Powered Crimping Tool to Secure a Cap Onto a Bottle or Vial

1. Field of the Invention

The present invention relates to a powered crimping tool used to secure a cap onto a bottle or vial. The powered tool has a housing portion which the user holds and includes switches for the user to control the crimping action. The crimping action results from a motor causing a plunger to move downward, thereby initially closing a plurality of jaws and continuing downward to cooperate with the jaws to secure the cap on the bottle or vial. Means are provided to adjust the starting point of the crimping cycle or the plunger upper limit, as well as the finishing point of the crimping cycle or the plunger lower limit.

2. Description of the Prior Art

Some bottles or vials to contain liquid samples or other laboratory materials have an opening thereinto which includes a lip onto which a cap is crimped to seal the bottle or vial. In general, for example, the cap can be aluminum or steel, with sample diameters of from about 8 mm to about 22 mm, or greater. Typically the cap has a cylindrical portion which fits over the bottle lip and is then crimped thereunder; the cap has a top with a circular opening therein; the inside of the cap contains a rubber circular portion next to the cap and a Teflon circular portion next to the bottle, although many variations are known. In use, a sample is placed into the bottle or vial and a cap is placed thereon. A crimping tool is then employed to crimp the cap onto the bottle. When a portion of the sample is to be removed, a syringe is inserted through the rubber and Teflon circular portions and the desired amount of the sample is removed.

U.S. Pat. No. 5,579,626, to Applicant Thomas, incorporated herein by reference, teaches a manually operated crimping tool for securing a cap onto a bottle or vial. That invention teaches the use of jaws 70 and a manually driven plunger 50 which have a similar vertically downward crimping movement to the instant invention without the adjustment means for the crimping cycle. That reference teaches horizontal handle movement resulting in vertical plunger movement.

U.S. Pat. No. 4,987,722, to Koebbeman, teaches a hand-held bottle cap crimper having a pair of horizontal crimping handles, one upper fixed handle and one lower lever handle which moves about a single pivot point to move a crimper, the pivot point being between jaws and the handles so that the tool functions in a see saw fashion.

U.S. Pat. No. 4,745,729, to Bethge et al., teaches a container closing apparatus used to put on a screw cap. U.S. Pat. No. 3,998,032, to Koebbeman, teaches a hand-held bottle cap crimper having a pair of horizontal crimping handles, one lower fixed handle and one upper lever handle which moves about a single pivot point to move a crimper, the jaws being between the pivot point and the handles.

U.S. Pat. No. 3,332,211, to Koll et al., teaches a cap applying apparatus. U.S. Pat. No. 3,217,519, to Demler, teaches a coaxial crimping tool. U.S. Pat. No. 2,415,896, to Marsh et al., a cap applying implement.

U.S. Pat. No. 5,327,697, to Kent, teaches a chuck for a bottle capper. U.S. Pat. No. 3,771,284, to Boeckmann et al., teaches a capping apparatus. Finally, U.S. Pat. No. 3,747,441, to Amtsberg et al., teaches a pneumatic tool having combined nut running and crimping mechanism.

The present invention relates to a powered crimping tool used to secure a cap onto a bottle or vial. The powered tool has a vertical housing portion which the user holds while activating the crimping action. The crimping action results from a motor causing a plunger to move downward, thereby initially closing a plurality of jaws and continuing downward to cooperate with the jaws to secure the cap on the bottle or vial. Means are provided to adjust the starting point of the crimping cycle or the plunger upper limit, as well as the finishing point of the crimping cycle or the plunger lower limit.

More particularly, the present invention comprises a housing containing a battery-operated motor. A speed reduction system having a ratio of about 64 to 1 causes a plunger lead screw to rotate at a speed of about 1/64th the motor speed. The plunger lead screw has a threaded drive shaft which is threadably received within the plunger threaded drive channel. Rotation of the plunger lead screw threaded drive shaft results in vertical movement of the plunger, as limited by the plunger hex guide members vertical travel within the hex plunger channel in an insert. With the plunger toward its upper limit, the powered crimping tool is in a "jaws open" position, whereby a portion of the jaws fit into an hour glass shaped portion of the plunger to permit the jaws to be open. As the plunger moves downward, the jaws close and then, as the plunger continues downward, a cap is crimped onto a vial or bottle by the cooperation of the plunger and the jaws. Preferably, the jaws are retained about the plunger by a circular spring, band, or other confining means which tries to pull the jaws together toward their upper end, as limited by the plunger.

