, after tensioning the strap, attaches overlapping portions of the strap to one another by cutting notches into a seal element positioned around the overlapping portions of the strap and into the overlapping portions of the strap themselves (referred to as “notching” in the strapping industry and in this Detailed Description) and cuts the strap from the strap supply.

The strapping toolincludes a housing, a working assembly, first and second handlesand, a display assembly, an actuating assembly, a power supply, a controller(), one or more sensors(), a retaining assembly(), and a retainer-activation assembly().

The housing, which is best shown in, is formed from multiple components (not individually labeled) that collectively at least partially enclose and/or support some (or all) of the other assemblies and components of the strapping tool. The housing also supports the retaining assemblyand the retainer-activation assembly, as explained below with reference to. In this example embodiment, the housingincludes a front housing section that at least partially encloses and/or supports at least some of the components of the working assembly, the display assembly, and the actuating assembly; a rear housing section that at least partially encloses and/or supports the power supplyand the controller; and a connector housing section that extends between and connects the bottoms of the front and rear housing sections. The first handleextends between the tops of the front and rear housing sections, and in some embodiments is integrally formed with the housing sections. This is merely one example, and in other embodiments the components of the strapping tool may be supported and/or enclosed by any suitable portion of the housing. The housingmay be formed from any suitable quantity of components joined together in any suitable manner. In this example embodiment, the housingis formed from plastic, though it may be made from any other suitable material in other embodiments.

The working assemblyincludes the majority of the components of the strapping toolthat are configured to carry out the strapping cycle to tension the strap around the load, attach the overlapping portions of the strap to one another, and cut the strap from the strap supply. Specifically, the working assemblyincludes a support, a tensioning assembly, a sealing assembly, a drive assembly, a rocker-lever assembly, a gate assembly, and a decoupling assembly.

The support, which is best shown in, serves as a direct or indirect common mount for the tensioning assembly, the sealing assembly, the drive assembly, the rocker-lever assembly, the gate assembly, and the decoupling assembly. The supportalso includes components configured to help change the effective length of a linkageof the conversion assemblyof the drive assemblyduring the sealing cycle, as explained below with respect to.

The supportincludes a body, a footextending transversely from a bottom of the body, a tensioning-assembly-mounting elementextending rearward from the body, and a drive-and-conversion-assembly-mounting elementextending upwardly from the body. A front side of the bodydefines a gate-receiving recesssized, shaped, oriented, and otherwise configured to receive a gateof the gate assemblyand to enable the gateto move between a lower home position and an upper strap-insertion position (described below with respect to). The bodyincludes aligned first and second sealing-assembly-mounting tonguesandon one side of the gate-receiving recessand aligned third and fourth sealing-assembly-mounting tonguesandon the other side of the gate-receiving recess. Circumferentially spaced first and second linkage engagersandproject from the drive-and-conversion-assembly-mounting element. A rolleris coupled to and freely rotatable relative to the foot.

The tensioning assembly, which is best shown in, is configured to tension the strap around the load during the tensioning cycle. The tensioning assemblyincludes a tensioning-assembly support, tensioning-assembly gearing, a tension wheeldriven by the tensioning-assembly gearing, and covers (not labeled) mounted to the tensioning-assembly supportto partially or completely enclose certain components of the tensioning-assembly gearingand the tension wheel.

The tensioning-assembly gearingincludes: a driven gear; a first sun gear; first planet gears,, and; a carrier; a first ring gear; a spacer; a second ring gear; a tension-wheel mount; and second planet gears,, and. The components of the tensioning-assembly gearingare centered on—and certain of them are rotatable about-a tension-wheel rotational axis. The carrierincludes a first planet-gear carrierto which the first planet gears-are rotatably mounted (such as via respective bearings and mounting pins) and a second sun gearrotatable with (and here integrally formed with) the planet-gear carrierabout the tension-wheel rotational axis. The first ring gearincludes internal teethand external teeth. The second ring gearincludes internal teeth. The tension-wheel mountincludes a second planet-gear carrierand a tension-wheel shaftrotatable with (and here integrally formed with) the second planet-gear carrierabout the tension-wheel rotational axis. The second planet gears-are rotatably mounted to the second planet-gear carrier(such as via respective bearings and mounting pins).

