[0001] The present disclosure relates to a strapping machine with an improved strap sealing bar. More specifically, the present disclosure relates to a strapping machine with an improved strap sealing bar, improved strap sealing bars, methods of manufacturing improved strap sealing bars, and methods of using a strapping machine with an improved strap sealing bar.
Background
[0002] Semiautomatic strapping machines are used to secure plastic strap around loads (such as around corrugated shipping boxes). One known semiautomatic strapping machine includes a pressing bar and a gripper. Initially, a leading end portion of the plastic strap extends from a strap supply through a strap receiving opening of the gripper and to the exterior of the strapping machine. An operator wraps the leading end portion of the plastic strap around the load before directing the leading end portion of the plastic strap back inside the strapping machine and to the gripper. Once a sensor (such as a limit switch or a micro switch) senses the leading end portion of the plastic strap, the gripper moves to hold the leading end portion of the plastic strap while a feed drive takes up the slack in and tensions the plastic strap around the load to a designated tension. The strapping machine aligns the leading end portion of the plastic strap with a trailing portion of the plastic strap (which at this point is still connected to the strap supply) while the pressing bar moves to engage and cut the trailing portion of the plastic strap from the strap supply to form a trailing end portion of the plastic strap. After a heating element heats the leading and trailing end portions of the plastic strap such that these portions of the plastic strap are nearly molten, the pressing bar presses the trailing end portion of the plastic strap against the leading end portion of the plastic strap to: (1) deboss the trailing end portion of the plastic strap;

and (2) connect the trailing end portion of the plastic strap to the leading end portion of the plastic strap to form a tensioned loop of plastic strap around the load.
[0003] One issue with this semiautomatic strapping machine is that the known pressing bar includes only two cutting edges on opposing sides of the pressing bar for cutting the plastic strap. Over time and after numerous uses, these cutting edges dull and become ineffective at cutting the plastic strap, which requires the operator to cease operation of the strapping machine and replace the pressing bar.
[0004] Another issue with this semiautomatic strapping machine is that the pressing bar makes a relatively simple debossment in the trailing end portion of the plastic strap. This simple debossment can be quickly and easily duplicated and therefore does not readily inhibit the contents of the load from being stolen during shipment by a person having access to the load. More specifically, during the shipment process, a person having access to the load can cut and remove the loop of strap from the load, remove the contents of the load, and tension and seal a replacement loop of plastic strap around the load using a pressing bar that forms a similar (or even identical) debossment. Due to this easily-duplicated debossment, it is often difficult to quickly identify if a load was tampered with or pilfered and, if so, exactly at what point during the shipment process this event occurred.
Summary
[0005] Various embodiments of the present disclosure provide a strapping machine with an improved strap sealing bar, an improved strap sealing bar with a tamper-evident debossing feature and four cutting edges, methods of manufacturing the improved strap sealing bar, and a method of operating a strapping machine with the improved strap sealing bar.
[0006] Various example embodiments of the present disclosure provide a strap sealing device for a strapping machine. The strap sealing device include a strap

sealing bar including (1) a strap engaging head, and (2) a body connected to and extending from the strap engaging head, the body configured to be mounted to the strapping machine. The strap engaging head includes (1) a strap engagement block comprising a top surface having multiple edges that form a perimeter of the top surface, wherein one of the edges is a cutting edge, and (2) a strap engagement wall set comprising multiple strap engagement walls integrally connected to and extending from the top surface and positioned inward of the edges of the top surface.
[0007] Various example embodiments of the present disclosure provide a method of operating a strapping machine to form a tensioned loop of strap around a load. The method includes: (1) holding a leading end portion of the strap against an anvil while tensioning the strap around the load; (2) moving a strap sealing bar such that one of three different cutting edges of the strap sealing bar cuts a trailing portion of the strap from a strap supply to form a trailing end portion of the strap, wherein the cutting edges at least partially form a perimeter of a top surface of the strap engaging head; (3) heating the leading end portion and the trailing end portion of the strap; (4) after heating the leading and trailing end portions of the strap, moving the strap sealing bar such that a strap engagement wall set of a strap engaging head of the strap sealing bar engages and debosses the trailing end portion of the strap while sandwiching the leading and trailing end portions of the strap against the anvil, wherein the strap engagement wall set includes multiple strap engagement walls that are positioned inward of edges that form a perimeter of a top surface of the strap engaging head; and (5) holding the strap sealing bar in place to enable the leading and trailing end portions of the strap to cool and fuse together to form the loop of strap.
Brief Description of the Figures
[0008] Figure 1 is a perspective view of an example embodiment of a strapping machine of the present disclosure.

[0009] Figure 2 is a diagrammatic fragmentary perspective view of certain interior components of the strapping machine of Figure 1 and including a first example embodiment of a strap sealing bar of the present disclosure.
[0010] Figure 3 is a diagrammatic side view of certain interior components of the strapping machine of Figure 1 and including the strap sealing bar of Figure 2.
[0011] Figure 4 is an enlarged diagrammatic fragmentary perspective view of certain interior components of the strapping machine of Figure 1 and including the strap sealing bar of Figure 2.
[0012] Figure 5 is an enlarged top perspective view of the strap sealing bar of Figure 2 shown removed from the strapping machine of Figure 1.
[0013] Figure 6 is an enlarged top view of the strap sealing bar of Figure 2 shown removed from the strapping machine of Figure 1.
[0014] Figure 7 is a first side view of the strap sealing bar of Figure 2 shown removed from the strapping machine of Figure 1.
[0015] Figure 8 is a second side view of the strap sealing bar of Figure 2 shown removed from the strapping machine of Figure 1.
[0016] Figure 9 is a fragmentary perspective view of a trailing end portion and a leading end portion of a plastic strap connected together using the strapping machine of Figure 1 and debossed using the strap sealing bar of Figures 1 and 2.
[0017] Figure 10 is an enlarged perspective view of another example embodiment of the strap sealing bar of the present disclosure shown removed from the strapping machine of Figure 1.
[0018] Figure 11 is an enlarged top view of the strap sealing bar of Figure 10 shown removed from the strapping machine of Figure 1.
[0019] Figure 12 is a first side view of the strap sealing bar of Figure 10 shown removed from the strapping machine of Figure 1.
[0020] Figure 13 is a second side view of the strap sealing bar of Figure 10 shown removed from the strapping machine of Figure 1.

[0021] Figure 14 is a fragmentary perspective view of a trailing end portion and a leading end portion of a plastic strap connected together using the strapping machine of Figure 1 and debossed using the strap sealing bar of Figure 10.
[0022] Figure 15 is a flowchart illustrating an example method of manufacturing the strap sealing bar of the present disclosure.
[0023] Figure 16 is a diagrammatic fragmentary side view of the strapping machine of Figure 1 and showing a first gripper holding a leading end portion of a plastic strap and the strap sealing bar of Figure 2 before engaging and cutting the trailing portion of the plastic strap to form the trailing end portion of the plastic strap.
[0024] Figure 17 is a diagrammatic fragmentary side view of the strapping machine of Figure 1 and showing the first gripper holding the leading portion of the plastic strap and the strap sealing bar of Figure 2 engaging and cutting the trailing portion of the plastic strap to form the trailing end portion of the plastic strap.
[0025] Figure 18 is a diagrammatic fragmentary side view of the strapping machine of Figure 1 and showing a heating blade inserted between the leading end portion of the plastic strap and the trailing end portion of the plastic strap and the strap sealing bar of Figure 2 starting to deboss the trailing end portion of the plastic strap.
[0026] Figure 19 is a diagrammatic fragmentary side view of the strapping machine of Figure 1 after the heat blade has been removed from being between the leading end portion of the plastic strap and the trailing end portion of the plastic strap, and the strap sealing bar of Figure 2 debossing the trailing end portion of the plastic strap.
Detailed Description
[0027] While the features, devices, and apparatus described herein may be embodied in various forms, the drawings show and the specification describe 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 coupled, mounted, connected, and the like, are not intended to be limited to direct mounting methods but should be interpreted broadly to include indirect and operably coupled, 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.
Example Strapping Machine and Method of Operation
[0028] Turning now to the figures, Figures 1, 2, 3, 4, 16, 17, 18, and 19 generally illustrate an example embodiment of a strapping machine 10 of the present disclosure that is configured to employ an example strap sealing bar 100 of the present disclosure. As generally shown in Figures 16, 17, 18, and 19, the strapping machine 10 is generally configured to form a tensioned loop 80 of plastic strap S (sometimes referred to herein as the “tensioned loop 80” for brevity) around the load 96. The method of forming the tensioned loop 80 includes in part cutting a trailing portion of the plastic strap S from a strap supply (not shown) to form a trailing end portion 88 of the plastic strap S and connecting that trailing end portion 88 of the plastic strap S to a leading end portion 84 of the plastic strap S. The method also includes debossing the trailing end portion 88 of the plastic strap S. The load 96 in this illustrated example embodiment includes a corrugated box, though the load may include any suitable item