Both the upper and lower limits of the plunger can be adjusted. The total movement of plunger from the upper to lower limit and back to the upper limit is controlled. Further, once the plunger has moved through a pre-set vertical distance, the plunger will complete one crimping cycle without the user having to continue to engage a control. This frees the user to concentrate on the crimping operation.

Further, the present invention comprises a crimping tool, having a housing containing a motor therein; a plunger movable by the motor between a start position and a stop position; a plurality of jaws extending from the housing, each of the plurality of jaws having an upper opening portion and a lower crimping portion with an arcuate plunger slide area therebetween; the crimping portion having an inward crimping lip; the plurality of jaws and the plunger being in an abutting relationship; the jaws being in an open position when the plunger is at the start position and in a closed position when the plunger is at the stop position; and, means for electronically adjusting the stop position. The tool can also include means for electronically adjusting the start position.

Finally, the present invention is for a powered crimping tool, comprising: a housing containing a motor therein, the housing having a trigger switch, a rocker switch, and a reset switch; the housing containing a circuit board having a controller operably connected thereto, the trigger switch, the rocker switch, and the reset switch being operably connected to the controller; the motor includes a pulse disk on a motor powered shaft and where the tool includes a pulse sensor, the motor powered shaft being operably connected through a speed reduction system and a plunger lead screw to a plunger movable between a start position with a value of "x" counts and a stop position having a value of "y" counts; where, by operation of the trigger switch and the motor thereby, the controller will cause the motor powered shaft to rotate until the pulse sensor has detected a first selected number of pulses with a value of "y-x" counts from the pulse disk to move the piston from the start to the stop position, unless a stall condition is detected, and when the first selected number of pulses has been detected or the stall condition is detected, the motor powered shaft will rotate to return the piston to the start position; a plurality of jaws extending from the housing, each of the plurality of jaws having an upper opening portion and a lower crimping portion with an arcuate plunger slide area therebetween; the crimping portion having an inward crimping lip; the plurality of jaws and the plunger being in an abutting relationship; the jaws being in an open position when the plunger is at the start position and in a closed position when the plunger is at the stop position; where, when the tool is in a reset mode, the rocker switch can be pressed to adjust the start position and the value of "x" counts"; and, where, when the tool is in a crimp mode, the rocker switch can be pressed to adjust the stop position and the value of "y" counts. Also, the plunger may have a no return position with a value of "z" counts, the no return position being intermediate of the start position and the stop position; and, where, upon activation of the trigger switch with the tool in the crimp mode, after the plunger has moved a value of "z-x" counts, the activation of the trigger switch becomes unnecessary for the controller to move the plunger an additional "y-z" to the stop position, unless the stall condition is detected, and to return the piston to the start position.

A better understanding of the present invention will be had upon reference to the following description in conjunction with the accompanying drawings, wherein:

FIG. 1 shows a first perspective view of the tool of the present invention;

FIG. 2 shows a second perspective view of the tool of FIG. 1, the tool being rotated about 90.degree. clockwise from the view of FIG. 1;

FIG. 3 shows a exploded view of the tool of FIGS. 1 and 2 with a portion of the housing and insert removed to show how the housing receives the various components;

FIG. 4 shows a cross-sectional view of the tool of FIGS. 1 and 2 along the lines 4--4 of FIG. 2;

FIG. 5 shows an enlarged lower portion of the cross-sectional view of FIG. 4 along the lines 5--5 of FIG. 4;

FIG. 6 shows an exploded perspective view of the jaws, circular spring, and steel bushing of the tool of the present invention;

FIG. 7 shows a top view of the jaw of FIG. 8 along the lines 7--7;

FIG. 8 shows a side view of one of the four jaws of the tool of the present invention;

FIG. 9 shows a bottom view of the jaw of FIG. 8 along the lines 9--9;

FIG. 10 is a block diagram of the electronic controls of the present invention;

FIG. 11 schematically shows the electronic controls of the present invention; and,

FIG. 12 is a computer flowchart for the powered crimper setup or adjustment and operation.

With reference to FIGS. 1-9, the tool 10 of the instant invention is shown having a housing 20; a motor 90 which drives a plunger lead screw 110 through a speed or gear reduction system 95, the plunger lead screw 110 interfacing a plunger 130; four jaws 70 circumscribing plunger 130 and retained by circular spring 86. Tool 10 also contains electronics which permit the plunger 130 starting point to be adjusted and also permit the crimping cycle to be adjusted.

