Patent Grant
7946565
1. Technical Field
The present invention, involving bookbinding apparatuses that bind a spine endface of sheet blocks having been collated into bundles and that finish the sheet bundles into booklets, relates to improvements in bookbinding apparatuses that aligningly stack into bundles sheets onto which images have been formed by, for example, a device such as an imaging apparatus, bind the sheets together into booklets, and trim the booklets' open edges true.
2. Description of the Related Art
Generally, this type of bookbinding apparatus is broadly known as a finishing device that collates into bundles sheets conveyed out from an imaging apparatus or similar source, and that bookbinding-processes the bundle by such operations as adhesive-binding, staple-binding, or adhesive-tape binding the bundle's spine edge. Furthermore, apparatuses furnished with a trimming unit that trims true the open edges of a sheet bundle (booklet bundle) having in this way been binding-processed, as well as apparatuses furnished with a sheet-folding unit, upstream of the sheet stacking tray where sheets are collated into bundle form, that folds sheets in half, in thirds, etc. are also known.
For example, Japanese Unexamined Pat. App. Pub. No. 2005-335262 discloses a bookbinding apparatus wherein sheets onto which images have been formed in an image-forming apparatus are conveyed to the bookbinding apparatus, and in the bookbinding apparatus the sheets are collated and stacked, an adhesive paste is applied to the endface of the spine portion of the sheet bundles, and the sheet bundles are encased with and bound into a cover sheet. The cover-sheet bound bundles are then spine-creased to post-process them into booklet form, and the sheet bundles now made into booklets are finished by trimming true their head/tail portions and fore-edge portions.
In another example, Japanese Unexamined Pat. App. Pub. No. 2006-076779 discloses a post-processing device that in a folding unit folds in half or in thirds sheets onto which images have been formed in an image-forming apparatus, collates the sheets into a stack and staples the stack closed. Therein, proposed are both single-folding, whereby a sheet is folded substantially in half over on itself, as well as Z-folding, whereby in divisions into thirds a sheet is folded inward and then is folded outward back onto itself. It is to be noted that for the sheet-folding device of this reference a trimming-cut configuration that trims true the open edges of sheets having been staple-bound is neither disclosed nor suggested.
As described above, for example, publications such as the foregoing JP 2005-335262 do propose bookbinding devices that collate into bundles (collating/stacking) sheets onto which images have been formed, bind a cover sheet to the spine-portion edge of the sheet bundles (spine-binding process), and then trim true the open edges of the encased bundle (trimming cut). Meanwhile, as bookbinding machines different from this sort of device, publications such as the foregoing JP 2006-076779 do propose bookbinding devices that fold sheets, conveyed out from an image-forming apparatus, in half or in thirds as needed (folding process), collate and stack the sheets (collating/stacking), and bind them together along the edge of the spine portion (spine-binding process).
Against this backdrop, the present inventors attempted the provision, in an image-forming system—like that of the foregoing JP 2005-335262—that collates sheets into bundles and encases the bundles into cover sheets to form booklets, of a device that folds collated sheets in half or thirds, processing them into booklets, and then trims true the open edges (head/tail portions and fore-edge portions). In doing so, however, they came up against the difficulty that in trimming the fore-edge true, the pleat-edge of sheets that had been folded would get sliced.
This slicing of folded sheets is caused by the fact that when trimming the edges of sheet having been formed into a booklet, the folded sheets are trimmed at the same time. A trimming cut on post-bookbinding sheets trims true, by slicing a predetermined amount off, the open edges of book-bound sheets, with as a reference either the sheet edges of the bound inner leaves having been encased into a cover sheet, or the cover sheet itself, whichever is shorter. To solve the fold-slicing problem, the pleat in a folded sheet presumably could be prepositioned in a location where it will not be trimmed off.
Nevertheless, when a sheet bundle is encased in a cover sheet and bound into a booklet, the fore-edge of the cover sheet will be indeterminate if the thickness of the sheet bundle (thickness when covered) is not preestablished. That is, the length from the spine-closure edge to the fore-edge of the cover sheet will differ depending on the sheet-bundle thickness (fore-edge length={cover-sheet size−bundle thickness}/2). Yet the fact that the thickness of a sheet bundle is detected at the stage where the sheets have been collated and stacked into a bundle on the stacking tray means that the final sheet bundle thickness when the sheets (for example the first sheet) have been fold-processed cannot be differentiated. Consequently, in instances where a folded sheet is mixed into a sheet bundle made into a booklet, trim-finishing the booklet after the bookbinding process invites the problems discussed above.
The present invention provides a bookbinding apparatus and image-forming system that does not cut a folded sheet if one is included in a sheet bundle when trimming true the sheet edges of sheets that have been collated into a bundle and covered by a cover sheet. The present invention provides an image-forming system that forms images on a sheet fed from a sheet feeding portion provided inside the apparatus, and does not cut a folded sheet when the sheet is folded and finished into a booklet.
The present invention employs the following configuration to attain the aforementioned objects. The system is provided sheet folding means that folds sheets sequentially fed from a sheet conveyance path; stacking means that collates and stacks sheets fed from the sheet folding means and/or the sheet conveyance path; binding means that binds a spine edge portion of the sheet bundle conveyed from the stacking means; trimming means that trims edges of the bound sheet bundle to align edges; folding position calculating means that sets the folding position of the sheet folding means; and trimming amount calculating means that calculates a trim depth for trimming using the trimming means. When a sheet is folded into a Z-fold by the sheet folding means, the folding position calculating means is configured to set the inner folding position of the sheet backside based on the trim depth of the sheet fore-edge portion from the trimming amount calculating means.