or items. The strap S may be made of any suitable material such as, but not limited to, polypropylene or polyethylene terephthalate (PET).
[0029] This illustrated example strapping machine 10 generally includes, among other components: (1) a housing 12 that supports and houses the various components of the strapping machine 10; (2) an anvil 20; (3) a first gripper 26 defining a strap receiving opening 27; (4) the strap sealing bar 100; (5) a second gripper 30; (6) a heater element 36; (7) a strap feeder 40; (8) a first gripper cam 46; (9) a sealing bar cam 50; (10) a second gripper cam 56; (11) heater element cam (not shown); (12) a camshaft (not labeled) to which the first gripper cam 46, the sealing bar cam 50, the second gripper cam 56, and the heater element cam are fixedly connected to rotate with the camshaft; (13) a drive 60 (such as an electromagnetic clutch, a motor, or any other suitable actuator); (14) a controller (not shown); and (15) various sensors (such as limit switches, micro switches, and the like, not shown).
[0030] The controller is communicatively connected to the sensors to receive signals from the sensors and is operatively connected to the strap feeder 40 and the drive 60 to control operation of these components based on the signals received from the sensors. Briefly, in a typical operation, the controller controls the components of the strapping machine 10 to perform a strapping cycle including: (1) a gripping cycle to hold the leading end portion 84 of the strap S responsive to determining receipt of the leading end portion 84 of the plastic strap S at the first gripper 26; (2) a tensioning cycle to tension the plastic strap S around the load 96; and (3) a sealing cycle to: (i) cut the trailing portion of the plastic strap S from the strap supply to form the trailing end portion 88 of the plastic strap S; (ii) attach the trailing end portion 88 of the plastic strap S to the leading end portion 84 of the plastic strap S to form the tensioned loop 80 around the load 96; and (iii) deboss the trailing end portion 88.
[0031] More specifically, before the strapping cycle has begun, the controller operates in standby mode and awaits a leading-end-portion detection signal from a first gripper sensor (not shown) associated with the first gripper 26 that

indicates that the leading end portion 84 of the strap S has been received at the first gripper 26. When the operator wraps the leading end portion 84 of the strap S around the load 96 and inserts the leading end portion 84 into the strapping machine 10 and near the first gripper 26, the first gripper sensor senses the presence of the leading end portion 84 and sends the leading-end-portion detection signal to the controller. In response, the controller starts the gripping cycle and controls the drive 60 to begin rotating the camshaft and therefore the cams connected to the camshaft. The cams are shaped such that this rotation of the camshaft causes the first gripper cam 46 to push the first gripper 26 upward and into contact with the leading end portion 84 of the strap S to hold the leading end portion 84 against the underside of the anvil 20 (Figure 16). Once a first gripper cam sensor (not shown) senses that the first gripper cam 46 has rotated enough to cause the first gripper 26 to contact and hold the leading end portion 46 of the strap S against the anvil 20 (such as 45 degrees), the first gripper cam sensor sends a corresponding signal to the controller. This causes the controller to stop controlling the drive 60 to rotate the camshaft, end the gripping cycle, and start the tensioning cycle.
[0032] In the tensioning cycle, as the first gripper 26 firmly holds the leading end portion 84 of the strap S against the anvil 20, the controller controls the strap feeder 40 to retract the strap S to take up the slack and tension the strap S around the load 96. Once a designated tension is reached in the strap S, another sensor (not shown) sends a corresponding signal to the controller. This causes the controller to stop controlling the strap feeder 40 to retract the strap S, end the tensioning cycle, and start the sealing cycle.
[0033] In the sealing cycle, as the first gripper 26 firmly holds the leading end portion 84 of the strap S against the anvil 20, the controller again controls the drive 60 to continue rotating the camshaft (and the connected cams). The cams are shaped such that this further rotation of the camshaft causes: (1) the second gripper cam 56 to move the second gripper 30 upward and into contact with a trailing portion of the

plastic strap S to hold the trailing portion against the underside of the anvil; (2) the sealing bar cam 50 to move the strap sealing bar 100 upward such that the strap sealing bar 100 contacts the strap S and a cutting edge (explained below) of the strap sealing bar 100 cuts the strap S from the strap supply and adjacent the strap receiving opening 27 of the first gripper 26 to form a trailing end portion 88 of the strap S (Figure 17); and (3) the heater element cam to move the heater element 36 in between the leading edge portion 84 and the trailing edge portion 88 of the strap S.
[0034] The strap sealing bar 100 presses against the bottom surface of the trailing edge portion 88 to sandwich the trailing edge portion 88, the heater element 36, and the leading edge portion 84 against the underside of the anvil 20. The heater element 36 heats the bottom of the leading edge portion 84 and the top of the trailing edge portion 88 of the strap S. The cams are shaped such that continued rotation of the camshaft enables the first gripper cam sealing bar 100 to move downward (such as in response to a biasing force applied by a biasing member) to release the pressure on the heater element 36 and to enable the heater element 36 to move from between the leading end portion 84 and the trailing end portion 88 (such as in response to a biasing force applied by a biasing member).
[0035] The sealing bar cam 50 is shaped such that continued rotation of the camshaft causes the sealing bar cam 50 to push the strap sealing bar 100 back upward to press against the bottom surface of the trailing end portion 88 to sandwich the trailing edge portion 88 and the leading end portion 84 against the underside of the anvil 20. At this point the leading end portion 84 and the trailing end portion 88 are almost molten, and a strap engagement wall set (explained below) in the strap sealing bar 100 debosses the bottom surface of the trailing end portion 88 as the strap sealing bar 100 presses against the trailing end portion 88. The controller controls the drive 60 to stop rotating the camshaft for a designated period of time, such as 0.3 to 0.6 seconds, to enable the leading and trailing end portions to cool while the strap sealing

bar 100 sandwiches them against the anvil 20. As the leading and trailing end portions cool, they fuse together to form the tensioned loop 80.
[0036] Afterwards, the controller controls the drive 60 to again begin rotating the camshaft. The cams are shaped such that the first gripper 26, the second gripper 30, and the strap sealing bar 100 move downward to release the strap S from the anvil 20 and such that the anvil 20 moves (such as via the camshaft and a corresponding cam and cam follower) relative to the first and second grippers, the strap sealing bar, and the tensioned loop to release the tensioned loop and enable the load to be removed from the strapping machine. This completes the sealing cycle.
[0037] The size of the area of the plastic strap at which the leading and trailing end portions connect to one another (sometimes referred to herein as the “connection area”) depends on the type of strapping machine and type of plastic strap.
[0038] This example strapping machine 10 is meant to be a non-limiting example of the strapping machine provided by the present disclosure, and the strap sealing bars of the present disclosure can be employed with other suitable strapping machines (such as, but not limited, to other semi-automatic strapping machines or automatic strapping machines) in accordance with the present disclosure.
First Example Strap Sealing Bar
[0039] Figures 2, 3, 4, 5, 6, 7, 8, 16, 17, 18, and 19 illustrate the first example strap sealing bar 100 of the present disclosure. In this illustrated example embodiment, the strap sealing bar 100 generally includes: (a) a strap engaging head 110; and (b) a body 150 integrally connected to and extending from the strap engaging head 110. Figures 2, 3, 4, 5, 6, 7, 8, 16, 17, 18, and 19 primarily show two sides of the strap sealing bar 100. In this illustrated example embodiment, each of the two opposite sides of the strap sealing bar 100 that are not shown are identical to the two sides of the strap sealing bar 100 that are shown. In other words, in this illustrated example embodiment,

the first side and the opposing third side are identical, and the second side and the opposing fourth side are identical.
[0040] The strap engaging head 110 is configured to engage and deboss the trailing end portion 88 of the plastic strap and to compress the trailing end portion 88 and the leading end portion 84 of the plastic strap S against the anvil 20 to connect these two end portions 84 and 88 of the plastic strap S as generally shown in Figure 9. The debossed trailing end portion 88 of the plastic strap and the connected leading end portion 84 of the plastic strap S have been inverted in Figure 9 for illustrative purposes. The body 150 is configured to receive and be removably mounted on and connected to a suitable strap sealing bar support member (not shown) that is configured to support the strap sealing bar 100 and that includes a cam follower in the form of a roller (such as a bearing) that in turn engages the sealing bar cam 50.
[0041] More specifically, the strap engaging head 110 includes: (a) a strap engagement block 112; and (b) a strap engagement wall set 113 including a plurality of strap engagement walls integrally connected to and extending from a top surface 114 of the strap engagement block 112.
[0042] The strap engagement block 112 is integrally connected to the body 150 in this illustrated example embodiment. The strap engagement block 112 includes a generally cube-shaped solid body. The body of the strap engagement block 112 includes a top surface 114; four side surfaces 116, 117, 118, and 119; and four cutting edges 120, 121, 122, and 123. Respective portions of the four side surfaces 116, 117, 118, and 119 and portions of the top surface 114 meet to form the four cutting edges 120, 121, 122, and 123. More specifically, each of the top portions of the four side surfaces 116, 117, 118, and 119 intersect respective end portions of top surface 114 at an angle that is 90 degrees or approximately 90 degrees to form the four cutting edges 120, 121, 122, and 123. Each of the four cutting edges 120, 121, 122, and 123 is configured to be positioned in the housing 12 (and, particularly, relative to the first gripper 26) to cut a trailing portion of the plastic strap S (to form the trailing end

