Patent Grant
10421307
This patent application is based on and claims priority pursuant to 35 U.S.C. 119(a) to Japanese Patent Application No. 2016-018521 filed on Feb. 3, 2016 in the Japan Patent Office, the entire disclosure of which is hereby incorporated by reference herein.
Embodiments of the present disclosure relate to a sheet binding system that binds a sheet bundle, an image forming apparatus, such as a copier, a printer, a facsimile, or a multi-function device (MFD) having multiple functions of these devices, etc., with the sheet binding system, and a method of binding a sheet bundle.
A sheet binding system is sometimes employed in an image forming apparatus, such as a copier, a printer, a facsimile, or a multi-function device (MFD) having multiple functions of these devices, etc. A known sheet binding system conducts a sheet binding process without using a metal needle. That is, the sheet binding system forms an uneven portion on a sheet bundle composed of multiple sheets in a thickness direction of the sheet bundle by engaging a pair of dentate uneven portions each other while putting the sheet bundle therebetween during a metal needleless binding process. For this reason, the sheet binding system is known as an environmentally friendly device.
One aspect of the present disclosure provides a novel sheet binding system that includes a sheet stacking section to stack multiple sheets and generate a sheet bundle, a sheet binding unit to apply a sheet binding process to the sheet bundle stacked on the sheet stacking section at at least one sheet binding portion of the sheet bundle, and a unit shifting device to shift and stop the sheet binding unit from a retracted position to the sheet binding portion of the sheet bundle. The sheet binding unit includes a first sheet binder having first and second dentate uneven sheet binding elements to conduct a first sheet binding process by engaging each other by a prescribed meshing depth while sandwiching the sheet bundle therebetween to form a dentate unevenness on the sheet bundle in a thickness direction of the sheet bundle at a first sheet binding portion of the sheet bundle. A second sheet binder having third and fourth dentate uneven sheet binding elements also included in the sheet binding unit to conduct a second sheet binding process by engaging each other by a greater meshing depth than that made by first and second dentate uneven sheet binding elements of the first sheet binder while sandwiching the sheet bundle therebetween to form a dentate unevenness on the sheet bundle in the thickness direction of the sheet bundle at a second sheet binding portion different from the first sheet binding portion of the sheet bundle.
Another aspect of the present disclosure provides a novel image forming apparatus that includes a housing to house at least one toner image forming device, the above-described sheet binding system, and a sheet ejector to eject a sheet bearing the toner image thereon into the sheet binding system.
Yet another aspect of the present disclosure provides a novel method of binding a sheet bundle. The method includes the steps of stacking multiple sheets on a sheet stacking section to generate a sheet bundle, shifting and stopping a first set of a first dentate uneven sheet binding element and a second dentate uneven sheet binding element and a second set of a third dentate uneven sheet binding element and a fourth dentate uneven sheet binding element from a retracted position to sheet binding portions of the sheet bundle, respectively, and engaging the first set of a first dentate uneven sheet binding element 93a and a second dentate uneven sheet binding element each other by a prescribed meshing depth while sandwiching the sheet bundle between the first dentate uneven sheet binding element and the second dentate uneven sheet binding element. The method further includes the steps of forming a dentate unevenness on the sheet bundle in a thickness direction of the sheet bundle at the first sheet binding portion of the sheet bundle, engaging the second set of the third dentate uneven sheet binding element and the fourth dentate uneven sheet binding element 94b each other by a different meshing depth from the prescribed meshing depth while sandwiching the sheet bundle between the third dentate uneven sheet binding element and the fourth dentate uneven sheet binding element, and forming a dentate unevenness on the sheet bundle in a thickness direction of the sheet bundle at the second sheet binding portion deviated from the first sheet binding portion of the sheet bundle.
A more complete appreciation of the present disclosure and many of the attendant advantages of the present disclosure will be more readily obtained as substantially the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
In a known sheet binding system, a sheet binding process is conducted by rotating a pair of rotators having dentate uneven portions meshing with each other, respectively, while putting a sheet bundle conveyed in a given direction therebetween. In yet another known sheet binding system, rather than conveying a sheet bundle and conducting the sheet binding process in parallel, only after stacking the sheet bundle on a stacking section and moving a sheet binding system having a pair of dentate uneven portions to a sheet binding section, the sheet binding process is started by engaging the pair of uneven portions each other while putting the sheet bundle therebetween. In yet another known sheet binding system that employs a revolver binding technology, to apply a sheet binding process to a sheet bundle with optimal binding force in accordance with a thickness and the number of sheets, multiple binders having different binding powers from each other (a pair of binders) are mounted on a supporting plate and are selectively used.