FIGS. 1 and 2 show the tool 10 having a split housing 20 having parts 20a and 20b. Housing 20 comprises an upper housing portion 30 and a lower housing portion 40. Lower housing portion 40 is the "grip" portion and will be held in a vertical orientation by a user when using the crimper. From portion 30 to jaws 70, portion 40 contains a trigger portion 42 and a vertically elongated chamber portion 50 adjacent portion 30. Adjacent chamber portion 50 is a middle plunger/gear receiving portion 56. Finally, there is a lower jaw receiving portion 60.

With reference to FIGS. 1-3, upper housing portion 30 includes a horizontal elongated chamber 32 which contains circuit board 38. The operation of the electronics is explained later with reference to FIG. 10. However, the circuit board 38 is operationally connected to the power source, shown as a pair of 3.6 volt batteries 36, motor 90, pulse sensor or encoder 91, trigger 44, rocker switch 47, and LED 48. One or more batteries 36 can be used to power the tool 10 and are received in battery receiving channels 34. If multiple batteries are used, they can be in parallel to provided more crimps per charge or in series to provide more power. Naturally, they will be matched to the motor requirements. As shown, a pair of batteries 36 provide 3.6 volts DC. Also, external power sources can be used to power the tool 10. On the outside of chamber 32 are rocker switch 47 and LED 48, the operation of which is explained with the description of the electronics with FIG. 10.

Trigger portion 42 includes a trigger 44 and a trigger spring 46. The trigger 44 is used to activate the crimping cycle and the spring 46 is used to deactivate the trigger 44. Any comparable activation means can be employed in place of the trigger system. For example, a simple push button could be used which makes a simple contact when pressed to activate the crimp cycle. This push button could be anywhere on housing 20 and would replace the entire trigger portion 42. So, instead of holding a trigger grip, the user would grip the cylindrical lower housing 40. For ergonomic design, the external shape of lower housing portion 40 could altered from cylindrical without operational effect.

With particular reference to FIGS. 3-5, the internal connectivity of the components is described. Chamber 50 contains an internal upper motor receiving portion 52 with a motor seat 53 at its lower portion. FIGS. 4 and 5 show how motor 90 is received within portion 52 and seat 53. Motor 90 is a typical DC 24 pole motor found in battery operated power tools, such as a Black & Decker model VP720 powered screwdriver. Without load, the motor powered shaft 92 rotates at about 5760 rpm. Attached to shaft 92 are a pulse disk 94 and a shaft gear 96. Pulse disk 94 provides for 8 pulses for every 360.degree. rotation of shaft 92. Disk 94's cooperation with pulse sensor 91 and the tool's electronics are explained later.

A wear plate 98 is received on the lower side of motor seat 53 in middle portion 56. Adjacent the wear plate 98 is a unitary injection molded insert 57, a portion of which is shown in FIG. 3. Insert 57 and chamber 50 contain a plurality of aligned bores 62 therein which receive screws or bolts 64 therein to attach insert 57 in its desired location within chamber 50. Insert 57 contains a hex plunger channel 58 on its lower end and a gear channel 61 on its upper end, with a retaining member 59 with an opening therethrough in between 58/61. Gear channel 61 receives the speed or gear reduction system 95 therein.

Speed or gear reduction system 95 contains a pair of 8 to 1 speed reduction assemblies which first reduce the motor revolutions from approximately 5760 rpm to approximately 720 rpm and then to approximately 90 rpm. Three first gears 100 are received on shafts 102 attached to the upper side of a rotor 104. Motor shaft gear 96 is received within and engages the three first gears 100. The interior circumference of gear channel 61 is channeled to match the gearing of gears 100. With shaft gear 96 rotating at 5760 rpm, gears 100 rotate around shafts 102 and translate within gear channel 61 thereby causing the rotor 104 and gear shaft 105 on the lower side of rotor 104 to rotate at 720 rpm.

Three second gears 106 are received on shafts 108 attached to the upper side of plunger lead screw 110. Rotor shaft gear 105 is received within and engages the three second gears 106. With gear shaft 105 rotating at 720 rpm, gears 106 rotate around shafts 108 and translate within gear channel 61 thereby causing the plunger lead screw and the plunger threaded drive shaft 112 extending downward therefrom to rotate at 90 rpm. This results in a 64 to 1 reduction of motor 90 rotational speed in two 8 to 1 reduction stages. Similar speed reduction systems in more or less stages can be employed to achieve the desired rotational speed of the plunger lead screw 110. Also, under load, the rotational speeds will generally be less.