Also, the folding position calculating means calculates so that the spine edge of the sheets and the length of the inner folded position are shorter than the sheet spine edge after the trimming finish and the fore-edge portion edge.
In the configuration described above, the stacking means stacks inner folded sheets conveyed from the sheet folding means, and inner single sheets that have not been folded, conveyed from the sheet conveyance path. A cover sheet feeding path that feeds cover sheets that cover the inner sheets fed from the stacking means is connected to the binding position of the binding process means. The trimming amount calculating means calculates the trim depth of the cover sheet from the preset bookbinding finishing size, and the trimming means cuts the edges of the sheet bundle at a longer trim depth of the cover sheet trim depth and the inner sheet trim depth.
The system is provided image-forming means that forms images on sheets based on predetermined image data; sheet folding means that folds sheets conveyed from the image-forming means; stacking means that collate and stack sheets conveyed from the sheet folding means or the image-forming means; cover sheet binding means that covers cover sheet over a sheet bundle conveyed from the stacking means; trimming means that trims the fore-edge portion of the sheet bundle bound with the cover sheet; and folding position calculating means that sets the folded position of the sheet folded using the sheet folding means. The sheet folding means is equipped with a sheet conveyance path that conveys a folded sheet to a location other than the stacking means. The folding position calculating means is furnished with a first control mode that conveys a sheet folded by the folding means to the stacking means, and a second control mode that conveys the sheet folded by the folding means to a location other than the stacking means from the sheet conveyance path. In such a case, the folding position calculating means is configured to set the folded position from a virtual trim depth cut by the trimming means when in the first control mode, and to set the folded position based on sheet size information received from the image-forming means when in the second control mode. The virtual trim depth is calculated based on the preset maximum tolerable booklet thickness, or sheet bundle thickness information attained from the number of sheets formed with images by the image-forming means.
The folded sheet position calculating means calculates the virtual trim depth from sheet bundle thickness information, sheet size information obtained from the image-forming means, and cover sheet size information, and sets so that the distance of the spine edge portion and length of the folded position is shorter than the distance of the spine edge portion and fore-edge portion edge after trimming.
The sheet conveyance path is configured to convey folded sheets to a stacking means that stores folded sheets, or to a finishing means that implements a finishing process such as punching holes therein, or stapling and the like.
The trimming means is provided trimming amount calculating means that sets the trim depth to trim and align the fore-edge portion of the sheet bundle covered by the cover sheet. The trimming amount calculating means sets the trim depth from the sheet bundle thickness obtained from the thickness detection means of a sheet bundle stacked in the stacking means, the length of the sheets formed with images by the image-forming means, cover sheet length, and a preset minimum trimming amount.
Sheet feeding means that feed sheets is equipped on the image-forming means. The image-forming means forms images on the sheet conveyed from the sheet feeding means to form a binding margin at the spine portion of the sheet, and a trimming margin at the fore-edge portion. The trimming margin is set to be larger than the virtual trim depth.
The image-forming means is provided with sheet feeding means that stores a plurality of sizes of sheets, and sheet feeding control means that selects and feeds one type of sheet from the sheet feeding means. The sheet feeding control means is configured to select a size appropriate for the image data from the sheets prepared in the sheet feeding means or a minimum sized sheet larger than that. The folding position calculating means calculates the preset maximum tolerable booklet thickness, or sheet bundle thickness information attained from the number of sheets formed with images by the image-forming means, and the virtual trim depth based on the sheet size information that is proper for the image data.
A bookbinding apparatus collates inner leaves of sheets conveyed from the image-forming apparatus into a sheet bundle and covers the sheet bundle with a cover sheet, the system being provided sheet folding means that folds sheets conveyed from the image-forming means; stacking means that collates and stacks sheets conveyed from the sheet folding means or the image-forming means; cover sheet binding means that covers a cover sheet over the inner leaves of sheets of the sheet bundle conveyed from the stacking means; trimming means that trims the fore-edge portion of the sheet bundle bound with the cover sheet; and folding position calculating means that sets the folded position of the sheet folded using the sheet folding means. The folding position calculating means calculates the virtual trim depth to cut using the trimming means from (1) inner sheet size information from the image-forming apparatus; (2) cover sheet size information; and (3) preset, tolerable maximum booklet thickness information, or thickness information of inner leaves of the sheet bundle calculated from the number of sheets formed with images. Also, the folding position calculating means sets the folding position so that the distance of the length of the spine edge and the folding position is shorter than the distance of the length of the spine edge and the fore-edge portion edge after trimming, based on the virtual trim depth.
It calculates based on the size of inner leaves of sheets that are not folded, when folded sheets from the sheet folding means and sheets that are not folded conveyed from the sheet conveyance path are stacked together in the stacking means and the folding position calculating means is calculating the virtual trim depth.
The cover sheet binding means is furnished with either one of a stapling means, adhesive application means, or adhesive tape binding means to bind a spine of a sheet bundle collated at the stacking means.