However, in the above-described first and second known sheet binding systems, due to resistance caused during conveyance of the sheet bundle, the sheet bundle skews, and accordingly the sheet binding process is applied to the skewing sheet bundle. By contrast, the above-described third known sheet binding system is expected to resolve a problem in that the sheet binding process is applied to the skewing sheet bundle. However, since only after detecting a thickness and the number of sheets of the sheet bundle, a supporting plate that accommodates multiple binding units (e.g., a pair of binding units) rotates and brings an optimum binding unit out of the multiple binding units to a position opposed to a sheet binding position of the sheet bundle, the sheet binding process takes a certain time while complicating a configuration and operation of the sheet binding system.
Referring now to the drawings, wherein like reference numerals designate identical or corresponding member throughout the several views of the drawings, and in particular to
As shown in
An original document conveying unit 10 is included in the image forming apparatus 1 to convey the original document D set to an original document setting table to the original document reading unit 2. Multiple sheet cassettes 12 to 14 are also included in the image forming apparatus 1 to accommodate sheet bundles of multiple transfer sheets P, respectively. A pair of registration rollers (i.e., a pair of timing rollers) 17 is provided to timely convey the sheet P toward a toner image transfer station 7. A fixing unit 20 is further included in the image forming apparatus 1 to fix an unfixed toner image borne on the sheet P onto the sheet P. A fixing roller 21 is disposed in the fixing unit 20. A pressing roller 22 is also disposed in the fixing unit 20 as well. A duplex copy conveying unit 30 is further included in the image forming apparatus 1 to turn the sheet P upside down after the toner image is formed and transfer onto a front side thereof and to convey the sheet P toward the image forming unit. A post-processing machine 50 is provided downstream of the image forming apparatus 1 to apply a post process to the sheet P ejected from a body of the image forming apparatus 1 and delivered thereinto. A sheet stacking section (i.e., an inner tray) 61 is installed in the post-processing machine 50. Multiple trays (i.e., sheet ejection trays) 71 to 73 are also included in the post-processing machine 50 to stack either the sheet P or the sheet bundle PT discharged after the post process is completed. A sheet binding system 90 is installed in the post-processing machine 50 as well. Multiple binding units 91 and 92 are included in the sheet binding system. The post-processing machine 50 is detachably attached to the body of the image forming apparatus 1.
Now, a typical toner image forming process conducted in the body of the image forming apparatus 1 is described with reference to
At the same time, in the image forming unit 4, since the photoconductive drum 5 rotates clockwise in the drawing, a toner image (e.g., a monochrome toner image) is formed on the photoconductive drum 5 when a toner image forming process (i.e., a charging process, an exposing process, a developing process) is applied thereto corresponding to the image information. After that, the toner image formed on the photoconductive drum 5 is transferred on to the sheet P conveyed by a pair of registration rollers 17 in the toner image transfer station 7 acting as a toner image forming section.
Here, the sheet P to be conveyed to the toner image transfer station 7 (i.e., the image forming section) is handled as described herein below. First of all, among these multiple sheet cassettes 12, 13, and 14 provided in the body of the image forming apparatus 1, one of these multiple sheet cassettes 12, 13, and 14 is chosen either automatically or manually. In the present example, the topmost sheet cassette 12 is chosen. Then, the topmost sheet among the multiple sheets P stored in the sheet cassette 12 is conveyed toward a sheet conveyance path K1, in which multiple sheet conveying rollers are disposed.
After that, the sheet P reaches the pair of registration rollers 17 after passing through the sheet conveyance path K1. Then, the sheet P positioned at the pair of registration rollers 17 is timed and conveyed toward the toner image transfer station 7 (i.e., a toner image forming section) to synchronize with the toner image formed and borne on the photoconductive drum 5.