portion 88) when the strap engagement block 112 moves relative to the first gripper 26 as generally explained above and shown in Figures 16 and 17. As further discussed below, the walls of the strap engagement wall set 113 are spaced inwardly from each of the four cutting edges 120, 121, 122, and 123. When a cutting edge (such as cutting edge 120) wears out or becomes dull, the strap sealing bar 100 can be detached from clevis (not shown), partially rotated (90 degrees), and re-attached to the clevis (not shown) such that another cutting edge (such as cutting edge 121) can be employed for cutting the plastic strap S. In this way, each of the four cutting edges 120, 121, 122, and 123 of the strap sealing bar 100 of the present disclosure can be employed before having to replace the strap sealing bar 100. This substantially extends the life of the strap sealing bar 100 of the present disclosure. The engagement wall set 113 of the strap sealing bar 100 of the present disclosure is configured to enable the strap sealing bar 100 to be employed in any of these four different rotational positions and to still deboss the trailing end portion 88 of the plastic strap S and connect trailing end portion 88 to the leading end portion 84 of the plastic strap S.
[0043] In this illustrated example embodiment, this is partially achieved by providing a generally square pattern for the strap engagement wall set 113 of the strap sealing bar 100 that is symmetrical about: (a) a first vertical plane extending through a center longitudinal axis of the strap sealing bar from the first side of the strap sealing bar to the third opposing side of the strap sealing bar; (b) a second vertical plane extending through the center longitudinal axis of the strap sealing bar from the second side of the strap sealing bar to the fourth opposing side of the strap sealing bar; (c) a third vertical plane extending through the center longitudinal axis of the strap sealing bar from a first corner of the strap sealing bar to a third opposing corner of the strap sealing bar; and (d) a fourth vertical plane extending through the center longitudinal axis of the strap sealing bar from a second corner of the strap sealing bar to a fourth opposing corner of the strap sealing bar. In this illustrated example embodiment, the

debossment in the trailing end portion 88 of the strap S is thus identical regardless of which of the four different rotational positions the strap sealing bar 100 is oriented in.
[0044] In other example embodiments of the present disclosure that are not shown, the strap engagement wall set of the strap sealing bar that is symmetrical about one or more of the following but not all of the following: (a) a first vertical plane extending through a center longitudinal axis of the strap sealing bar from the first side of the strap sealing bar to the third opposing side of the strap sealing bar; (b) a second vertical plane extending through the center longitudinal axis of the strap sealing bar from the second side of the strap sealing bar to the fourth opposing side of the strap sealing bar; (c) a third vertical plane extending through the center longitudinal axis of the strap sealing bar from a first corner of the strap sealing bar to a third opposing corner of the strap sealing bar; and (d) a fourth vertical plane extending through the center longitudinal axis of the strap sealing bar from a second corner of the strap sealing bar to a fourth opposing corner of the strap sealing bar.
[0045] Returning to the illustrated sealing bar 100, each of the plurality of strap engagement walls of the engagement wall set 113 are integrally connected to and extend upwardly from the top surface 114 of the strap engagement block 112. The engagement wall set 113 in this illustrated example embodiment includes: (a) a plurality of outer strap engagement walls 124a, 124b, 124c, and 124d; (b) a plurality of first inner strap engagement walls 126a, 126b, 126c, 126d, 126e, 126f, 126g, and 126h; and (c) a plurality of second inner strap engagement walls 128a, 128b, 128c, 128d, 128e, 128f, 128g, and 128h. All of these walls of the strap engagement wall set 113 are spaced inwardly from each of the four cutting edges 120, 121, 122, and 123. These plurality of outer strap engagement walls, the plurality of first inner strap engagement walls, and the plurality of second inner strap engagement walls form a relatively complicated symmetrical strap engagement wall pattern. In this illustrated example embodiment, the pattern is a grid that defines a plurality of partially enclosed cavities (as further described below). The complicated pattern may vary in accordance with the present

disclosure as further discussed below. The quantity of strap engagement walls and cavities may also vary in accordance with the present disclosure as further discussed below.
[0046] In this illustrated example embodiment, each of the plurality of outer walls 124a, 124b, 124c, and 124d includes opposing end portions (not labeled). These respective end portions are connected to each other to form a rectangular and particularly a square shaped perimeter. In this illustrated example embodiment, each of the plurality of outer walls 124a, 124b, 124c, and 124d is respectively spaced apart from each of the four cutting edges 120, 121, 122, and 123 at a same predetermined distance. Two or more of these distances may vary in accordance with the present disclosure.
[0047] In this illustrated example embodiment, the plurality of first inner
strap engagement walls 126a, 126b, 126c, 126d, 126e, 126f, 126g, and 126h and the plurality of second inner strap engagement walls 128a, 128b, 128c, 128d, 128e, 128f, 128g, and 128h are formed within the perimeter formed by the plurality of outer strap engagement walls 124a, 124b, 124c, and 124d. One or more of the inner strap engagement walls may extend outside of the perimeter in accordance with the present disclosure.
[0048] In this illustrated example embodiment, the plurality of first inner strap engagement walls 126a, 126b, 126c, 126d, 126e, 126f, 126g, and 126h and the plurality of second inner strap engagement walls 128a, 128b, 128c, 128d, 128e, 128f, 128g, and 128h are formed such that the plurality of first inner strap engagement walls extend in a first direction and the plurality of second inner strap engagement walls extend in a second different direction that is transverse to (and in this illustrated example embodiment that is perpendicular to) the first direction. These angles of intersection may vary in accordance with the present disclosure. One or more of the angles of intersection may vary in accordance with the present disclosure.
[0049] In this illustrated example embodiment, each of the plurality of first inner strap engagement walls 126a, 126b, 126c, 126d, 126e, 126f, 126g, and 126h and

the plurality of second inner strap engagement walls 128a, 128b, 128c, 128d, 128e, 128f, 128g, and 128h includes opposite end portions respectively integrally connected to two opposing outer strap engagement walls 124. The opposite end portions need not be integrally connected to the outer strap engagement walls in accordance with the present disclosure.
[0050] In this illustrated example embodiment, each of the plurality of first inner strap engagement walls 126a, 126b, 126c, 126d, 126e, 126f, 126g, and 126h includes a plurality of intermediate portions that respectively intersect and are integrally connected with intermediate portions of the plurality of second inner strap engagement walls 128a, 128b, 128c, 128d, 128e, 128f, 128g, and 128h. These respective intermediate portions do not need to or all need to intersect or be integrally connected in accordance with the present disclosure.
[0051] In this illustrated example embodiment, each of the plurality of outer strap engagement walls 124a, 124b, 124c, and 124d; the plurality of first inner strap engagement walls 126a, 126b, 126c, 126d, 126e, 126f, 126g, and 126h; and the plurality of second inner strap engagement walls 128a, 128b, 128c, 128d, 128e, 128f, 128g, and 128h include a bottom end (not labeled) and a top end (not labeled). The bottom end of each of these strap engagement walls is integrally connected to the top surface 114 of the strap engagement block 112. The top end of each of these strap engagement walls includes a strap engagement surface (not labeled) for directly engaging the trailing end portion 88 of the plastic strap S. In this illustrated example embodiment, each of these strap engagement surfaces is generally flat. One or more of these strap engagement surfaces can alternatively configured such as having one or more pointed edges.
[0052] In this illustrated example embodiment, the heights and widths of each of the plurality of outer strap engagement walls 124a, 124b, 124c, and 124d; the plurality of first inner strap engagement walls 126a, 126b, 126c, 126d, 126e, 126f, 126g, and 126h; and the plurality of second inner strap engagement walls 128a, 128b, 128c,