Also, the image-forming system according to the present invention is composed of an image-forming apparatus that forms images on sheets, and a bookbinding apparatus that collates sheets conveyed from the image-forming apparatus and binds them into a booklet. The folding position calculating means and trimming amount calculating means are disposed in the image-forming apparatus or the bookbinding apparatus.
The trimming amount calculating means calculates the trim depth to cut using the trimming means from the length information of the size of the finished booklet input using input means, length information of the sheet formed with images at the image-forming apparatus, and length information of the cover sheet supplied from said binding-process means.
A bundle thickness detection means that detects the thickness of the collated sheet bundle is provided between the stacking means and the cover sheet binding means, and the trimming means is provided trimming amount calculating means to trim and align the fore-edge portion of the sheet bundle covered by cover sheet at the cover sheet binding means. The trimming amount calculating means is configured to calculate the trimming amount from the size information of the inner sheets, the size information of the cover sheet, and the sheet bundle thickness detected by the bundle thickness detection means.
The image-forming system is provided image-forming means that forms images on sheets based on predetermined image data; sheet folding means that folds sheets conveyed from the image-forming means; stacking means that collates and stacks sheets conveyed from the sheet folding means or the image-forming means; cover sheet binding means that covers a cover sheet over a sheet bundle conveyed from the stacking means; trimming means that cuts the fore-edge portion of the sheet bundle bound with the cover sheet; and trimming position calculating means that sets the trimming amount of the fore-edge portion cut using the trimming means; and folding position calculating means that sets the folded position of the sheet folded using the sheet folding means. The sheet folding means is equipped with a sheet conveyance path that conveys a folded sheet to a location other than the stacking means. The folding position calculating means is furnished with a first control mode that conveys a sheet folded by the folding means to the stacking means, and a second control mode that conveys the sheet folded by the folding means to a location other than the stacking means from the sheet conveyance path. In such a case, the folding position calculating means is configured to set the folded position from a trim depth set by the trimming amount setting means when in the first control mode, and to set the folded position based on sheet size information received from the image-forming means when in the second control mode. The folding position in the first control mode is set so that the distance of the length of the spine edge and the folding position is shorter than the distance of the length of the spine edge and the fore-edge portion edge after trimming.
In an apparatus configuration that forms a booklet by collating and stacking sheets formed with image and covers the sheet bundle with a cover sheet, then trims edges thereof, the present invention has the following effects because the folding position calculating means that sets the sheet folding position sets the folding position based on a virtual trim depth by calculating the virtual trim depth from either a tolerable maximum booklet thickness or from the number of sheets calculated from image data, when sheets are folded by the sheet folding means disposed upstream of the stacking means.
It is possible to set the folding position folded by the folding means so that the distance of the length of the spine edge and the folding position is shorter than the distance of the length of the spine edge and the fore-edge portion edge after trimming, based on the virtual trim depth. In other words, the folded sheet folding position is set to inside the trimming margin so the fore-edge portion edge is not cut off when trimming to align that edge according to the thickness of the sheet formed with images on all sheets.
At the same time, even if sheets of various lengths are selected as folding sheets, it is possible to set the folding position to the predetermined position half position or ⅓ position. Also, when ⅓ folding specifications are applied, the folded piece does not project outward from the edge, so it is possible to for a booklet with a good finish. The fore-edge portion edge of all sheets including the folded sheets is trimmed, so an aesthetically appealing finish is possible when forming bookbinding.
Still further, the folding position calculating means that sets the folded position to fold the sheet using the sheet folding means of the present invention is composed of a first control mode and a second control mode. The first control mode sets the folded position from a virtual trim depth cut by the trimming means, and the second control mode sets the folded position based on sheet size information received from the image-forming means. This will not cut the folded position when trimming the sheet conveyed from the image-forming apparatus, and it is possible to attain the effect of folding a sheet at a predetermined folding position corresponding to the sheet size even when finishing without the trimming process (such as stapling and the like).
A preferred embodiment of the present invention will be explained based on the drawings provided.
Configuration of Image-Forming System
The image-forming system shown in
Detailed configurations of each unit will be described below. However, a feature of the present invention is that the image-forming unit A, the sheet folding unit B, and the bookbinding unit C are disposed downstream in that order. Also, as shown in
With such a system configuration, images are sequentially formed on sheets using image data da1 stored in a data storage unit provided in the image-forming unit A, or sent thereto, and these sheets are folded, collated and collected. Thereafter, the collated sheet bundle is covered by a cover sheet to form a book. After the bookbinding process, a finishing process to cut three sides of the sheet bundle, excluding the spine portion of the sheet bundle is possible. (Hereinafter, this is called a bookbinding operation.) At the same time, it is possible to feed sheets formed with images to the finisher unit D passing through the bookbinding unit C without their undergoing the bookbinding process and to be finished at the finisher unit with a process such as stapling, stamping, or hole-punching. (Hereinafter, this is called a finishing operation.) For that reason, in addition to folded sheets fed from the sheet folding unit B are sent to the stacking means 41, and a sheet conveyance path 38 is provided to convey the sheets to the finishing means 39. Therefore, it is possible to select whether sheets formed with images are sent either to the stacking means 41 via the sheet folding unit B for the bookbinding operation, or to the finisher unit D for the finishing operation.