The first sun gearis fixedly mounted to the driven gear(such as via a splined connection) such that the driven gear and the first sun gear rotate together about the tension-wheel rotational axis. The first sun gearmeshes with and drivingly engages the first planet gears-. The first planet gears mesh with the internal teethof the first ring gear. The second planet gears mesh with the internal teethof the second ring gear. The spacerseparates the first and second ring gearsand. The second sun gearextends through the spacerand meshes with and drivingly engages the second planet gears-. The tension wheelis fixedly mounted to the tension-wheel shaft(such as via a splined connection) such that the tension-wheel shaft and the tension wheel rotate together about the tension-wheel rotational axis

The tensioning-assembly gearingis mounted to the tensioning-assembly support. The second ring gearis fixed in rotation about the tension-wheel rotational axisrelative to the tensioning-assembly support(that is, the second ring gearis not rotatable about the tension-wheel rotational axisrelative to the tensioning-assembly support). In this example embodiment, pins (which are shown but not labeled) are positioned between the outer surface of the second ring gearand the tensioning-assembly supportto prevent relative rotation, though any suitable components (such as set screws, glue, or high-friction components or fasteners) may be used to do so. The decoupling assembly(except when actuated, as described below) fixes the first ring gearin rotation about the tension-wheel rotational axisrelative to the tensioning-assembly support(so the first ring gear cannot rotate about the tension-wheel rotational axisrelative to the tensioning-assembly support).

During the tensioning cycle, the drive assemblydrives the driven gear, as described below. The driven gearbegins rotating itself and the first sun gearabout the tension-wheel rotational axisin a tensioning rotational direction (clockwise from the perspective ofin this example embodiment). The first sun geardrives the first set of planet gears-. Since the decoupling assemblyprevents the first ring gearfrom rotating about the tension-wheel rotational axis, rotation of the planet gears-causes the carrier—including the second sun gear—to rotate about the tension-wheel rotational axisin the tensioning rotational direction, the second sun geardrives the second set of planet gears-. Since the second ring gearcannot rotate about the tension-wheel rotational axis, rotation of the planet gears-causes the tension-wheel mountand the tension wheelmounted thereto to rotate about the tension-wheel rotational axisin the tensioning rotational direction. Accordingly, the tensioning-assembly gearingoperatively connects the drive assemblyto the tension wheelto rotate the tension wheelabout the tension-wheel rotational axisin the tensioning rotational direction.

The tensioning assemblyis movably mounted to the tensioning-assembly-mounting elementof the supportand configured to pivot relative to the support—and particularly relative to the footof the support—under control of the rocker-lever assembly(as described below) and about a tensioning-assembly-pivot axisof a tensioning-assembly-pivot shaftbetween a strap-tensioning position (, andB) and a strap-insertion position (). When the tensioning assemblyis in the strap-tensioning position, the tension wheelis adjacent to (and in this embodiment contacts) the rollerof the support(or the upper surface of the strap if the strap has been inserted into the strapping tool). When the tensioning assemblyis in the strap-insertion position, the tension wheelis spaced-apart from the rollerto enable the top portion of the strap (described below) to be inserted between the tension wheeland the roller. A tensioning-assembly-biasing element(), which is a compression spring in this example embodiment but may be any other suitable type of biasing element, biases the tensioning assemblyto the strap-tensioning position.

The decoupling assembly, which is best shown in, is configured to enable the tension wheelto rotate about the tension-wheel rotational axisin a direction opposite the tensioning rotational direction to facilitate removal of the toolfrom the strap after the tensioning process is complete. The decoupling assemblyincludes a decoupling-assembly shaft, a decoupling-assembly housing, a first engageable element, an expandable element, a second engageable element, and first and second bearingsand

The decoupling-assembly shaftincludes a bodyhaving a first endhaving an irregular cross-section and second endhaving teeth. A first bearing supportextends from the first end, and a second bearing supportextends from the second end. The decoupling-assembly housingincludes a tubular bodyhaving teethextending around its outer circumference. The bodydefines an opening. The first engageable elementcomprises a tubular bushing having a cylindrical outer surface and an interior surface having a perimeter that matches the perimeter of the first endof the bodyof the decoupling-assembly shaft. The expandable elementincludes a torsion spring having a first endand a second end. The second engageable elementincludes a tubular bodyand an annular flangeat one end of the body. An openingis defined through the flange.