128d, 128e, 128f, 128g, and 128h are the same as or substantially the same as each other. One or more of the strap engagement walls can be alternatively sized in accordance with the present disclosure.
[0053] In this illustrated example embodiment, the plurality of outer strap engagement walls 124a, 124b, 124c, and 124d, the plurality of first inner strap engagement walls 126a, 126b, 126c, 126d, 126e, 126f, 126g, and 126h, and the plurality of second inner strap engagement walls 128a, 128b, 128c, 128d, 128e, 128f, 128g, and 128h define a plurality of partially or generally cube shaped partially enclosed cavities (not labeled). Each of the cavities is: (1) enclosed on five sides by the top surface 114 and by four of the respective strap engagement walls; and (2) open at the top. The plurality of cavities are configured such that when the strap sealing bar 100 engages and debosses the trailing end portion 88 of the plastic strap S, the pressure applied by the strap sealing bar 100 is concentrated on the strap engagement surfaces, and portions of the plastic strap S compressed by the strap engagement surfaces are forcefully expelled into the these cavities. One or more of the plurality of cavities can be alternatively sized and shaped in accordance with the present disclosure.
[0054] The body 150 is integrally connected to and extends downwardly from the strap engaging head 110. The body 150 includes: (a) an upper portion 152; and (b) a lower portion 160 integrally connected to and extending downwardly from the upper portion 152.
[0055] In this illustrated example embodiment, the upper portion 152 of the body 150 includes a partially solid body having: (a) a first side surface 151a; (b) a second side surface 151b; (c) a third side surface (not labeled); and (d) a fourth side surface (not labeled). The body of the upper portion 152 includes: (a) a first threaded cylindrical inner surface 154 that extends in the first transverse direction and that defines a threaded first element receiving bore 155; and (b) a second threaded cylindrical inner surface 156 that extends in a second transverse direction and that defines a second element receiving bore 157. A first entrance to the first element receiving channel 155

is defined in the center of the first side surface 151a, and a second entrance to the first element receiving channel 155 is defined in the center of the third side surface. A first entrance to the second element receiving channel 157 is defined in the center of the second side surface 151b, and a second entrance to the second element receiving channel 157 is defined in the center of the fourth side surface. The first element receiving channel 155 extends transversely to the second element receiving channel 157 and both extend transversely with respect to the central longitudinal axis of the strap sealing bar 100. The first element receiving channel 155 and the second element receiving channel 157 intersect each other within the upper portion 152 of the body 150 as generally shown in Figures 7 and 8. The first element receiving channel 155 is configured to receive a first attachment element 78 as generally shown in Figures 2, 3, 4, 16, 17, 18, and 19. Likewise, the second element receiving channel 157 is configured to receive the first attachment element 78 when the strap sealing bar 100 is in a rotated position (as discussed above). Each of the first element receiving channel 155 and the second element receiving channel 157 is configured to receive the first attachment element 78 from either side to facilitate the strap sealing bar 100 being mountable and usable in any of the four different rotational positions.
[0056] In this illustrated example embodiment, the first side surface 151a, the second side surface 151b, the third side surface, and the fourth side surface of the upper portion 152 of the body 150 are respectively connected to and lie in a same plane as each of the respective side surfaces of the strap engagement block 112.
[0057] In this illustrated example embodiment, the upper portion 152 of the body 150 further includes: (a) a first chamfered side surface 158a; (b) a second chamfered side surface 158b; (c) a third chamfered side surface (not labeled) opposing the first chamfered side surface 158a; and (d) a fourth chamfered side surface 158d opposing the second chamfered side surface 158b. The first chamfered side surface 158a connects the first side surface 151a and the second side surface 151b. The second chamfered side surface 158b connects the second side surface 151b and the third side

surface. The third chamfered side surface connects the third side surface and the fourth side surface. The fourth chamfered side surface 158d connects the fourth side surface and the first side surface 151a. Thus, when viewed in cross-section taken along a plane perpendicular to the longitudinal axis of the strap sealing bar 100, the external side surfaces of the upper portion 152 of the body 150 have an octagonal shape. These chamfered surfaces define lubrication-receiving cavities when the strap sealing bar 100 is received in its corresponding cavity in the housing 12 sized to receive and house lubricating oil to facilitate smooth movement of the strap sealing bar 100 within the cavity.
[0058] In this illustrated example embodiment, the lower portion 160 of the body 150 is integrally connected to and extends downwardly from the upper portion 152 of the body 150. The lower portion 160 generally includes: (a) a first wall (not labeled) having an first outer surface 161a and a first inner surface (not labeled); (b) a second wall (not labeled) having a second outer surface 161b and a second inner surface (not labeled); (c) a third wall (not labeled) having a third outer surface (not labeled) and a third inner surface (not labeled); and (d) a fourth wall (not labeled) having a fourth outer surface (not labeled) and a fourth inner surface (not labeled). The first outer surface 161a, the second outer surface 161b, the third outer surface, and the fourth outer surface of the lower portion 160 of the body 150 respectively lie in the same planes as the first outer surface 151a, the second outer surface 151b, the third outer surface, and the fourth outer surface of the upper portion 152 of the body 150.
[0059] The lower portion 160 of the body 150 further includes a bottom surface 164 that is at the bottom ends of the first, second, third, and fourth walls of the lower portion 160 of the body 150. The first inner surface, the second inner surface, the third inner surface, and the fourth inner surface of the lower portion 160 of the body 150 define a receiving slot 162 that has a generally rectangular cross section. The bottom surface 164 defines the entrance to the receiving slot 162. The lower portion

160 of the body 150 also defines transversely extending locking element receipt bores 165 and 167.
[0060] More specifically, the lower portion 160 of the body 150 includes: (a) a first cylindrical inner surface 164 that extends in the first transverse direction and that defines a cylindrical first locking element receiving bore 165; and (b) a second cylindrical inner surface 166 that extends in a second transverse direction and that defines a cylindrical second locking element receiving bore 167. A first entrance to the first locking element receiving bore 165 is defined in the first side surface 161a, and a second entrance to the first locking element receiving bore 165 is defined in the third side surface. A first entrance to the second locking element receiving bore 167 is defined in the second side surface 161b, and a second entrance to the second locking element receiving bore 167 is defined in the fourth side surface. The first locking element receiving bore 165 extends transversely to the second locking element receiving bore 167 and both extend transversely with respect to the central longitudinal axis of the strap sealing bar 100. The first locking element receiving bore 165 and the second locking element receiving bore 167 intersect each other as generally shown in Figures 7 and 8.
[0061] In this illustrated example embodiment, the first locking element receiving bore 165 (and the surface that defines this bore) is not continuous or is formed from multiple spaced apart sections because the receiving slot 162 extends transversely to the first locking element receiving bore 165. Likewise, the second locking element receiving bore 167 (and the surface that defines this bore) is not continuous or is formed from multiple spaced apart sections because the receiving slot 162 extends transversely to the second locking element receiving bore 167.
[0062] In this illustrated example embodiment, the lower portion 160 of the body 150 further includes: (a) a first chamfered side surface 168a; (b) a second chamfered side surface 168b; (c) a third chamfered side surface (not labeled); (d) a fourth chamfered side surface 168d; (e) a first chamfered bottom surface 169a; (f) a

second chamfered bottom surface 169b; (g) a third chamfered bottom surface (not labeled); (h) a fourth chamfered bottom surface (not labeled); (i) a first bottom corner surface (not labeled); (j) a second bottom corner surface (not labeled); (k) a third bottom corner surface (not labeled); and (l) a fourth bottom corner surface (not labeled). The chamfered surfaces facilitate easy insertion of the strap sealing bar 100 into its corresponding cavity in the housing 12.
[0063] As noted above, the strap sealing bar 100 is mountable to a strap sealing bar support member and to the housing 12 such that rotation of the camshaft causes reciprocal motion of the strap sealing bar 100 relative to the housing 12. To mount the strap sealing bar 100 to the strap sealing bar support member, a compression spring (not shown) is longitudinally positioned in the receiving slot 162. A post of the strap sealing bar support member (that is opposite the cam follower) is then inserted into the receiving slot 162 to (at least partially) compress the spring until a locking element receiving channel of the post is aligned with one of the locking element receiving bores 165 and 167, depending on the orientation of the strap sealing bar 100. The locking element receiving channel of the post is offset from the longitudinal axis of the post, which is why the locking element receiving bores 165 and 167 are not aligned with the element receiving channels 155 and 157. A locking element, such as a pin (not shown), is then inserted into the locking element receiving bore 165 or 167 such that the locking element extends into the locking element receiving bore of the post. This locks the strap sealing bar support member to the strap sealing bar 100 with the cam follower extending below the bottom of the strap sealing bar 100. Each of the first locking element receiving bore 165 and the second locking element receiving bore 167 is configured to receive the locking pin from either side to facilitate the strap sealing bar 100 being mountable and usable in any of the four different rotational positions.
[0064] To mount the strap sealing bar 100 and the attached strap sealing bar support member to the housing, a first attachment element 78 is inserted into the one of the element receiving channels 155 or 157, depending on the orientation of the strap