The present invention has a feature to automatically execute processes with this system configuration from the image-forming process to the finishing process with the “print-out mode,” “folding mode,” “bookbinding mode,” and “finishing mode.” These modes can be set using a mode setting means 72, as described below, for example, but here the processes of each mode will now be explained.
Print-Out Mode
In this mode, sheets formed with images at the image-forming unit A are stacked on a discharge tray. This mode forms images on sheets of a size specified by the image data da1 in the same way as with an ordinary copier or printer, or of a size specified using an input means (a control panel 71 described below), and stacks and stores the sheets in the discharge tray. The system shown in
Folding Process Mode
In this mode, sheets formed with images at the image-forming unit A are folded for bookbinding or for finishing. Bookbinding folding specifications, staple folding specifications, and the letter folding specifications can be specified for the sheet folding method. Note that the system shown in
The present invention has a feature to determine the folding position N to fold the sheet according to the type of each final finishing process, of “bookbinding, finishing, and sheet-folding” when the system is set for the “folding process mode.” Specifically, a folding position computing means 73 for determining folding position N when the above-described sheet folding means 21, disposed in the sheet folding unit B, folds sheets over is configured as follows to derive the folding position N in a first control mode and in a second control mode.
The first control mode sets the folding position N for the sheet when the “bookbinding finish” is set. This control sets the folding position N so that the folded edge of the folded sheet is not cut when a sheet bundle covered with a cover sheet bound by the bookbinding finish is being trimmed for alignment. For that reason, the folding position computing means 73 is composed to set the sheet folding position N based on a virtual trim depth, by computing the trim depth for bookbinding finish as the virtual trim depth.
This virtual trim depth is computed in the following way, using initial setting conditions (setting values) for example for image forming. First, with the initial settings, the finishing mode selection, the sheet size selection and the image-forming area (page layout) are set. When supplying the cover sheet for the bookbinding finishing from the inserter unit E, the operator specifies the size of the cover sheet on the control panel 71. For the virtual trim depth, to begin with the lengthwise/widthwise orientation of the sheet is differentiated based on the page layout setting. The cover sheet, the longitudinal length L of the inner leaves of sheets, and the lateral length R are compared to set the trimming position based on the shortest sheet. This is to trim the sheets based on a small sized sheet to align the cover sheet and all the leaves of inner sheets (the sheet bundle). To explain this based on
Note that the comparison of the length between spine bound edge and fore-edge portion edge is calculated by [(sheet length−bundle thickness t)/2] for the cover sheet. In other words, to cover and bookbinding the inner leaves of the sheet bundle Sn with the cover sheet Sh, the cover sheet Sh is folded to form the spine cover at the central portion. The spine cover sheet width at this time substantially matches the thickness of the inner leaves of sheets of the bundle.
However, the spine cover sheet width (the thickness t of the sheet bundle of inner leaves) is determined when images are formed on the inner leaves of sheets to be aligned, and the sheet bundle is aligned in the stacking means. Meanwhile, in some cases there will be a sheet-folding process in which sheets, starting with the first for example, are fold-processed. Herein, when computing the virtual trim depth, the present invention features finding “bundle thickness (termed ‘assumed bundle thickness’ below) t” (1) from the maximum tolerable bookbinding thickness, or finding t (2) from the number of image-forming sheets. The former is set in advance from the apparatus configuration (for example, a maximum gripping amount of a gripping conveyance means 47, described below) of the bookbinding unit C. The latter is determined by multiplying an average sheet thickness (paper thickness) by the number of sheets to be printed that is known by the initial page layout settings.
Therefore, as shown in
Next, the second control mode sets the folding position N for the sheet when “finishing·sheet folding” are set. This control calculates the folding position according to the preset folding specifications such as a half fold, a standard gate fold, and ⅓ Z-fold and the like which are described below. In such a case, the folding position computing means 73 is configured to calculate the folding position N from the folding specifications and the sheet size (the default value). Each folding specification will be described later.
Bookbinding Mode
This mode stacks and collates in stacking means 41 sheets fed from the image-forming unit A and dispenses adhesive (or adhesive tape) for example to the sheet bundle. Then, this sheet bundle is covered and bound by a cover sheet, and three sides, excluding the bound spine portion, of the sheet bundle are cut for alignment. A portion of the sheets stacked in this stacking means 41 are folded by the sheet folding means 21. Then, the sheet bundle formed into a cut and aligned booklet is stored in a storage stacker 67.
Finishing Mode
This mode conveys sheets from the image-forming unit A directly into a processing path (hereinafter referred to as a finishing path 39a) via the bookbinding unit C after being folded at the sheet folding unit B. After undergoing a finishing process by the finishing means 39, such as a stapling means, stamping means or a hole-punching means and the like prepared in this path, the sheets are conveyed out to the discharge tray 37.
Image-Forming Apparatus Configuration
The following will now explain the image-forming unit A shown in
A static electric drum 10 is equipped at the printing unit 3. A print head 9, a developer 11 and a transfer charger 12 are disposed around this drum 10. The print head 9 is composed of a laser emitter, for example, to form electrostatic latent images on the electrostatic drum 10. Toner ink adheres to the latent image at the developer 11, and is this is transferred and printed on the sheet at the transfer charger 12. The printed sheet is the fixed at the fixer 13 and discharged to the discharge path 17. A discharge outlet 14 formed in the casing 1 and a discharge roller 15 are disposed at the discharge unit 4. Note that the symbol 16 in the drawing represents a recirculation path. A printed sheet from the discharge path 17 is turned over from front to back at the switchback path and fed to the registration roller 7 to be formed with images on its backside. In this way, a sheet formed with images on one side or both sides is conveyed from the discharge outlet 14 by the discharge roller 15.