The first engageable elementis mounted on the first endof the bodyof the decoupling-assembly shaftfor rotation therewith and is disposed within the bodyof the decoupling-assembly housing. The second engageable elementis also disposed within the bodyof the decoupling-assembly housingsuch that the bodyof the second engageable elementis adjacent the first engageable elementand such that at least part of the decoupling-assembly shaftextends through the second engageable element. The expandable element, which is a torsion spring in this example embodiment, is disposed within the bodyof the decoupling assembly housingand circumscribes the first engageable elementand the bodyof the second engageable element. The outer diameters of the first engageable elementand the bodyof the second engageable element are substantially the same and are equal to or larger than the resting inner diameter of the torsion spring. This means that the torsion springexerts a compression force on the first engageable elementand the bodyof the second engageable element that prevents those components (and the decoupling-assembly shaft) from rotating relative to one another. The first endof the expandable elementis received in the openingdefined through the flangeof the second engageable element, and the second endof the expandable elementis received in the openingdefined in the bodyof the decoupling-assembly housing. The bearingsandare mounted on the first and second bearing supportsand, respectively, of the decoupling-assembly shaft.

As best shown in, the decoupling assemblyis mounted to the tensioning-assembly supportand operatively connected to the tensioning-assembly gearing. More specifically, the decoupling assemblyis mounted to the tensioning-assembly supportvia a fastener (not labeled) that fixes the second engageable elementin rotation relative to the tensioning-assembly supportsuch that the second engageable element—and the first endof the expandable elementreceived in the openingof the flangeof the second engageable element—cannot rotate relative to the tensioning-assembly support. The teeth on the second endof the bodyof the decoupling-assembly shaftmesh with the outer teethof the first ring gearof the tensioning-assembly gearingof the tensioning assembly. Since the bodyis fixed in rotation relative to the tensioning-assembly supportand the decoupling-assembly shaftis fixed in rotation with the first engageable element, the decoupling-assembly shaftis fixed in rotation relative to the tensioning-assembly housing. Since the teeth on the second endengage the outer teethof the first ring gearof the tensioning-assembly gearing, the decoupling assemblyprevents the first ring gearfrom rotating about the tension-wheel rotational axis

The decoupling assemblyis actuatable (such as by the rocker-lever assemblyas described below) to eliminate the connection between the torsion springand the first engageable elementsuch that the first engageable elementand the decoupling-assembly shaftmay rotate relative to the second engageable element. As explained above, the second engageable elementand the first endof the expandable element(that is received in the openingof the flangeof the second engageable element) are fixed in rotation relative to the tensioning-assembly support. To eliminate the connection between the torsion springand the first engageable element, the decoupling-assembly housingis rotated relative to the tensioning-assembly support, the first endof the torsion spring, and the second engageable element. The second endof the torsion spring, which is received in the openingdefined in the bodyof the decoupling-assembly housing, rotates with the decoupling-assembly housing. As this occurs, the inner diameter of the torsion springnear its second endbegins expanding, and eventually expands enough (thereby reducing the compression force or eliminating it altogether) to enable the first engageable elementand the decoupling-assembly shaftto rotate relative to the second engageable element(and the torsion spring).