sealing bar 100, as generally shown in Figures 2, 3, 4, 16, 17, 18, and 19. Each of the first element receiving channel 155 and the second element receiving channel 157 is configured to receive the first attachment element 78 from either side to facilitate the strap sealing bar 100 being mountable and usable in any of the four different rotational positions. After the first attachment element 78 is received in one of the first element receiving channel 155 and the second element receiving channel 157 (based on the position of the strap sealing bar 100), a spring (not labeled) is connected at one end to the first attachment element 78 and at the other end to the housing (not labeled) such that the spring biases the strap sealing bar 100 and the attached strap sealing bar support member downward such that the cam follower (not shown) engages the sealing bar cam 50. The rotation of the camshaft causes the sealing bar cam 50 to rotate, which in turn causes reciprocal motion of the strap sealing bar 100 via contact with the cam follower.
Second Example Strap Sealing Bar
[0065] Figures 10, 11, 12, and 13 illustrate a second example strap sealing bar 1000 of the present disclosure. In this illustrated example embodiment, the strap sealing bar 1000 generally includes: (a) a strap engaging head 1110; and (b) a body 1150 integrally connected to and extending downwardly from the strap engaging head 1110. Figures 10, 11, 12, and 13 primarily show two sides of the strap sealing bar 1000. In this illustrated example embodiment, the two opposite sides of the strap sealing bar 1000 that are not shown are identical to the two sides of the strap sealing bar 100 that are shown (except with regard to the strap engagement wall set 1113). The strap engaging head 1110 is configured to engage the trailing end portion 88 and compress the trailing end portion 88 and the leading end portion 84 of the plastic strap S against the anvil 20 to connect these two end portions 84 and 88 of the plastic strap S as generally shown in Figure 14. The strap engaging head 1110 is also configured to deboss the trailing end

portion 88 of the plastic strap S as generally shown in Figure 14. The debossed trailing end portion 88 and the connected leading end portion 84 of the plastic strap S have been inverted in Figure 14 for illustration purposes.
[0066] The strap engaging head 1110 includes: (a) a strap engagement block 1112; and (b) a strap engagement wall set 1113 extending from the top surface 1114 of the strap engagement block 1112.
[0067] In this illustrated example embodiment, the strap engagement block
1112 is the same as the strap engagement block 112 of the first example strap sealing
bar 100 as shown in Figures 2, 3, 4, 5, 7, and 8. Thus, for brevity, the strap engagement
block 1112 will not be described again.
[0068] Likewise, in this illustrated example embodiment, the body 1150 is the same as the body 150 of the first example strap sealing bar 100 as shown in Figures 2, 3, 4, 5, 7, and 8. Thus, for brevity, the body 1150 will not be described again.
[0069] In this illustrated example embodiment, the strap engagement wall set 1113 is different from the strap engagement wall set 113. The strap engagement wall set 1113 includes a plurality of strap engagement walls integrally connected to and extending from the top surface 1114 of the strap engagement block 1112. In this illustrated example embodiment, the plurality of strap engagement walls include: (a) a plurality of first strap engagement walls 1124a, 1124b, 1124c, 1124d, and 1124e; (b) a plurality of second strap engagement walls 1126a, 1126b, 1126c, 1126d, 1126e, 1126f, 1126g, and 1126h; and (c) a plurality of third strap engagement walls 1128a, 1128b, 1128c, 1128d, 1128e, 1128f, 1128g, 1128h, 1128i, 1128j, 1128k, 1128l, 1128m, 1128n, 1128o, 1128p, 1128q, and 1128r. All of these walls of the strap engagement wall set
1113 are spaced inwardly from each of the four cutting edges 1120, 1121, 1122, and
1123.
[0070] These strap engagement walls form a relatively complicated pattern. In this illustrated example embodiment, the pattern is in the form of three adjacent separated different shapes that generally correspond to the inverted capital letters S, I,

and G. In these illustrated embodiments, multiple strap engagement walls define each of these inverted letters, and each of these inverted letters partially defines one of the cavities.
[0071] This type of complicated letter related pattern may vary in accordance with the present disclosure. In other words, the present disclosure contemplates the use of any suitable of inverted letters, numerals, or other symbols and combinations thereof. Inverted shapes are used so that they form the letters, numerals, or other symbols of the debossment in a readable orientation. The present disclosure contemplates that the letters, numeral, or symbols may vary in size, shape, font, and/or style. The quantity and placement of the shapes may vary in accordance with the present disclosure.
[0072] In this illustrated example embodiment, two or more of the plurality of first strap engagement walls 1124a, 1124b, 1124c, 1124d, and 1124e form an irregular shape. In this illustrated example embodiment, two or more of the plurality of first strap engagement walls 1124a, 1124b, 1124c, 1124d, and 1124e are respectively spaced apart from the four cutting edges 1120, 1121, 1122, and 1123 at different distances. These distances may vary in accordance with the present disclosure.
[0073] In this illustrated example embodiment, the plurality of second strap
engagement walls 1126a, 1126b, 1126c, 1126d, 1126e, 1126f, 1126g, and 1126h, and the plurality of third strap engagement walls 1128a, 1128b, 1128c, 1128d, 1128e, 1128f, 1128g, 1128h, 1128i, 1128j, 1128k, 1128l, 1128m, 1128n, 1128o, 1128p, 1128q, and 1128r are generally formed within a boundary of the plurality of first strap engagement walls 1124a, 1124b, 1124c, 1124d, and 1124e. One or more of the second and/or third strap engagement walls may extend outside of the boundary in accordance with the present disclosure.
[0074] In this illustrated example embodiment, the plurality of second strap
engagement walls 1126a, 1126b, 1126c, 1126d, 1126e, 1126f, 1126g, and 1126h each have one or more curvatures and thus extend in multiple different directions, are

connected to one or more of the plurality of first strap engagement walls 1124a, 1124b, 1124c, 1124d, and 1124e, and are connected to one or more of the plurality of third strap engagement walls 1128a, 1128b, 1128c, 1128d, 1128e, 1128f, 1128g, 1128h, 1128i, 1128j, 1128k, 1128l, 1128m, 1128n, 1128o, 1128p, 1128q, and 1128r.
[0075] In this illustrated example embodiment, the plurality of third strap engagement walls 1128a, 1128b, 1128c, 1128d, 1128e, 1128f, 1128g, 1128h, 1128i, 1128j, 1128k, 1128l, 1128m, 1128n, 1128o, 1128p, 1128q, and 1128r are each straight, are connected to one or more of the plurality of first strap engagement walls 1124a, 1124b, 1124c, 1124d, and 1124e, and are connected to one or more of the plurality of second strap engagement walls 1126a, 1126b, 1126c, 1126d, 1126e, 1126f, 1126g, and 1126h.
[0076] In this illustrated example embodiment, the plurality of second strap engagement walls 1126a, 1126b, 1126c, 1126d, 1126e, 1126f, 1126g, and 1126h do not transversely intersect with the first strap engagement walls 1124a, 1124b, 1124c, 1124d, and 1124e. One or more of the second and/or third strap engagement walls may transversely intersect with one or more of the first strap engagement walls in accordance with the present disclosure.
[0077] In this illustrated example embodiment, the plurality of second strap engagement walls 1126a, 1126b, 1126c, 1126d, 1126e, 1126f, 1126g, and 1126h transversely intersect the plurality of third strap engagement walls 1128a, 1128b, 1128c, 1128d, 1128e, 1128f, 1128g, 1128h, 1128i, 1128j, 1128k, 1128l, 1128m, 1128n, 1128o, 1128p, 1128q, and 1128r at angles other than right angles (e.g., at angles other than perpendicularly). These angles of intersection may vary in accordance with the present disclosure.
[0078] In this illustrated example embodiment, each of the plurality of first strap engagement walls 1124a, 1124b, 1124c, 1124d, and 1124e; the plurality of second inner strap engagement walls 1126a, 1126b, 1126c, 1126d, 1126e, 1126f, 1126g, and 1126h; and the plurality of third strap engagement walls 1128a, 1128b, 1128c, 1128d,

1128e, 1128f, 1128g, 1128h, 1128i, 1128j, 1128k, 1128l, 1128m, 1128n, 1128o, 1128p, 1128q, and 1128r include a bottom end (not labeled) and a top end (including a top surface) (not labeled). The bottom end of each of these strap engagement walls is integrally connected to the top surface 1114 of the strap engagement block 1112. The top end of each of these strap engagement walls includes a strap engagement surface (not labeled) for directly engaging the trailing end portion 88 of the plastic strap S. In this illustrated example embodiment, each of these strap engagement surfaces is generally flat. One or more of these strap engagement surfaces can alternatively configured as having pointed edges.
[0079] In this illustrated example embodiment, the height and width of each of the plurality of first strap engagement walls 1124a, 1124b, 1124c, 1124d, and 1124e; the plurality of second strap engagement walls 1126a, 1126b, 1126c, 1126d, 1126e, 1126f, 1126g, and 1126h; and the third strap engagement walls 1128a, 1128b, 1128c, 1128d, 1128e, 1128f, 1128g, 1128h, 1128i, 1128j, 1128k, 1128l, 1128m, 1128n, 1128o, 1128p, 1128q, and 1128r are the same as or substantially the same as each other. The strap engagement walls can be alternatively sized in accordance with the present disclosure.
[0080] In this illustrated example embodiment, the plurality of first strap engagement walls 1124a, 1124b, 1124c, 1124d, and 1124e; the plurality of second strap engagement walls 1126a, 1126b, 1126c, 1126d, 1126e, 1126f, 1126g, and 1126h; and the plurality of third strap engagement walls 1128a, 1128b, 1128c, 1128d, 1128e, 1128f, 1128g, 1128h, 1128i, 1128j, 1128k, 1128l, 1128m, 1128n, 1128o, 1128p, 1128q, and 1128r define a plurality of irregular shaped and sized different cavities (not labeled). Each of the cavities is enclosed by the top surface 1114 and on multiple sides by a plurality of the respective strap engagement walls. The plurality of irregular shaped and sized cavities are configured, such that when the strap sealing bar 1000 engages the trailing end portion 88 and debosses the trailing end portion 88 of the plastic strap S, the pressure applied by the strap sealing bar 1000 is concentrated on the strap