Note that the symbol 20 in the drawing is a scanner unit (image-forming means). This optically reads original images to print using the print head 9. As is generally known in the art, the scanner is composed of a platen 18 where an original sheet is set; a carriage 20a that scans the original image along the platen 18; and an optical reading means (for example, a CCD device) 20b that photo-electrically converts optical images received from the carriage 20a. The drawing shows an original feeding apparatus 19 that automatically feeds the original sheet to the platen, installed over the platen 18.
Sheet Folding Unit Configuration
The following will now describe the configuration of the sheet folding unit B. The sheet folding unit B is composed of a folding unit B1 and a folded sheet stacker B2. A conveyance inlet 24a linked to a discharge outlet 14 of the image-forming unit A is equipped in the sheet folding unit B, and a sheet conveyance path P1 that sends sheets from the conveyance inlet 24a to the bookbinding unit C, described below, is connected to traverse the apparatus. A folding process path P2 and a sheet feed path P3 are branchingly connected to the sheet conveyance path P1.
Explanation of Sheet Folding Specifications
The following will now explain the folding specifications performed by the sheet folding unit B1. Folding sheets in half or in thirds are the types of folds (folding specifications) that are commonly applied with the image-forming system described above. Each type of sheet fold will now be explained.
Single Fold
This creases or folds a sheet conveyed out from the image-forming unit A at substantially the half position of the length of the direction of conveyance. Although not shown, the sheet is folded in half at a central position. The folded ends of sheets can then be bound by stapling or gluing and the like to form a closed-end document. Furthermore, if holes are punched into the folded sheets, they can be used in a variety of document organizing methods, such as filing. The folding position computing means 73 that sets the folding position N uses the first control mode for the bookbinding operation, and the second control mode for the finishing and sheet folding operations.
Gate Fold
In this folding method, the sheet is folded at desired positions (for example at ⅓ positions) of the leading edge and the trailing edge of the sheet in the length direction. The two end panels, specifically, the leading and trailing ends of the sheet, are mutually folded inward over a middle third panel. As shown in
Z-Fold
In this folding method, the sheet is folded at desired ⅓ positions of the leading edge and the trailing edge of the sheet in the length direction of sheet conveyance. Specifically, the leading and trailing ends of the sheet are folded in opposite directions. The leading edge of the sheet is folded inward, and the trailing edge of the sheet is folded outward. If a sheet is folded at ⅓ positions as shown in
Specifically, as shown in
Folding Unit Configuration
The structure of the folding unit B1 will be now explained with reference to
A conveyance roller 25 that conveys the sheet is disposed in the folding process path P2; the folding roller mechanism 21 is positioned downstream of the conveyance roller. A switchback roller 22f that is capable of both forward and reverse rotations and a sheet sensor SS1 are disposed in the switchback path 22 downstream of the folding process path P2. The sensor SS1 detects the leading edge of the sheet fed downstream (
On the other hand, a trailing edge registration stopper 25S is provided downstream of the conveyance roller 25 to calculate the folding position based on the trailing edge of the sheet. After the trailing edge of the sheet is fed past the registration stopper 25S by the switchback roller 22f, the switchback roller 22f rotates in reverse thereby abutting the trailing edge of the sheet against the registration stopper 25. This causes the sheet to form a bow based on the sheet's trailing edge position. The bowed portion advances into the nipping point Np1 of the first and second rollers 21a, and 21b (the first folding unit). Thus, the first folding process is executed based on the trailing edge of the sheet. Note that the sheet stopper mechanism is composed of a flapper-shaped stopper 25S. This stopper 38 is configured to retract from the path when the sheet advances downstream in the folding process path P2, and to advance back into the path when the sheet is being conveyed upstream to stop the trailing edge of the sheet. This stopper that registers the trailing edge of the sheet can also be composed of the conveyance roller 25 as a switchback roller capable of forward and reverse rotations. Switchback roller 22f at the leading end of the path can also be configured for position registration.
Sheets whose folding positions are calculated by either their leading edge or their trailing edge when supplied to the first folding unit Np1 are folded by the first and second folding rollers 21a, and 21b, and then conveyed into the folded sheet path 23. A sheet detection sensor SS2 and movable stopper 23S are disposed in the folded sheet path 23. The movable stopper 23S is configured to move into the folded sheet path 23 to register the leading edge position of the sheet according to the sheet size and folding specifications. The leading edge of the folded sheet fed by the first and second rollers 21a, and 21b abuts the movable stopper 23S and is registered. This also forms a bow in the trailing edge side. This bow causes the sheet to advance into the nipping point between the second 21b and third roller 21c so the trailing edge side of the sheet is folded. A first discharge path P4 is disposed downstream of the nipping point (the second folding unit) Np2 of the second and third rollers 21b and 21c. Sheets folded at the first and second folding units Np1, Np2 are conveyed out to the first discharge path P4. Note that in the event that the sheet does not require a second folding, for example if only a single fold is applied to the sheet, the movable stopper 23S retracts to a non-operational, standby position so that the sheet can be conveyed out to the first discharge path P4 without being folded at the nipping position of the second and third rollers 21b and 21c.