The plunger threaded drive shaft 112 receives an upper thrust bearing 116 thereover and then the shaft 112 is received through the opening in the insert 57 retaining member 59, extending into the hex plunger channel 58. On the under side of the member 59, shaft 112 sequentially receives a lower thrust bearing 118, a bearing housing 120, a retaining washer 122 and a retaining clip 114. The thrust bearings 116 and 118 help to minimize the torque requirements, the bottom thrust bearing 118 being leaded when the plunger 130 is moving downward and the upper thrust bearing 116 being loaded when the plunger 130 is moving upward.

Threaded drive shaft 112 is threadably received within plunger 130's threaded drive channel 131. Plunger hex guide member 132 and hex plunger channel 58 cooperate to prevent rotation of the plunger 130, but permit movement toward or away from the member 59. It is the rotation of plunger lead screw 110's threaded drive shaft 112 within plunger drive channel 131 and the cooperation of hex channel 58 and plunger hex guide member 132 which cause the circular rotation of motor 90's shaft 92 to be translated into a vertical movement of the plunger 130.

At the lower end of chamber 50 is a stop washer ridge 65 which has a stop washer 140 adjacent it's upper side. The lower side of stop washer 140 starts the lower jaw receiving portion 60 of the lower housing portion 40. At the lower portion of portion 60 is a steel bushing ridge 66 which has a steel bushing 128 adjacent it's upper side. Between stop washer 140 and steel bushing 128 are a plurality of crimping jaws 70. The upper part of jaws 70 abut stop washer 140. The lower part of jaws 70 extend downward through an opening in steel bushing 128. For the preferred embodiment, four jaws 70 are used, although other numbers can be employed within the scope of the invention. The lower portion of the plunger 130 is received within the central circular opening through the jaws 70.

FIGS. 3-6 show that four jaws 70 are retained on plunger 130 by circular spring 86. Other means, such as an elastic or rubber band can be employed. FIGS. 7-9 show one of the jaws 70. Jaw 70 includes a lower crimping portion 72 and an upper opening portion 74. Portion 72 includes a curved crimping lip 76. The inside curved surface of jaw 70 has a plunger slide area 78 shaped such that when the four jaws 70 are placed together the areas 78 are generally cylindrical shaped with a diameter which approximates that of plunger 130. An engagement point for opening 80 permits jaws 70 to open when received by plunger 130's jaw opening portion 134. A generally horizontal groove 82 is provided to receive circular spring 86.

With particular reference to FIG. 5, the plunger 130 also includes a jaw crimping slide portion 133, the jaw opening portion 134, a cap engaging head 135, a curved surface 136 for centering the cap, and a flat surface 137 to engage the cap top. It is seen that the jaw opening portion 134 has an hour glass shape. In FIG. 5, the jaws 70 are closed, as the plunger 130 has moved downward beyond the cap open position. It can be seen that, if the plunger 130 was moved upward, the jaw opening engagement point 80 will align with the start of the inward slope of jaw opening portion 134. As the plunger 130 continues to move upward, the circular spring 86 in groove 82 causes point 80 to follow the inward slope, thereby causing the jaws 70 to spread apart at the bottom or open so that they can be placed over a bottle or vial for the crimping of a cap thereon. The jaws 70 would be the most open when point 80 is at the smallest diameter part of the hour glass of jaw opening portion 134. As is explained hereinafter, this would generally be the starting point for the crimping cycle. However, if working in confined places, the tool user may not want the jaws to open to this widest opening. Therefore, the starting point can be adjusted by movement of the piston downward to slightly close the jaws 70. For example, the hour glass portion of portion 134 toward portion 133 slopes inward at about 20.degree. from vertical. The cooperation of the plunger 130 and the curved crimping lip 76 cause a cap to be crimped onto a vial or bottle. As explained hereinafter, this cooperation can be adjusted by controlling the stop point of the downward movement of the plunger 130.