Upon completion of the tensioning cycle, the tension wheelholds a significant amount of tension in the strap, and the strap exerts a counteracting force (or torque) on the tension wheelin a direction opposite the tensioning direction. Actuation of the decoupling assemblyafter the tensioning process is completed enables the tension wheelto rotate in the direction opposite the tensioning direction to release that tension in a controlled manner. Specifically, upon completion of the tensioning cycle, the decoupling-assembly shaftcontinues to prevent the first ring gearof the tensioning-assembly gearingfrom rotating about the tension-wheel rotational axis, which prevents the tension wheelfrom rotating in the direction opposite the tensioning direction. As the decoupling-assembly housingis rotated (such as via actuation of the rocker-lever assemblyas described below), the inner diameter of the torsion springnear its second endbegins expanding. Eventually, the force the first ring gearexerts on the decoupling-assembly shaftexceeds the compression force the torsion springexerts on the first engageable element. When this occurs, the first ring gearrotates in the direction opposite the tensioning direction about the tension-wheel rotational axis. Since the first sun gearis fixed in rotation (by the drive assembly), this causes the first planetary gears-to rotate in the direction opposite the tensioning direction about the tension-wheel rotational axis. This (as explained above) causes the tension wheelto rotate in the direction opposite the tensioning direction about the tension-wheel rotational axis

The rocker-lever assembly, which is best shown in, is operably connected to: (1) the tensioning assemblyand configured to move the tensioning assemblyrelative to the supportfrom the strap-tensioning position to the strap-insertion position; and (2) the decoupling assemblyand configured to actuate the decoupling assembly, thereby enabling the tension wheelto rotate in the direction opposite the tensioning rotational direction. The rocker-lever assemblyincludes a rocker lever, a rocker-lever gear, a rocker-lever pivot pin, a rocker-lever travel pin, and a rocker-lever biasing element (not shown). The rocker leverincludes a rocker-lever bodydefining two aligned travel-pin slots, a rocker-lever armextending rearwardly from the rocker-lever body, and a blocking fingerextending upwardly from the rocker-lever bodyand transverse to the rocker-lever arm.

The rocker-lever pivot pinand the rocker-lever travel pinattach the rocker leverto the tensioning assemblysuch that the rocker leveris pivotable relative to the tensioning assemblybetween a home position () and an intermediate position (). Specifically, the rocker-lever pivot pinextends through openings (not shown) defined through the tensioning-assembly supportand the rocker-lever bodyof the rocker leversuch that the rocker leveris pivotable about the pivot pin—which defines a rocker-lever pivot axis (not shown)—and relative to the tensioning assemblyand the decoupling assembly. The rocker-lever travel pinextends through an opening (not shown) defined through the tensioning-assembly supportand through the travel-pin slotsof the rocker-lever body.

As the rocker leverpivots about the pivot pin(and the rocker-lever pivot axis) and relative to the tensioning assemblyand the support, the travel-pin slotsmove relative to the rocker-lever travel pin(which is mounted to the tensioning-assembly support). The size, shape, position, and orientation of the travel-pin slotsenable the rocker leverto pivot about the pivot pinfrom the home position to, but not past, the home position. More specifically, as shown in, when the rocker leveris in its home position, the rocker-lever travel pinis positioned at and engages the upper ends (not labeled) of the travel-pin slots, preventing the rocker leverfrom further rotation relative to the tensioning assemblyin the clockwise direction. Conversely, and as shown in, when the rocker leveris in its intermediate position, the rocker-lever travel pinis positioned at the lower ends (not labeled) of the travel-pin slots, preventing the rocker leverfrom further rotation relative to the tensioning assemblyin the counter-clockwise direction. Although not shown here, the rocker-lever biasing element, which is a torsion spring in this example embodiment but may be any other suitable component, biases the rocker leverto its home position.

As best shown in, the rocker-lever gearis attached to the rocker-lever bodyof the rocker levervia the rocker-lever travel pinsuch that the rocker-lever gearis rotatable about the rocker-lever travel pin. The rocker leveris operably connected to the rocker-lever gearand configured to rotate the rocker-lever gearabout the rocker-lever travel pinas the rocker leverpivots from its home position to its intermediate position. As the rocker-lever gearrotates, it actuates the decoupling assembly, as described above. More specifically, as the rocker-lever gearrotates, it meshes with the teethof the bodyof the decoupling-assembly housing, thereby forcing the decoupling-assembly housingto rotate (thereby actuating the decoupling assembly).