The first discharge path P4 is equipped with a conveyance out rollers 27b. These roller nip the folded sheet and convey it to downstream. A folded sheet storage tray 29 and a second discharge path P5 are disposed downstream of the first discharge path P4 interposed by path switching member 29f. Conveyance rollers 27c are disposed at proper intervals in the second discharge path P5 to convey a folded sheet to the sheet conveyance path P1.
Inserter Configuration
As described above, a printed sheet is conveyed in from the image-forming unit A to the folding unit B1 but in addition to this, a sheet can be selectively conveyed from the inserter E for the folding process. As shown in
Sheet Folding Operation
The following will now explain actions of the sheet folding unit B configured as described above. The present invention has the possibility of trimming a folding position N when trimming to align the edges of sheets bound in the bookbinding process when a sheet has been applied with a Z-fold, when applying the bookbinding process at the bookbinding unit C, on sheets folded into a Z-fold at the sheet folding unit B. The present invention has a feature of setting the sheet folding position N according to the trimming amount.
The following will explain folding operations to fold a sheet into a Z-fold at the sheet folding unit B. The control unit 59 of the sheet-folding unit B is composed of a control CPU. The control unit 59 can be integrated to the control unit 70 of the image-forming unit A or the control unit 75 of the bookbinding unit C, or it can be furnished separately to the sheet-folding unit B. A ROM 74 that stores folding execution programs and a RAM 77 that stores control data are provided in the control unit (control CPU) 59. The folding execution program executes folding processes with the folding specifications described above by controlling the conveyance roller 25 of the folding process path P2, the conveyance out rollers 27b, the folding roller mechanism 21 and the movable stopper 23S. This folding process execution program selects whether to move the folded sheet fed into the first discharge path P4 from the first discharge outlet 27a to the folded sheet storage tray 29 or to move the folded sheet from the second discharge path P5 to the bookbinding unit C according to the folding specifications, at the same time as executing a folding process described above. The drawings show sheet sizes of A4 or letter size. The sheet is conveyed from the first discharge path P4 and is stored in the folded sheet storage tray 29 for gate fold folding specifications. For other folding specifications, the sheet is conveyed out from the second discharge path P5 to the bookbinding unit C.
When a gate fold is applied to the sheet, the control unit (control CPU) 59 discharges the sheet from the discharge outlet 14 of the image-forming unit A facing downward. The sheet is handed over and conveyed into the folding process path P2 in the manner indicated by arrow a in
In this way, the sheet folded to face outside is fed to the folded sheet path 23 by the first and second rollers 21a, 21b. At this time, the CPU59 moves the movable stopper 23S using a drive motor, not shown, to align the distance of the sheet folding position and the nipping point Np2 to the inner folding position N2 (see
Bookbinding Unit Configuration
The following will now explain the bookbinding unit C that is attached to the image-forming unit A. The bookbinding unit C is composed of a stacker 40 that stacks and aligns printed sheets into bundles; an adhesive applicator means 55 that applies adhesive to the sheet bundle conveyed from the stacker 40; and cover sheet binding means 60 that binds the cover sheet to the sheet bundle applied with adhesive, in the casing 30.
Conveyance Path Configuration
A conveyance path 31 having a conveyance inlet 31a linked to the discharge outlet 14 of the image-forming unit A is provided in the casing 30, and the intermediate sheet conveyance path 32 and cover sheet conveyance path 34 are linked from this conveyance path 31 via the path switching flapper 36. The bookbinding path 33 is linked to the cover sheet conveyance path 34 via the stacker 40, and a finishing path 39a is connected to the cover sheet conveyance path 34. The bookbinding path 33 is disposed to traverse the apparatus longitudinally in a substantially vertical direction, and the cover sheet conveyance path 34 is disposed in a direction to traverse the apparatus in a horizontal direction.
The bookbinding path 33 and the cover sheet conveyance path 34 mutually intersect (orthogonally); the cover sheet binding means 60, described below, is disposed in the intersection. The conveyance path 31 configured as described above is linked to the discharge outlet 14 of the image-forming unit A to receive printed sheets from the image-forming unit A. Sheets printed with content information (the leaves of sheets), and sheets printed with a title and the like to be used as a cover sheet (hereinafter referred to as a cover sheet) are conveyed out from the image-forming unit A. This conveyance path 31 is branched into the intermediate sheet conveyance path 32 and the cover sheet conveyance path 34, and sort printed sheets to convey them into each path by the use of a path switching flapper 36.