After completing the toner image transfer process and passing through the toner image transfer station 7, the sheet P reaches a fixing unit 20 after passing through the sheet conveyance path K. The sheet P now reaching the fixing unit 20 is fed into a gap between a fixing roller 21 and a pressing roller 22. Then, the toner image borne on the sheet P is fused by heat provided from the fixing roller 21 and pressure provided from both of the fixing roller 21 and the pressing roller 22. The sheet P with the toner image now having been fixed exits from the body of the image forming apparatus 1 after being launched from the gap between the fixing roller 21 and the pressing roller 22 (i.e., a fixing nip).
When a duplex printing mode is chosen as an option to form toner images on both sides (i.e., on the front side and back side) of the sheet P, respectively, the sheet P completing a toner image fixing process on the front side thereof is not ejected as is but is guided by a duplex printing sheet conveyance path K2 as different from when a single-sided print mode, in which the sheet P exits as is, is chosen. Specifically, a sheet conveying direction is reversed in a duplex printing sheet conveying unit 30 and is conveyed once again toward the toner image transfer station 7 (i.e., the image forming section). Then, a similar toner image forming process to the toner image forming process as described earlier is conducted in the toner image transfer station 7 thereby forming another toner image on the backside surface of the sheet P. The sheet P is then discharged from the body of the image forming apparatus 1 after receiving the fixing process in the fixing unit 20 and passing through a sheet conveyance path.
Further, in this embodiment of the present disclosure, as shown in the drawings, a post-processing machine 50 is attached to the image forming apparatus 1. Hence, the sheet P is discharged from the body of the image forming apparatus 1 and enters the post-processing machine 50. The sheet P is then post-processed by the post-processing machine 50 therein. Also as shown in
Specifically, as shown in
Hence, when a mode without conducting the post process is chosen, the sheet P conveyed into the first sheet conveyance path K3 is discharged onto the first sheet ejection tray 71 by a third pair of sheet conveying rollers 53. When a sort mode is chosen, the sheet P conveyed onto the second sheet conveyance path K4 is further conveyed while being shifted per sheet P by a given amount in a widthwise direction of the sheet P (i.e., perpendicular to a plane of the drawing of
The external tray 72 is now more specifically described with reference to
By contrast, when a sheet binding mode (e.g., a staple mode) is chosen, the sheet P conveyed onto the second sheet conveyance path K4 is further conveyed without being shifted by the fourth pair of sheet conveying rollers 54 and is successively stacked on the sheet stacking section 61 (i.e., the inner tray). Then, every when the sheets P (i.e., a sheet bundle PT) are placed on a stacking surface of the sheet stacking section 61, a sheet slapping roller 64 and an auxiliary sheet conveying roller 65 (see
At the same time, as shown in
Further, when a folding mode is chosen, the sheet P is firstly conveyed to the second sheet conveyance path K4. The sheet P is then switch backed with its trailing end being sandwiched by the pair of fourth sheet conveying rollers 54 when the pair of fourth sheet conveying rollers 54 is reversely rotated and is further conveyed to the third sheet conveyance path K5. Then, the sheet P conveyed to the third conveyance path K5 is further conveyed by pairs of sixth to eighth sheet conveying rollers 56 to 58 to a position at which a central portion of the sheet P is opposed to the second sheet binding system 83 (i.e., a position at which a pair of conveyance guide plates acts as a stacking section). Then, after the desired number of sheets P (i.e., the sheet bundle PT) are stacked at the position, a sheet binding process is applied to a middle portion of the sheet bundle PT by the second sheet binding system 83. Subsequently, these plural sheets P (i.e., the sheet bundle PT) having received the sheet binding process are further conveyed by the pairs of seventh and eighth sheet conveying rollers 57 and 58 to a prescribed position, at which the middle portion of the sheet P (i.e., the sheet bundle PT) is again opposed to a sheet folding blade 84. At that time, a leading end of each of the multiple sheets P (i.e., the sheet bundle PT) bumps against a stopper 85 moved by a stopper moving mechanism in the sheet conveying direction. Then, the multiple sheets P (i.e., the sheet bundle PT) are folded at the center thereof by the sheet folding blade 84 as it moves to a left side in
Now, an exemplary configuration and operation of the sheet binding system 90 of this embodiment of the present disclosure is described more in detail mainly with reference to