As explained above and as shown in, once the rocker leverreaches its intermediate position, the rocker-lever travel pinis positioned at the lower ends of the travel pin slots, preventing the rocker leverfrom further rotation relative to the tensioning assemblyin the counter-clockwise direction. At this point, if the tensioning assemblyis in its strap-tensioning position, as shown in, continued application of force on the rocker lever(and particularly the rocker-lever arm) towards the handlecauses the rocker leverand the tensioning assemblyto rotate together about the tensioning-assembly-pivot axisuntil the rocker leverreaches its actuated position and the tensioning assemblyreaches its strap-insertion position.shows the rocker leverin its actuated position and the tensioning assemblyin its strap-insertion position.

The blocking fingeris sized, shaped, positioned, oriented, and otherwise configured such that, when the rocker leveris in its home position and the tensioning assemblyis in its strap-tensioning position, the blocking fingerprevents the tensioning assemblyfrom moving from its strap-tensioning position to its strap-insertion position (and the resultant movement of the rocker levertowards the handle). As best shown in, the housingdefines a blocking finger openingsized and shaped to enable the blocking fingerto pass through the openingand into the housingas the rocker leverpivots from its home position to its intermediate position.

When the tensioning assemblyis in its strap-tensioning position and the rocker leveris in its home position, as shown in, the blocking fingeris adjacent a portion of the housingthat defines the blocking finger opening(though it may be adjacent any other suitable portion of the housing or other component of the tool used for this purpose). If at this point a force acts on the tensioning assembly(such as the force caused by cutting the strap from the strap supply and releasing the stored tension therein) and attempts to move the tensioning assemblyfrom its strap-tensioning position to its strap-insertion position, the resultant upward movement of the rocker lever—without pivoting away from its home position relative to the tensioning assembly—results in the blocking fingerengaging the housing. As shown in, this prevents further movement of the tensioning assemblytoward its strap-insertion position and prevents further movement of the rocker levertoward the handle.

The blocking fingerdoes not prevent the tensioning assemblyfrom moving from its strap-tensioning position to its strap-insertion position when the rocker leveris in its intermediate position and the tensioning assemblyis in its strap-tensioning position. As shown in, the blocking fingerpasses through the blocking finger openingand into the housing as the rocker levermoves from its home position to its intermediate position. As shown in, as the operator keeps moving the rocker leverto its actuated position, the blocking fingerdoes not prevent the tensioning assemblyfrom pivoting upwards about the tensioning-assembly-pivot axisto its strap-insertion position. Accordingly, for the rocker leverto move the tensioning assemblyfrom its strap-tensioning position to its strap-insertion position, the rocker levermust first be moved from its home position to its intermediate position while the tensioning assemblyis in its strap-tensioning position (best shown in).

The retaining assembly, which is best shown in, is mounted to the housingand configured to retain the tensioning assemblyin its strap-insertion position and, responsive to initiation of the tensioning cycle, to automatically release the tensioning assemblyand enable the tensioning assemblyto move (via the tensioning-assembly-biasing element) to its strap-tensioning position. The retaining assemblyincludes a retainer, a retainer mount, and a retainer biasing element.

The retainerincludes a bodywith a mounting earat one end, a tension-wheel-shaft engagerat the opposite end, and a biasing-element engagerprojecting from the bodybetween the mounting earand the tension-wheel-shaft engager. The retainer mountincludes a mounting pin attached to and projecting inward from the housing. The retaineris mounted to the retainer mountvia the mounting earso the retaineris rotatable about the retainer mountand relative to the tension-wheel shaft(and here the entire tensioning assembly) between a release position () and a retaining position (). The retainer biasing element(here, a torsion spring though it may include any suitable spring or other type of biasing element) exerts a force on the biasing-element engagerthat biases the retainertoward its retaining position.