engagement surfaces, and portions of the plastic strap S compressed by the strap engagement surfaces are forcefully expelled into the plurality of irregular shaped and sized cavities.
[0081] In this illustrated example embodiment, the relative distances between the second strap engagement walls 1126a and 1126b vary (as shown by the wider section of the S) such that the shape and sizes (such as the width) of the different portions of the cavity between these engagement walls are different. Likewise, in this illustrated example embodiment, the relative distances between the second strap engagement walls 1126c and 1126d vary (as shown by the wider section of the G) such that the shape and size of the portions of the cavity between these engagement walls vary.
[0082] The engagement wall set 1113 of the strap sealing bar 1000 is configured to deboss the trailing end portion 88 of plastic strap S as generally shown in Figure 14. The engagement wall set 1113 provides a debossment of the trailing end portion 88 of plastic strap S that adds additional security to the strapped load. More specifically, this debossment of the plastic strap S is customized such that it is relatively difficult to quickly and easily duplicate. That is, if a person cuts the loop to obtain access to the strapped load 96 (and steal contents of the load), it is difficult for the person to deboss a replacement strap with the same debossment without knowing the complicated pattern on the debossed strap S. Thus, immediately after the person accesses the load 96 and applies a replacement loop using a different debossment (i.e., without the above-described complicated debossment), the debossment used for the strapped load will enable someone inspecting the load to quickly determine that the load has been tampered with. In other words, the replacement of the debossed strap S with another debossment can be immediately, easily, and quickly checked for and determined at each different point in the shipment process. Using an engagement wall set with a combination of inverted letters such as the engagement wall set 1113 enables the debossment to also represent an entity (such as a companies name, initials, or logo)

that is quickly identifiable. This can assist the senders, shippers, and/or receivers of the loads in determining at what point in the shipping process that the load was tampered with, and in addressing these issues to prevent this tampering at that point in the future. The debossment will also indicate to the receiver that a strapped load has not been tampered with or pilfered.
[0083] In alternative example embodiments of the present disclosure, one or more of the shapes (such as the inverted letters) do not have spaces between walls that define such letters. In these alternative example embodiments, the cavities are defined outside of the letters, and specifically outside of the strap engagement walls that define such letters.
Example Method of Manufacturing Strap Sealing Bar
[0084] The strap sealing bars of the present disclosure may be manufactured in any suitable manner in accordance with the present disclosure. In various example embodiments, the method of manufacturing the strap sealing bar of the present disclosure generally includes: (a) acquiring a solid block; (b) forming the receiving slot in the bottom of the solid block to partially form the body; (c) forming the element receiving bores in the solid block to partially form the body; (d) forming the chamfered sides in the solid block to partially form the body; and (e) forming the strap engagement wall set to form the strap engaging head.
[0085] Figure 15 more specifically illustrates one example method of manufacturing the strap sealing bar 100 of the present disclosure.
[0086] This example method 4000 includes acquiring a solid block as indicated by block 4010. In various embodiments, the solid block is a solid steel block made of a high-carbon, high-chromium (HCHC) steel containing approximately 1.5 to 2.35% carbon and approximately 12% chromium. In various embodiments, the solid steel block is approximately 21x21x70 mm.

[0087] This example method 4000 includes forming the receiving slot 162 in the bottom of the solid block, and more specifically includes drilling a hole in the bottom surface of the solid block as indicated by block 4020. In various embodiments, the method includes drilling the hole to a predetermined depth of approximately 46.5 mm from the bottom surface of the solid block.
[0088] This example method 4000 includes forming the locking element receiving bores 165 and 167 in the solid block, and more specifically includes drilling transverse holes in the side walls of the solid block as indicated by block 4030. In various embodiments, each of the locking element receiving bores has an inner diameter of approximately 3 mm. In various embodiments, each of the locking element receiving bores is off center and is approximately 6 mm away from a side edge of the solid block.
[0089] This example method 4000 includes forming the first and second element receiving bores 155 and 157 in the solid block, and more specifically includes drilling intersecting transverse holes in the side walls of the solid block as indicated by block 4040. In various embodiments, each element receiving bore has an inner diameter of approximately 11 mm. In various embodiments, the center of each of these bores is approximately 53 mm from the bottom surface of the solid block.
[0090] This example method 4000 includes chamfering the side and bottom edges of the solid block as indicated by block 4050.
[0091] This example method 4000 includes performing a milling operation on the external surfaces of the solid block as indicated by block 4060. In various embodiments, the milling operation removes material to a depth of approximately 0.25mm to obtain smooth surfaces. In various embodiments, the milling operation includes using rotary cutters to remove the material by advancing the solid block in a direction at an angle to the axis of rotation of the rotary cutters.

[0092] This example method 4000 includes applying heat to the solid block as indicated by block 4070. In various embodiments, the solid block is heated to achieve a predetermined Rockwell scale (e.g., HRC of 58).
[0093] This example method 4000 includes grinding the surfaces of the block to predetermined dimensions as indicated by block 4080.
[0094] This example method 4000 includes preparing an electrode configuration for the strap engagement wall set as indicated by block 4090. That is, the electrode configuration corresponds to the desired debossment and, therefore, the desired configuration for the strap engagement wall set.
[0095] This example method 4000 includes transferring the electrode configuration to the solid block via electrical discharge machining, as indicated by block 4100. Note that this transfer causes the walls of the strap engagement wall set to be spaced from the top edges of the top surface of the block so that the cutting edges 120, 121, 122, and 123 can be formed.
[0096] This example method 4000 includes sharpening the top edges of the top surface of the solid block to form the cutting edges 120, 121, 122, and 123 of the strap engaging head 110 as indicated by block 4110.
[0097] This example method 4000 includes cleaning the block including the bores 155, 157, 165, and 167 in the solid block as indicated by block 4120.
[0098] The order of these steps may vary in accordance with the present disclosure.
[0099] Thus, in various embodiments, the present disclosure provides a strap sealing device for a strapping machine, the strap sealing device comprising: a strap sealing bar comprising: a strap engaging head comprising: a strap engagement block comprising a top surface having multiple edges that form a perimeter of the top surface, wherein one of the edges is a cutting edge, and a strap engagement wall set comprising multiple strap engagement walls integrally connected to and extending from the top surface and positioned inward of the edges of the top surface; and a body

connected to and extending from the strap engaging head, the body configured to be mounted to the strapping machine.
[00100] In various such embodiments of this strap sealing device, two of the strap engagement walls intersect one another to at least partially define a cavity.
[00101] In various such embodiments of this strap sealing device, two of the strap engagement walls form at least part of an inverted letter and at least partially define a cavity.
[00102] In various such embodiments of this strap sealing device, the strap engaging head includes first, second, third, and fourth sides, wherein the first and third sides are opposite one another and the second and fourth sides are opposite one another, wherein the strap engagement walls form a pattern that is symmetrical about one or more of: (1) a first plane including a center longitudinal axis of the strap sealing bar and extending between the first side of the strap engaging head and the third side of the strap engaging head; (2) a second plane including the center longitudinal axis and extending between the second side of the strap engaging head and the fourth side of the strap engaging head; (3) a third plane including the center longitudinal axis and extending between an intersection of the first and second sides of the strap engaging head and an intersection of the third and fourth sides of the strap engaging head; and (4) a fourth plane including the center longitudinal axis of the sealing bar and extending between an intersection of the first and fourth sides of the strap engaging head and an intersection of the second and third sides of the strap engaging head.
[00103] In various such embodiments of this strap sealing device, the pattern is symmetrical about each of the first, second, third, and fourth planes.
[00104] In various such embodiments of this strap sealing device, a first strap engagement wall intersects a second strap engagement wall and a third strap engagement wall such that the top surface and the first, second, and third strap engaging walls partially define multiple cavities.