Here, the sheet stacking section 61 is configured with its mounting surface tilting upward from one end thereof (i.e., on the right in
That is, in the sheet binding system 90 in this embodiment of the present disclosure, there are provided two sheet binding units 91 and 92. Specifically, as shown in
Similarly, as a system to operate the second sheet binding unit 92, the unit shifting device includes a second bearing 250 that secures the second sheet binding unit 92 to a second guide rail 212 and a second drive belt 251 at the same time. The unit shifting device also includes a second drive motor 255 to transmit power of the second drive motor 255 to the second drive belt 251 via second driven pulleys 252 and 254 and a second drive belt 253. The second drive motor 255 is controlled by a second drive controller 256 to shift and stop the second sheet binding unit 92 at a prescribed sheet binding position as shown by a broken line in
Hence, the first sheet binding unit 91 receives driving force from a first drive unit and accordingly shifts from a first reference position located at one end of the sheet bundle PT stacked on the sheet stacking section 61 in a widthwise direction thereof (i.e., a position as shown by a solid line in
By contrast, the second sheet binding unit 92 receives driving force from a second drive unit (i.e., a unit shifting device) and shifts from a second reference position located at the other end of the sheet bundle PT stacked on the sheet stacking section 61 in a widthwise direction thereof (i.e., a position as shown by a solid line in
As described heretofore and with additional reference to
Since the sheet binding system 90 is configured in this way, either of two sheet binding units 91 and 92 is chosen by the user (i.e., the operator) and a prescribed binding process is conducted based on a choice of him or her. Specifically, the user handles a control panel mounted on an exterior of the body of the image forming apparatus 1 (or that of the post-processing machine 50), for example, and chooses any one of the sheet binding processes (i.e., with the metal needle and without the metal needles). Hence, when the sheet binding process (with the metal needle) is chosen, the first sheet binding unit 91 conducts the sheet binding process. By contrast, when the second sheet binding process (without the metal needle) is chosen, the second sheet binding unit 92 conducts the other binding process. Hence, when the sheet binding process is conducted by one of the sheet binding units 91 and 92 chosen, the other one of the sheet binding units 91 and 92 not chosen is evacuated to the reference position thereof. In this way, by establishing the multiple binding units 91 and 92, a range of choice of the sheet binding process can be expanded for the user.
Now, an exemplary configuration and operation of the second sheet binding unit 92 constituting a distinctive feature of the sheet binding system 90 of the post-processing machine 50 is described more in detailed with reference to
Specifically, as shown in
Further, as shown in
Further, as shown in
Further, as shown there, a position of the first sheet binding portion N1 and that of the second sheet binding portion N2 each formed by the second sheet binding unit 92 on the sheet bundle PT are different from each other. Specifically, the second sheet binding portion N2 is displaced from the first sheet binding portion N1 on the sheet bundle PT. These binding portions N1 and N2 receive the sheet binding process without the metal needle.
More specifically, as shown in
In this way, the sheet binding system 90 (i.e., the second sheet binding unit 92) of this embodiment of the present disclosure does not apply the sheet binding process to the sheet bundle PT during conveyance of the sheet bundle PT. That is, the second sheet binding unit 92 of this embodiment of the present disclosure shifts to the sheet binding positions (i.e., the sheet binding portions N1 and N2) of the sheet bundle PT stacked and stopping at the sheet stacking section 61. More specifically, each of the sheet binders 93 and 94 conducts the sheet binding process by engaging the dentate uneven portions thereof each other while sandwiching the sheet bundle PT therebetween. For this reason, a problem in that the sheet binding process is applied to the sheet bundle PT skewing due to resistance caused during conveyance of the sheet bundle PT can be resolved. Especially, in this embodiment of the present disclosure, as described earlier, since the sheet bundle PT stacked on the sheet stacking section 61 is aligned by the end fence of 66 and the pair of jogger fences 68 collectively acting as the sheet aligner before the second sheet binding unit 92 (or the first sheet binding unit 91) applies the sheet binding process to the sheet bundle PT, the problem in that the sheet binding process is applied to the sheet bundle PT in a skew state can be more definitely resolved.