Stacker Configuration
The stacking tray 44 arranged at the discharge outlet 32b of the intermediate sheet conveyance path 32 stacks and stores sheets from the discharge outlet 32b in a bundle. As shown in
Configuration of Sheet Bundle Conveyance Means
Gripping conveyance means 47 are furnished in the bookbinding path 33 to convey a sheet from the stacking tray 41 to a downstream adhesive application position F. As shown in
Adhesive Application Unit Configuration
An adhesive application means 55 is disposed in the adhesive application position F of the bookbinding path 33. As shown in
Configuration of Cover Sheet Binding Means
The cover sheet binding means 60 is disposed in the cover sheet binding position G of the bookbinding path 33. As shown in
Configuration of Bundle-Posture Changing Means
A bundle posture changing means 64 that turns the sheet bundle over from top to bottom, and trimming means 65 that cuts the edges of the sheet bundle are disposed in the trimming position H positioned downstream of the folding rollers 63. The bundle posture changing means 64 turns the covered sheet bundle fed from the cover sheet binding position F to a predetermined direction (or posture) and conveys the sheet bundle downstream to the trimming means 65 or the storage stacker 67. The trimming means 65 trims the fringes of the sheet bundle to align the edges. Therefore, the bundle posture changing means 64 is equipped with rotating tables 64a, 64b that grip and turn the sheet bundle fed from the folding rollers 63. As shown in
Therefore, the sheet bundle guided to the bookbinding path 33 is gripped by the pair of left and right rotating tables 64a, 64b, then the posture of the sheet bundle is changed by the turning motors Mt1, Mt2. For example, the sheet bundle with its spine portion conveyed downward is rotated 180 degrees and fed to downstream discharge rollers 66 with the fore-edge portion facing downward. The sheet bundle is sequentially rotated 90 degrees to turn the sheet bundle's top and bottom and fore-edge portion at a downstream trimming position G to enable the trimming of three edge directions of the sheet bundle. Note that a grip sensor (not shown) is provided on the rotating table 64b of the movable side. This detects that the sheet bundle has been securely gripped between the left and right side rotating tables 64a, 64b. After detection, the rotating tables 64a, 64b are configured to revolvingly drive. Also, the unit frame 64x raises and lowers the sheet bundle along the bookbinding path 33 using an elevator motor MA. This is to configure a jog mechanism to offset a predetermined amount the sheet bundle fed by the discharge rollers 66 and convey the sheet bundle to a trimming position H when trimming edges of the sheet bundle, and to set the trimming width at the trimming position H by that feed amount.
Configuration of Trimming Means
Trimming means 65 are provided downstream of the bundle posture changing means 64. As shown in
In the trimming to align the booklet sheets, the top portion of the booklet sheets is cut with the trimming amount Lc1, as shown in
On the other hand the cover sheet trimming amount is calculated in the same way as described above. The trimming amount Ld3 of the fore-edge portion of the cover sheet is calculated by Ld3=[[(inner sheet size)−(bundle thickness)]÷2−(finished size)], for example. The trimming amount Ld of the cover sheet and the trimming amount Lc of the inner sheets are calculated for each, and the longer of the two is set to the trimming position to execute the trimming process. The trimming amount computing means 78, described below, is configured in this way.
Finisher Configuration
The bookbinding unit C is arranged in the finishing unit D. The finishing path 39a is connected to cover sheet conveyance path 34 for the finishing unit D, and a finisher, such as a staple unit, punch unit, and stamp unit or the like, is disposed in the finishing path 39a. Printed sheets are received from the image-forming unit A via the cover sheet conveyance path 34 and are stapled, punched or applied with a mark, then conveyed to the discharge tray 37. It is also possible not to apply any finishing process on printed sheets and to store them in the discharge tray 37 directly from the image-forming apparatus A.
Configuration of Control Means
The configuration of the control means in the apparatus described above will now be explained with reference to
This control CPU75 receives a finishing mode instruction signal, job end signal, sheet size information, and other information and command signals required in the bookbinding process from the control CPU70 of the image-forming unit A. On the other hand, sheet sensors Se1 to Se6 are arranged in the positions shown in
Configuration of Trimming Amount Calculation Means
The trimming amount calculation means 78 is configured in the control CPU75, and calculates the amount of the edges of the sheet bundle to trim after the bookbinding process. For that reason, the trimming amount calculation means 78 receives the folding specifications information and sheet size information set by the mode on the image-forming unit A from the control unit 70 of the image-forming unit A.
To explain this with reference to
The trimming amount calculation means 78 calculates the (1) inner sheet trimming amounts (hereinafter called the length) Lc1, Lc2 and Lc3 according to the trimming conditions above from that information. The calculating method is as described above when the finishing size is specified. (2) Next, the trimming amount calculation means 78 calculates the cover sheet trimming amount Ld1 (top), Ld2 (bottom), and Ld3 (fore-edge portion). In such a case, the bundle thickness of the inner sheets is considered.
Next, the trimming amount calculation means 78 compares the inner sheet trimming amount Lc and cover sheet trimming amount Ld with the top, bottom and fore-edge portion sides to set the longest of the inner sheet and cover sheet to the actual trimming amount. Note that such calculation of the trimming amount differs according to the system configuration. For example, if the size of sheet specified by the image-forming unit A is not prepared, and the bookbinding process is executed by printing on a size of sheet that is larger than the specified size and the excess portions are trimmed, it is necessary for the operator to specify “finished size.”