As shown in, when the tensioning assemblyis in its strap-tensioning position, the retaineris in its release position. When the retaineris in its release position, the retainer biasing elementforces the tension-wheel-shaft engagerinto contact with the tension-wheel shaft. This force is low enough (e.g., the spring constant is sufficiently low and the coefficient of friction between the tension-wheel shaft and the tension-wheel-shaft engager is sufficiently low) so as not to affect the ability of the tension-wheel shaftto rotate during the tensioning cycle. As the operator moves the rocker leverfrom its home position to its actuated position (such as to release strap from the strapping tool), the tensioning assemblybegins rotating to its strap-insertion position. As the tensioning assemblyreaches its strap-insertion position, the tension-wheel shaftascends above the tension-wheel-shaft engager. When this occurs, the retainer biasing elementforces the retainer, which at this point is no longer blocked by the tension-wheel shaft, to rotate to its retaining position. When the retaineris in its retaining position, the retainer biasing elementforces the bodyinto contact with the tension-wheel shaft

At this point, as shown in, the tension-wheel-shaft engageris beneath (between the tension-wheel shaftand the footof the support) and engages the underside of the tension-wheel shaft. When the operator releases the rocker lever, the tension-wheel-shaft engagerprevents the tensioning assemblyfrom moving to its strap-tensioning position. The tensioning-assembly-biasing elementcauses the tension-wheel shaftto impose a force on the tension-wheel-shaft engager. This force is large enough to prevent the tension-wheel-shaft engagerfrom moving to its release position as the strapping toolis moved around. Additionally, the force the retainer-biasing elementcontinues to exert on the retaineracts to resist against the retainermoving to its release position. Upon initiation of the tensioning cycle, the tension-wheel shaftbegins rotating (counter-clockwise from the viewpoint shown in). The coefficient of friction between the tension-wheel shaftand the retaineris sufficiently high and the force the retainer biasing elementexerts on the retaineris sufficiently low so that the rotation of the tension-wheel shaftforces the retainerto rotate to its release position. As this occurs, the tensioning-assembly-biasing element forces the tensioning assemblyto its strap-tensioning position, at which point the tensioning assemblybegins tensioning the strap.

The ability of the retaining assembly to retain the tensioning assembly in its strap-insertion position reduces operator fatigue by: (1) eliminating the requirement for the operator to continuously hold the rocker lever against the force of the tensioning-assembly-biasing element in its actuated position while removing the strap from the strapping tool; and (2) eliminating the requirement for the operator to, when ready to insert another strap into the strapping tool for tensioning, pull the rocker lever and continuously hold it against the force of the tensioning-assembly-biasing element in its actuated position while inserting the strap into the strapping tool.

The retainer-activation assembly, which is best shown in, is configured to enable an operator of the strapping toolto activate or deactivate the ability of the retaining assemblyto retain the tensioning assemblyin its strap-insertion position. The retainer-activation assemblyincludes a retainer-activation switch, a retainer-activation-switch biasing element(which is a spring in this example embodiment but may be any other suitable biasing element), and first and second biasing-element retainersand(which are washers in this example embodiment but may be any other suitable components). The retainer-activation switchincludes a disc-shaped head, a shaftextending from and rotatable with the head, and a retainer engager(which is a cam in this example embodiment but may be any other suitable component) at the end of the shaftopposite the headand rotatable with the headand the shaft. The retainer-activation-switch biasing elementcircumscribes the shaftand is positioned between the headand the retainer engager. The biasing-element retainersandalso circumscribe the shaftand are positioned on opposite sides of the retainer-activation-switch biasing element.

The retainer-activation assemblyis mounted to the housingsuch that the headof the retainer-activation switchis outside the housing, the shaftof the retainer-activation switchextends through an opening (not labeled) in the housing, and the retainer engageris inside the housingand adjacent the retainer. The retainer-activation-switch biasing elementis in a compressed state and thus exerts a force against the housingand the retainer engagervia the biasing-element retainersand. This force acts to resist rotation of the retainer-activation switch.

The retainer-activation assemblyis mounted to the housingsuch that the retainer-activation switchis rotatable relative to the housingand the retainerof the retaining assemblybetween a deactivated position and an activated position. As shown in, when the retainer-activation switchis in its deactivated position, the retainer engageris positioned to engage the bodyof the retainerand hold the retainerin a deactivated position against the biasing force of the retainer biasing element. In this example embodiment, when the retaineris in its deactivated position, the retaineris oriented so the tension-wheel-shaft engageris disengaged from the tension-wheel shaftof the tensioning assembly(though in other embodiments the deactivated position and the release position of the retainerare the same). By holding the retainerin the deactivated position, the retainer-activation switchprevents the retainer biasing elementfrom rotating the retainerto its retaining position and into contact with the tension-wheel shaftwhen the operator moves the rocker leverfrom its home position to its actuated position (such as to release the strap from the strapping tool). This necessarily prevents the tension-wheel-shaft engagerfrom engaging the underside of the tension-wheel shaftand retaining the tensioning assemblyin its strap-insertion position when the operator releases the rocker lever. Accordingly, when the retainer-activation switchis in its deactivated position, it deactivates the ability of the retaining assemblyto retain the tensioning assemblyin its strap-insertion position.