Further, in this embodiment of the present disclosure, to conduct series of binding processes with the second sheet binding unit 92, that is, to apply the sheet binding processes to the different sheet binding portions N1 and N2 in the sheet bundle PT without using the metal needles, since the sheet binders 93 and 94 (i.e., multiple devices) are utilized and have different meshing depths H1 and H2 from each other, respectively, a configuration and control of the sheet binding system can be simplified at the same time while suppressing waste of time during the sheet binding process. In addition, the sheet binding process can be precisely applied to the sheet bundle PT by using preferable binding forces in accordance with a thickness and the number of sheets of the sheet bundle PT even when the thickness or the number of sheets varies. That is, when the sheet bundle PT is constituted by either thick sheets P or a large number of sheets P and accordingly becomes thick, due to the small meshing depth H1, binding force generated by the first sheet binder 93 in the first sheet binding portion N1 becomes weak (i.e., insufficient to preferably bind the sheet bundle PT), thereby possibly causing a sheet binding error. However, since binding force generated by the second sheet binder 94 in the second sheet binding portion N2 is stronger and is preferably maintained due to the greater meshing depth H1, prescribed preferable binding force (i.e., binding quality) can be ensured by the second sheet binding unit 92 as a whole. Further, when the sheet bundle PT is constituted by either thin sheets P or a small number of sheets P and accordingly becomes thin, due to the great meshing depth H2, binding force generated by the second sheet binder 94 in the second sheet binding portion N2 becomes excessive, thereby generating a risk to tear the sheet P in the sheet bundle PT. However, since binding force generated by the first sheet binder 93 in the first sheet binding portion N1 is preferably maintained due to the small meshing depth H1, prescribed preferable binding force (i.e., binding quality) can be ensured by the second sheet binding unit 92 as a whole.
Here, in the second sheet binding unit 92 of this embodiment of the present disclosure, a time when the first sheet binder 93 applies the sheet binding process to the first sheet binding portion N1 of the sheet bundle PT and thereby generating the maximum pressure in the first sheet binding portion N1 thereof is designed to be not equivalent to a time when the second sheet binder 94 applies the sheet binding process to the second sheet binding portion N2 of the sheet bundle PT and thereby generating the maximum pressure in the second sheet binding portion N2 thereof. That is, as understood from
That is, as shown in
Now, an exemplary binding process conducted by the second sheet binding unit 92 is typically described herein below with further reference to
Hence, according to this embodiment of the present disclosure, since a time to apply the sheet binding process to the first sheet binding portion N1 by using the first sheet binder 93 is slightly deviated from a time to apply the sheet binding process to the second sheet binding portion N2 by using the second sheet binder 94, the maximum load on a driving source (e.g., the driving motor) employed in the second sheet binding unit 92 may be reduced more than when the above-described times are substantially the same. With this, the second sheet binding unit 92 can be downsized at low cost as well.
Now, an exemplary modification of the present disclosure is described with reference to
Again, in this exemplary modification of the present disclosure, as a system to operate the second sheet binding unit 92, the same unit shifting device as described with reference to
Hence, as described heretofore, according to one embodiment of the present disclosure, in the second sheet binding unit 92 of the sheet binding system 90, the first sheet binder 93 that includes a pair of dentate uneven portions 93a1 and 93b1 having a prescribed meshing depth is provided to conduct a sheet binding process by engaging the pair of dentate uneven portions 93a1 and 93b1 each other while sandwiching the sheet bundle PT therebetween to form a dentate unevenness in a thickness direction of the sheet bundle PT at a first sheet binding portion N1 of the sheet bundle PT. Also provided in the second sheet binding unit 92 of the sheet binding system 90 is a second sheet binder 94 also having a pair of dentate uneven portions 94a1 and 94b1 having a greater meshing depth than that of the first sheet binder 93 to form a denature unevenness in a thickness direction of the sheet bundle PT by engaging the pair of dentate uneven portions 94a1 and 94b1 each other while sandwiching the sheet bundle PT therebetween at a second sheet binding portion N2 different from the first sheet binding portion N1 of the sheet bundle PT. With this, the sheet binding process is applied to the sheet bundle PT not in the skew state by using appropriate sheet binding forces even if a thickness and the number of sheets of the sheet bundle PT vary.