Configuration of Folding Position Calculating Means
Next, the folding position calculating means 73 is configured in the control CPU75, and calculates the folded position of the sheets folded at the sheet folding unit B. To explain with reference to
In other words, when L1 (the length of the spine edge and the inner-facing folding position) is smaller than the length of the bookbinding finishing size, the calculated folding length is set to the inner-facing folding position N1. Also, when this L1 is L1≧bookbinding finishing size, this is set to L1=(bookbinding finishing size=β). Note that β is set to a preset, arbitrary value, considering discrepancy of the trimming position. By setting to this, the inner-facing folding position N1 (see
Explanation of Bookbinding Operation
Next, the bookbinding process operations using the control CPU75 will now be explained with reference to the flowchart block diagram of
In the print-out mode, a sheet formed with an image does not undergo the bookbinding process or the finishing, and is conveyed out to the discharge tray 37 (equipped on the finisher unit D shown in the drawings) and stored. With the bookbinding mode, sheets formed images are aligned and stacked, then joined with a cover sheet and stored in the storage stacker 67. Also, in the staple mode, sheets formed with images are stapled by a stapling unit equipped in the finisher unit D; in the marking mode, a mark is applied; in the hole-punching mode, holes are punched in the sheets; and in the jog mode, sheets are sorted. Each of these modes is executed by the finisher unit D, and then the finished sheets are stored in the discharge tray 37.
When the bookbinding mode is selected and the finishing mode, an image forming operation is executed by the image-forming unit A, and the sheet formed with images is conveyed out from the discharge outlet 14. (St002) With the bookbinding unit C, this sheet is received in the conveyance path 31. At this time the CPU75 positions the path switching flapper 36 in the state shown in
In parallel to the forming of images on the sheet, the control CPU75 calculates the trimming amounts Lc, Ld explained with reference to
There, when the job end signal (St006) is received from the image-forming unit A, the control CPU75 conveys the sheet bundle on the stacking tray 41 by the gripping conveyance means 47 to turn the sheet bundle posture 90 degrees. This changes the posture of the sheet bundle collated on the stacking tray 41 form a horizontal orientation to a vertical orientation to be conveyed over the bookbinding path 33 to the downstream adhesive application position F (St007).
The control CPU75 conveys a cover sheet from the cover sheet conveyance path 34 at the time the sheet bundle is conveyed to and set at the adhesive application position F. This cover sheet can be fed after being formed with an image at the image-forming unit A, or fed from the inserter unit E.
The sheet fed by the sheet feed path P3 is conveyed to the conveyance path 31. At this time the CPU75 positions the path switching flapper 36 in the state shown in
After finishing the adhesive application operation, the control CPU75 conveys the sheet bundle to the downstream cover sheet binding position G using the gripping conveyance means 47. When this happens, the cover sheet is set at that position so the cover sheet is backed up by the spine support plate 61 and joined to the sheet bundle in an upside-down T-shape. Next, the sheet bundle covered by the folding plates 62 press-forming the backside of the cover sheet.
After the covering process above, the control CPU75 determines whether a trimming mode has been selected (St011). For the trimming mode, the gripping conveyance means 47 releases from the sheet bundle and returns to its default position. A trimming blade 65x is positioned at the trimming position H and stops the descending sheet bundle (St012). In this state, the movable rotating table 64b moves from the standby position to a sheet gripping position to nippingly hold the sheet bundle between itself and rotating table 64a (St013). Next, after the control CPU75 moves the trimming blade 65x to the standby position, it revolves the rotating tables 64a, 64b to turn the sheet bundle so that its top is at the bottom side (St014). There, the trimming edge pressing member 65b pressingly holds the sheet bundle and the trimming blade 65x buts a predetermined amount (St016).
Next, the control CPU75 retracts the trimming edge pressing member 65b to the standby position, then turns the sheet bundle 180 degrees so that the other side is at the bottom to cut the bottom portion. Next, the control CPU75 retracts the trimming edge pressing member 65b to the standby position, then turns the sheet bundle 90 degrees so that the other side is at the bottom to cut the bottom portion. After the sides of the sheet bundle are cut and aligned in this way, the control CPU75 ends trimming the three directions of the sheet bundle and shifts to the discharge operation (St017). On the other hand, at step St011 above, if there is no trimming mode selected, the control means 75 shift to the discharge operation.
Alternative Embodiment Of Image-Forming System
Furthermore, the present invention can attain aforementioned objects with the configuration described below. The folding position with the first control mode in the apparatus described above was set using a “virtual trim depth.” The folding position in the first control mode can be configured as described below.
A trimming means that cuts and aligns the fore-edge portion of the sheet bundle bound to a cover sheet and trimming amount setting means that sets the amount of the fore-edge portion to cut using the trimming means are furnished. The folding position calculating means sets the folded position from the trim depth set by the trimming amount setting means when in the first control mode, and sets the folded position based on sheet size information from the image-forming means when in the second control mode. The folded position in the first control mode is set so that the distance of the length of the spine edge and the folding position is shorter than the distance of the length of the spine edge and the fore-edge portion edge after trimming.
With this configuration, when the first control mode is set, the folded position of the sheet will not be cut in the trimming process, and the same objects as described above can be attained. The present application claims priority rights from Japanese Pat. App. Nos. 2007-89282 and 2007-194363, which are herein incorporated by reference.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2007-089282 | Mar 2007 | JP | national |
| 2007-194363 | Jul 2007 | JP | national |
| Number | Name | Date | Kind |
|---|---|---|---|
| 20090035016 | Sanmiya et al. | Feb 2009 | A1 |
| Number | Date | Country |
|---|---|---|
| 2008247533 | Oct 2008 | JP |
| Number | Date | Country | |
|---|---|---|---|
| 20080237962 A1 | Oct 2008 | US |