As shown in, when the retainer-activation switchis in its activated position, the retainer engageris disengaged from the bodyand positioned to enable the retainerto rotate between its release and retaining positions and operate as described above with respect to. Thus, when the operator moves the rocker leverfrom its home position to its actuated position, the retainer biasing elementforces the retainerto rotate to its retaining position and contact the tension-wheel shaft. When the operator releases the rocker lever, the tension-wheel-shaft engagerof the retainerengages the underside of the tension-wheel shaftand prevents the tensioning assemblyfrom moving from its strap-insertion position to its strap-tensioning position. Accordingly, when the retainer-activation switchis in its activated position, it activates the ability of the retaining assemblyto retain the tensioning assemblyin its strap-insertion position.

The retainer-activation assemblythus provides operators the flexibility to choose whether they want to take advantage of the retaining assembly's ability to retain the tensioning assembly in its strap-insertion position, which may be desirable in certain use cases and not desirable in others. In certain embodiments, the tool includes the retaining assembly but not the retainer-activation assembly.

The gate assembly, which is best shown in, is configured to facilitate easy insertion of the strap and is adjustable to accommodate straps of differing thicknesses. The gate assemblyincludes a gateand multiple linkages,, and.

The gateis slidably received in the gate-receiving recessof the bodyof the supportand retained in that recess via a retaining bracket (not shown for clarity). A strap-receiving opening (not labeled) is defined between the bottom of the gateand the top surface of the footof the support. The gateis movable relative to the supportbetween a home position () and a retracted position (). When in the home position, the gateis positioned relative to the footso the height Hof the strap-receiving opening is equal to or just larger than the thickness of the particular strap to-be-tensioned and sealed. When in the retracted position, the gateis positioned relative to the footso the height Hof the strap-receiving opening is larger than the height H.

The position of the tensioning assemblycontrols the position of the gatevia the linkages,, and. The linkageis fixedly connected at one end to the tensioning assemblyand pivotably connected at the other end to one end of the linkage. The other end of the linkageis pivotably connected to one end of the linkage. The other end of the linkageis fixedly connected to the gate. The linkages,, andare sized, shaped, positioned, oriented, and otherwise configured such that: (1) when the tensioning assemblyis in the strap-tensioning position, the gateis in its home position (and the strap-receiving opening has the height H); and (2) when the tensioning assemblyis in its strap-insertion position, the gateis in its retracted position (and the strap-receiving opening has the height H). More specifically, when the tensioning assemblyis pivoted from the strap-tensioning position to the strap-insertion position, the linkageis pivoted counter-clockwise (from the viewpoint shown in). This causes the linkageto pivot clockwise, which forces the linkageto move upward and carry the gatewith it.

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

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

The position of the gaterelative to the footis also variable. Specifically, the gatecan be fixed to the linkagein any of several different vertical positions. By changing the vertical position of the gaterelative to the linkage, the operator can vary the height Hof the strap-receiving opening when the gateis in the home position. For instance, in this embodiment, the linkageis connected to the gatevia a screw. The screw extends through an elongated slot that extends along the length of the gate. To change the height Hof the strap-receiving opening when the gateis in its home position, the operator loosens the screw, slides the gateup or down relative to the linkage(taking advantage of the slot), and re-tightens the screw.

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

The gate assemblyof the present disclosure solves this problem by enabling the operator to vary the position of the gaterelative to the linkageand therefore the height Hof the strap-receiving opening when the gateis in its home position. This improves upon prior art strapping tools by enabling the operator to quickly and easily move the gate to accommodate straps of different thicknesses without having to swap out one gate for another.