According to one embodiment of the present disclosure, although it is applied to the first sheet binding system 90, the present disclosure can be naturally applied to the second sheet binding system 83 as well. Further, although one embodiment of the present disclosure is applied to the sheet binding system 90 that accommodates the second sheet binding unit 92 that applies the sheet binding process without using the metal needle in addition to the first sheet binding unit 91 that applies the sheet binding process with the metal needle, the present disclosure can be also naturally applied to a sheet binding system 90 that accommodates a sheet binding unit that only applies a sheet binding process without using the metal needle as well. Further, although one embodiment of the present disclosure is applied to the sheet binding system 90 installed in the post-processing machine 50 of a monochrome image forming apparatus 1, the present disclosure can be also naturally applied to a sheet binding system installed in a post-processing machine 50 of a color image forming apparatus as well. Further, although one embodiment of the present disclosure is applied to the sheet binding system 90 installed in the post-processing machine 50 of the image forming apparatus 1 that employs electrography, the present disclosure is not limited thereto and can be also naturally applied to a sheet binding system installed in a post-processing machine of a different type image forming apparatus, such as a stencil printing apparatus, an ink jet image forming apparatus, etc. Further, the present disclosure is not limited to the sheet binding system 90 included in the post-processing machine 50, but can be applied to a sheet binding unit as a standalone system as well. That is, for example, the present disclosure can be applied to a sheet binding system, to a sheet conveyance entrance 50a of which, a sheet cassette is attached, and in which a control panel to input an operation mode or the like is installed as well. Even in any one of situations, similar advantages as obtained in the above-described various embodiments of the present disclosure can be similarly obtained again.
Further, in the above-described various embodiments of the present disclosure, between the body of the image forming apparatus 1 and the post-processing machine 50, another post-processing machine (for example, a sheet folding device to fold a sheet P in a shape of letter Z) can also be installed as well. Further, although one embodiment of the present disclosure is applied to the post-processing machine 50 enabled to apply both the sheet binding process and the sheet folding process to the sheet P, the present disclosure is not limited to the above-described post-processing machine 50 and can be naturally applied to another post-processing machine that additionally performs a perforating process (e.g., a punching process), a post-processing machine that only applies the sheet binding process out of the above-described multiple processes, and a post-processing machine that applies combinations of the processes as well.
Further, although one embodiment of the present disclosure is applied to the sheet binding system 90, in which the widthwise direction (i.e., the direction in which the sheet binding units 91 and 92 shift) is perpendicular to the sheet conveying direction, the present disclosure can be naturally applied to a sheet binding system, in which the widthwise direction (i.e., the direction in which the sheet binding units 91 and 92 shift) corresponds to the sheet conveying direction as well. Even in any one of such modifications, similar advantages as obtained in the above-described various embodiments of the present disclosure can be similarly obtained again as long as the sheet binding process is applied to the sheet bundle PT stopping at the sheet biding position.
Further, although the second sheet binding unit 92 is configured to position at the two binding portions N1 and N2 in the corner of the sheet bundle PT as one embodiment of the present disclosure, the present disclosure is not limited thereto and these two binding portions N1 and N2 can be located in a trailing end of the sheet bundle PT (e.g., the multiple binding positions M1 to M3 in
Further, in the various embodiments of the present disclosure, the sheet includes all types of sheet as far as a toner image can be formed on a front surface thereof including, not to mention, a transfer sheet. Thus, the sheet bundle is defined as a bundle of these sheets, accordingly.
Further, the number, the position, and the shape of the element, the device, the unit, and the machine or the like are not limited to those as typically employed in the above-described various embodiments of the present disclosure, and can be any suitable number, a position, and a shape as well.
Numerous additional modifications and modifications of the present disclosure are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the present disclosure may be practiced otherwise than as specifically described herein. For example, the sheet binding system is not limited to the above-described various embodiments and modifications may be made as appropriate. Further, the image forming apparatus is not limited to the above-described various embodiments and modifications may be altered as appropriate as well. Further, the method of binding a sheet bundle is not limited to the above-described various embodiments and modifications may be altered again as appropriate. For example, a step of the method of binding a sheet bundle can be altered as appropriate as well.
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