FIGS. 10 and 11 show, in block diagram and schematic, the electronic controls for the tool 10, many of which are mounted on circuit board 38 or connected thereto. FIG. 12 shows a flowchart of how the computer program controls the setup and operation of the powered crimper. Battery or batteries 36 are shown providing power to motor 90 upon activation. When the battery or batteries have an insufficient charge remaining, the three-color LED 48 will be constantly illuminated in red. Pulse sensor 91 detects rotational movement of the motor 90 shaft. With motor 90 operating at 5760 rpm and the pulse disk identifying 8 pulses per motor shaft revolution, the starting and stopping points of the crimp cycle can be very accurately set, incrementally adjusted, and stored in memory. All of this is controlled by a Microchip Technologies PIC Micro Controller, model number PIC 16C58.

The tool 10 has a start-up mode and a crimp mode, which operate as shown by the flowchart of FIG. 12. The start-up mode is initiated by engaging a reset switch 49 or upon insertion of a charged battery into battery receiving channel 34 if the 0.1 Farad memory backup capacitor has discharged because of an extensive period without a connected or charged battery. First, the motor 90 reverses, moving the plunger 130 upward, until a stall condition is detected. A stall condition is detected when the motor rpm decreases and the time between pulses from disk 94 is about 10 times the normal operating time. Then, the motor 90 reverses direction and moves the plunger downward to a pre-set START position. In general, the motor will rotate until the pulse sensor has detected a pre-set number of pulses. Typically, this will move the plunger downward so that the jaws 70 are at their most open position, that is, where 80 is at the narrowest diameter portion of hour glass 134. The START or jaw open position can be adjusted by pressing the + or - on the rocker switch 47 to raise or lower the plunger. Each time the rocker switch 47 is pressed, the motor 90 rotates for a pre-set number of pulse counts and the LED will flash green one time. This can be any desired number, but is preferably 4 counts. Once the jaws 70 are set at the desired opening, the trigger 44 is pressed and released to disengage the start-up mode.

The tool 10 is now configured for the preset crimp cycle. That is, upon activation of the crimp cycle by pressing the trigger 44, the motor 90 will rotate until the pulse sensor has detected a pre-set number of pulses, thereby moving the piston from the START position to the STOP position. Then, the motor 90 will reverse and the piston will be returned to the START position. With the present embodiment, the piston moves through about 0.250 vertical inch between the START and STOP. The number of threads per inch of plunger drive shaft 112 and plunger threaded drive channel 131 affect how many pulses between START and STOP positions.

It is desirable that the operator not have to engage the trigger 44 for the entire crimp cycle. While it could be set so that a simple press and release of the trigger would cause the tool to go through a complete crimp cycle, a safety factor is desired. Therefore, the trigger 44 must be pressed and held until the motor 90 rotates for sensing of a pre-set number of pulses, for example, 640 pulses. If the pre-set number of pulses is not reached, the LED will flash yellow 10 times after the motor has reversed. Once this rotation has occurred, the "NO RETURN" position has been reached and the crimp cycle will be completed even if the trigger is released, unless a stall condition is sensed. If a stall condition is sensed, by a time period between pulses which is about 10 times than the normal time period between pulses, before the plunger reaches the STOP position, the motor will automatically reverse and return the plunger to the START position and the LED 48 will flash red 10 times in 5 seconds or until the start of the next crimp cycle, if less than 5 seconds, to notify the user that the crimp cycle was not completed.

In the crimp mode, the rocker switch 47 can be used to adjust the STOP position. By using the + or - on the rocker switch 47, the plunger STOP limit can be adjusted downward or upward. Each time the rocker switch 47 is pressed, the motor 90 rotates for a pre-set number of pulse counts. This can be any desired number, but is preferably 8 counts and the LED will flash green one time. Therefore, if the tool 10 user sees that a bottle or vial has not had the cap adequately crimped thereon, the rocker switch 47 can be adjusted so that the plunger 130 will move further downward for the STOP position and that vial or bottle re-crimped. If the user sees that a vial or bottle is having the cap crimped on too tightly, the rocker switch 47 can be adjusted so that the plunger will stop further upward for the STOP position so that future vials or bottles will not have the cap crimped on as tightly.

While the above-described means for electronically adjusting the stop position is the inventors' preferred embodiment, alternatives can be employed. For example, instead of using a controller which counts pulses to control the various positions, a limit switch could be employed. The motor would move the plunger one direction until a desired limit was reached and then the motor would be reversed and the plunger moved in the opposite direction. The limit switch limit could be altered to adjust the plunger downward limit.

The foregoing detailed description is given primarily for clearness of understanding and no unnecessary limitations are to be understood therefrom for modifications can be made by those skilled in the art upon reading this disclosure and may be made without departing from the spirit of the invention and scope of the appended claims.