[00105] In various such embodiments of this strap sealing device, two of the cavities are of different sizes or different shapes.
[00106] In various such embodiments of this strap sealing device, the strap engagement walls include a plurality of first strap engagement walls, a plurality of second strap engagement walls, and a plurality of third strap engagement walls, wherein each of the second strap engagement walls intersects each of the third strap engagement walls.
[00107] In various such embodiments of this strap sealing device, the strap engaging head includes first, second, third, and fourth sides, wherein the top surface of the strap engagement block comprises a first cutting edge on the first side of the strap engaging head, a second cutting edge on the second side of the strap engaging head, a third cutting edge on the third side of the strap engaging head, and a fourth cutting edge on the fourth side of the strap engaging head.
[00108] In various such embodiments of this strap sealing device, the first and third sides of the strap engaging head are opposite one another, the second and fourth sides of the strap engaging head are opposite one another, the first and third cutting edges are opposite one another, and the second and fourth cutting edges are opposite one another.
[00109] In various such embodiments of this strap sealing device, the body comprises opposing first and third sides and opposing second and fourth sides, the body defining a first locking member receiving bore extending between the first and third sides and a second locking member receiving bore extending between the second and fourth sides, wherein the body is partially hollow and defines a receiving slot aligned with a center longitudinal axis of the strap sealing bar.
[00110] Various such embodiments of this strap sealing device further comprise a strap sealing bar support member including a post and a cam follower, wherein the post defines a locking channel and is sized to be received in the receiving slot of the body and configured to be locked to the body via a locking member received

in one of the first and second locking member receiving channels and in the locking channel.
[00111] In various such embodiments of this strap sealing device, two of the strap engagement walls intersect one another to at least partially define a cavity.
[00112] In various embodiments, the present disclosure also provides a method of operating a strapping machine to form a tensioned loop of strap around a load, the method comprising: holding a leading end portion of the strap against an anvil while tensioning the strap around the load; moving a strap sealing bar such that one of three different cutting edges of the strap sealing bar cuts a trailing portion of the strap from a strap supply to form a trailing end portion of the strap, wherein the cutting edges at least partially form a perimeter of a top surface of the strap engaging head; heating the leading end portion and the trailing end portion of the strap; after heating the leading and trailing end portions of the strap, moving the strap sealing bar such that a strap engagement wall set of a strap engaging head of the strap sealing bar engages and debosses the trailing end portion of the strap while sandwiching the leading and trailing end portions of the strap against the anvil, wherein the strap engagement wall set comprises multiple strap engagement walls that are positioned inward of edges that form a perimeter of a top surface of the strap engaging head; and holding the strap sealing bar in place to enable the leading and trailing end portions of the strap to cool and fuse together to form the loop of strap.
[00113] In various such embodiments of this method, two of the strap engagement walls at least one of: intersect one another to at least partially define a cavity and form at least part of an inverted letter.
[00114] In various embodiments, the present disclosure also provides strap sealing bar for a strapping machine, the strap sealing bar comprising: a strap engaging head comprising: a strap engagement block having a top surface and a cutting edge, and a strap engagement wall set comprising multiple strap engagement walls integrally connected to and extending from the top surface, wherein two of the strap engagement

walls intersect one another such that the top surface and the intersecting strap engaging walls partially define a cavity; and a body connected to and extending from the strap engaging head.
[00115] In various such embodiments of this strap sealing bar, the strap engagement walls define a pattern that is symmetrical about one or more of: (a) a first vertical plane extending through a center longitudinal axis of the strap sealing bar from the first side of the sealing bar to the third opposing side of the strap sealing bar; (b) a second vertical plane extending through the center longitudinal axis of the strap sealing bar from the second side of the sealing bar to the fourth opposing side of the strap sealing bar; (c) a third vertical plane extending through the center longitudinal axis of the strap sealing bar from a first corner of the sealing bar to a third opposing corner of the strap sealing bar; and (d) a fourth vertical plane extending through the center longitudinal axis of the strap sealing bar from a second corner of the strap sealing bar to a fourth opposing corner of the sealing bar.
[00116] In various such embodiments of this strap sealing bar, the strap engagement walls define a pattern that is symmetrical about: (a) a first vertical plane extending through a center longitudinal axis of the strap sealing bar from the first side of the strap sealing bar to the third opposing side of the strap sealing bar; (b) a second vertical plane extending through the center longitudinal axis of the strap sealing bar from the second side of the strap sealing bar to the fourth opposing side of the strap sealing bar; (c) a third vertical plane extending through the center longitudinal axis of the strap sealing bar from a first corner of the strap sealing bar to a third opposing corner of the strap sealing bar; and (d) a fourth vertical plane extending through the center longitudinal axis of the strap sealing bar from a second corner of the strap sealing bar to a fourth opposing corner of the strap sealing bar.
[00117] In various such embodiments of this strap sealing bar, a first strap engagement wall intersects a second strap engagement wall and a third strap

engagement wall such that the top surface and the first, second, and third strap engaging walls partially define multiple cavities.
[00118] In various such embodiments of this strap sealing bar, two of the cavities are of different sizes or different shapes.
[00119] In various such embodiments of this strap sealing bar, two portions of the cavity have different widths.
[00120] In various such embodiments of this strap sealing bar, the strap engagement walls include a plurality of outer strap engagement walls connected to one another and form an outer perimeter of the strap engagement wall set.
[00121] In various such embodiments of this strap sealing bar, the strap engagement walls include a plurality of first strap engagement walls, a plurality of second strap engagement walls, and a plurality of third strap engagement walls, wherein each of the second strap engagement walls intersects each of the third strap engagement walls.
[00122] In various such embodiments of this strap sealing bar, a first plurality of the strap engagement walls are curved and a second plurality of the strap engagement walls are straight.
[00123] In various such embodiments of this strap sealing bar, one of the strap engagement walls form an inverted letter.
[00124] In various such embodiments of this strap sealing bar, two of the strap engagement walls form at least part of an inverted letter with at least part of the cavity between said two strap engagement walls.
[00125] In various such embodiments of this strap sealing bar, the strap engaging block further comprises four side surfaces and four cutting edges formed at respective intersections of the top surface and the four side surfaces.
[00126] In various such embodiments of this strap sealing bar, the strap engagement walls are spaced inwardly from the four cutting edges.

[00127] In various embodiments, the present disclosure also provides a strap sealing bar for a strapping machine, the strap sealing bar comprising: a strap engaging head comprising: a strap engagement block having a top surface, four side surfaces, and four cutting edges formed at respective intersections of the top surface and the four side surfaces, a strap engagement wall set comprising multiple strap engagement walls integrally connected to and extending from the top surface, the strap engagement walls are spaced inwardly from the four cutting edges, wherein multiple of the strap engagement walls intersect one another such that the top surface and the intersecting strap engaging walls partially define multiple cavities; and a body connected to and extending from the strap engaging head.
[00128] In various such embodiments of this strap sealing bar, two of the cavities are of different sizes or different shapes.
[00129] In various such embodiments of this strap sealing bar, two portions of the cavity have different widths.
[00130] In various such embodiments of this strap sealing bar, the strap sealing bar further comprises a high-carbon high-chromium steel.
[00131] In various such embodiments of this strap sealing bar, the strap sealing bar further comprises approximately 1.5 to 2.35% carbon.
[00132] In various such embodiments of this strap sealing bar, the strap sealing bar further comprises approximately 12% chromium.
[00133] In various embodiments, the present disclosure also provides a strap sealing bar for a strapping machine, the strap sealing bar comprising: a strap engaging head comprising: a strap engagement block having a top surface and a cutting edge, and a strap engagement wall set comprising multiple strap engagement walls integrally connected to and extending from the top surface, wherein two of the strap engagement walls form at least part of an inverted letter and define at least part of a cavity between said two strap engagement walls; and a body connected to and extending from the strap engaging head.

[00134] In various such embodiments of this strap sealing bar, the strap engagement walls define a pattern of inverted letters.
[00135] In various such embodiments of this strap sealing bar, a first strap engagement wall intersects a second strap engagement wall and a third strap engagement wall such that the top surface and the first, second, and third strap engaging walls partially define multiple cavities.
[00136] In various such embodiments of this strap sealing bar, two of the cavities are of different sizes or different shapes.
[00137] In various such embodiments of this strap sealing bar, two portions of the cavity have different widths.
[00138] In various such embodiments of this strap sealing bar, a first plurality of the strap engagement walls are curved and a second plurality of the strap engagement walls are straight.
[00139] In various such embodiments of this strap sealing bar, the strap engaging block further comprises four side surfaces and four cutting edges formed at respective intersections of the top surface and the four side surfaces.
[00140] In various such embodiments of this strap sealing bar, the strap sealing bar further comprises a high-carbon high-chromium steel.
[00141] In various such embodiments of this strap sealing bar, the strap sealing bar further comprises approximately 1.5 to 2.35% carbon.
[00142] In various such embodiments of this strap sealing bar, the strap sealing bar further comprises approximately 12% chromium.
[00143] In various embodiments, the present disclosure also provides a strap sealing machine having any of the strap sealing devices or the strap sealing bars described above.
[00144] In various embodiments, the present disclosure also provides a method of manufacturing a strap sealing bar having a body and a strap engaging head having a strap engagement block, the method comprising: forming a receiving slot in a

bottom of a solid metal block to partially form the body; forming element receiving bores in the solid metal block to partially form the body; forming a cutting edge in the solid metal block to partially form the strap engagement block; and forming a strap engagement wall set in the solid metal block by transferring an electrode configuration to the solid metal block to partially form the strap engaging head.
[00145] In various such embodiments of this method, the solid metal block comprises a solid steel block comprising a high-carbon high-chromium steel.
[00146] In various such embodiments of this method, the solid metal block comprises a solid steel block comprising approximately 1.5 to 2.35% carbon.
[00147] In various such embodiments of this method, the solid metal block comprises a solid steel block comprising approximately 12% chromium.
[00148] In various such embodiments of this method, the method further comprises forming a plurality of cutting edges in the strap engagement block.
[00149] In various such embodiments of this method, the method further comprises forming a four cutting edges in the strap engagement block, wherein a first cutting edge is opposite a third cutting edge, and a second cutting edge is opposite a fourth cutting edge.
[00150] In various such embodiments of this method, forming the strap engagement wall set further comprises forming multiple strap engagement walls integrally connected to and extending from a top surface of the strap engagement block.
[00151] In various such embodiments of this method, forming the strap engagement wall set includes forming multiple strap engagement walls integrally connected to and extending from the top surface, wherein two of the strap engagement walls intersect one another such that the top surface and the intersecting strap engaging walls partially define a cavity.
[00152] In various embodiments, the present disclosure also provides a method of manufacturing a strap sealing bar having a body and a strap engaging head

having a strap engagement block, the method comprising: forming a receiving slot in a bottom of the solid metal block to partially form the body; forming element receiving bores in the solid metal block to partially form the body; forming a cutting edge in the solid metal block to partially form the strap engagement block; and forming a strap engagement wall set in the solid metal block to partially form the strap engaging head, the forming comprising forming multiple strap engagement walls integrally connected to and extending from the top surface, wherein two of the strap engagement walls intersect one another such that the top surface and the intersecting strap engaging walls partially define a cavity.
[00153] In various such embodiments of this method, the solid metal block comprises a solid steel block comprising a high-carbon high-chromium steel.
[00154] In various such embodiments of this method, the solid metal block comprises a solid steel block comprising approximately 1.5 to 2.35% carbon.
[00155] In various such embodiments of this method, the solid metal block comprises a solid steel block comprising approximately 12% chromium.
[00156] In various such embodiments of this method, the method further comprises forming a plurality of cutting edges in the strap engagement block.
[00157] In various such embodiments of this method, the method further comprises forming a four cutting edges in the strap engagement block, wherein a first cutting edge is opposite a third cutting edge, and a second cutting edge is opposite a fourth cutting edge.
[00158] In various embodiments, the present disclosure also provides a method of manufacturing a strap sealing bar having a body and a strap engaging head having a strap engagement block, the method comprising: forming a receiving slot in a bottom of the solid metal block to partially form the body; forming element receiving bores in the solid metal block to partially form the body; forming a cutting edge in the solid metal block to partially form the strap engagement block; and forming a strap engagement wall set in the solid metal block to partially form the strap engaging head,

the forming comprising forming a strap engagement wall set comprising multiple strap engagement walls integrally connected to and extending from the top surface, wherein two of the strap engagement walls form at least part of an inverted letter and define at least part of a cavity between said two strap engagement walls.
[00159] In various embodiments, the present disclosure also provides a method of operating a strapping machine to tension a loop of strap around a load, the method comprising: holding a leading end portion of the strap while tensioning the strap around the load; cutting a trailing portion of the strap from a strap supply to form a trailing end portion of the strap; connecting the trailing end portion of the strap to the leading end portion of the strap to form the loop of strap; and moving a strap sealing bar such that a strap engagement wall set of the strap sealing bar engages and debosses the trailing end portion of the strap, wherein the strap engagement wall set comprises multiple intersecting strap engagement walls that partially define a partially enclosed cavity.
[00160] In various embodiments, the present disclosure also provides a method of operating a strapping machine to tension a loop of strap around a load, the method comprising: holding a leading end portion of the strap while tensioning the strap around the load; cutting a trailing portion of the strap from a strap supply to form a trailing end portion of the strap; connecting the trailing end portion of the strap to the leading end portion of the strap to form the loop of strap; and moving a strap sealing bar such that a strap engagement wall set of the strap sealing bar engages and debosses the trailing end portion of the strap, wherein the strap engagement wall set comprises multiple intersecting strap engagement walls that partially define a partially enclosed cavity.
[00161] Various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. These changes and modifications can be made without departing from the spirit and scope of

the present subject matter and without diminishing its intended advantages. It is intended that such changes and modifications be covered by the appended claims.

I/We Claim:
1. A strap sealing device for a strapping machine, the strap sealing device
comprising:
a strap sealing bar comprising:
a strap engaging head comprising:
a strap engagement block comprising a top surface having multiple edges that form a perimeter of the top surface, wherein one of the edges is a cutting edge, and
a strap engagement wall set comprising multiple strap engagement walls integrally connected to and extending from the top surface and positioned inward of the edges of the top surface; and
a body connected to and extending from the strap engaging head, the body configured to be mounted to the strapping machine.
2. The strap sealing device of claim 1, wherein two of the strap engagement walls intersect one another to at least partially define a cavity.
3. The strap sealing device of claim 1, wherein two of the strap engagement walls form at least part of an inverted letter and at least partially define a cavity.
4. The strap sealing device of claim 1, wherein the strap engaging head includes first, second, third, and fourth sides, wherein the first and third sides are opposite one another and the second and fourth sides are opposite one another, wherein the strap engagement walls form a pattern that is symmetrical about one or more of: (1) a first plane including a center longitudinal axis of the strap sealing bar and extending between the first side of the strap engaging head and the third side of the strap engaging head; (2) a second plane including the center longitudinal axis and

extending between the second side of the strap engaging head and the fourth side of the strap engaging head; (3) a third plane including the center longitudinal axis and extending between an intersection of the first and second sides of the strap engaging head and an intersection of the third and fourth sides of the strap engaging head; and (4) a fourth plane including the center longitudinal axis of the sealing bar and extending between an intersection of the first and fourth sides of the strap engaging head and an intersection of the second and third sides of the strap engaging head.
5. The strap sealing device of Claim 4, wherein the pattern is symmetrical about each of the first, second, third, and fourth planes.
6. The strap sealing device of Claim 1, wherein a first strap engagement wall intersects a second strap engagement wall and a third strap engagement wall such that the top surface and the first, second, and third strap engaging walls partially define multiple cavities.
7. The strap sealing device of Claim 6, wherein two of the cavities are of different sizes or different shapes.
8. The strap sealing device of Claim 1, wherein the strap engagement walls include a plurality of first strap engagement walls, a plurality of second strap engagement walls, and a plurality of third strap engagement walls, wherein each of the second strap engagement walls intersects each of the third strap engagement walls.
9. The strap sealing device of Claim 1, wherein the strap engaging head includes first, second, third, and fourth sides, wherein the top surface of the strap engagement block comprises a first cutting edge on the first side of the strap engaging head, a second cutting edge on the second side of the strap engaging head, a third

cutting edge on the third side of the strap engaging head, and a fourth cutting edge on the fourth side of the strap engaging head.
10. The strap sealing device of Claim 9, wherein the first and third sides of the strap engaging head are opposite one another, the second and fourth sides of the strap engaging head are opposite one another, the first and third cutting edges are opposite one another, and the second and fourth cutting edges are opposite one another.
11. The strap sealing device of claim 10, wherein the body comprises opposing first and third sides and opposing second and fourth sides, the body defining a first locking member receiving bore extending between the first and third sides and a second locking member receiving bore extending between the second and fourth sides, wherein the body is partially hollow and defines a receiving slot aligned with a center longitudinal axis of the strap sealing bar.
12. The strap sealing device of claim 11, further comprising a strap sealing bar support member including a post and a cam follower, wherein the post defines a locking channel and is sized to be received in the receiving slot of the body and configured to be locked to the body via a locking member received in one of the first and second locking member receiving channels and in the locking channel.
13. The strap sealing device of claim 9, wherein two of the strap engagement walls intersect one another to at least partially define a cavity.
14. A method of operating a strapping machine to form a tensioned loop of strap around a load, the method comprising:
holding a leading end portion of the strap against an anvil while tensioning the strap around the load;

moving a strap sealing bar such that one of three different cutting edges of the strap sealing bar cuts a trailing portion of the strap from a strap supply to form a trailing end portion of the strap, wherein the cutting edges at least partially form a perimeter of a top surface of the strap engaging head;
heating the leading end portion and the trailing end portion of the strap;
after heating the leading and trailing end portions of the strap, moving the strap sealing bar such that a strap engagement wall set of a strap engaging head of the strap sealing bar engages and debosses the trailing end portion of the strap while sandwiching the leading and trailing end portions of the strap against the anvil, wherein the strap engagement wall set comprises multiple strap engagement walls that are positioned inward of edges that form a perimeter of a top surface of the strap engaging head; and
holding the strap sealing bar in place to enable the leading and trailing end portions of the strap to cool and fuse together to form the loop of strap.
15. The strap sealing device of claim 14, wherein two of the strap engagement walls at least one of: intersect one another to at least partially define a cavity and form at least part of an inverted letter.