Patent Grant
9061844
1. Field of the Invention
The present invention relates to a sheet conveying apparatus capable of correcting a skew of a sheet and an image forming apparatus having the sheet conveying apparatus.
2. Description of the Related Art
In conventional image forming apparatuses for forming an image on a sheet, in order to form the image without a skew onto the sheet, a sheet conveying apparatus capable of correcting the skew of the sheet conveyed to an image forming unit is provided.
The configurations discussed in Japanese Patent Application Laid-Open No. 6-336353 and Japanese Patent Application Laid-Open No. 9-183539, a skew of a sheet is corrected by bringing the leading edge of the sheet into contact with a contact portion such as a nip portion of a registration roller pair and a shutter so as to form a loop of the sheet and to make the leading edge of the sheet fit along the nip portion.
In recent image forming apparatuses, there has been growing demands for forming an image onto various types of sheets of different sizes, different grammage, and different surface glossiness with enhanced productivity with a more compact body. Unfortunately, the conventional sheet conveying apparatuses have been in need of some improvements in achieving the high productivity while maintaining the skew correction performance for the various types of sheets.
For example, in conveying a sheet of a large grammage (so-called thick paper), since the sheet stiffness is large, the sheet slips at the nip portion of the roller pair provided upstream of the above-described contact portion when correcting the skew of the sheet. This may cause failure in the formation of the sheet loop of a desired size required to correct the skew of the sheet. If the sheet loop of the desired size cannot be formed, the skew of the sheet cannot be corrected. As a result, the image cannot be formed at an appropriate position on the sheet, causing an image failure. In consideration of the slip, if the loop formation is continued until the loop of a predetermined size is formed, the productivity may be significantly decreased. In other words, for the thick paper, the conventional sheet conveying apparatuses have not been able to achieve sufficient skew correction performance while maintaining high productivity.
The present invention is directed to a sheet conveying apparatus capable of correcting a skew for various types of sheets without decreasing productivity.
According to an aspect of the present invention, a sheet conveying apparatus includes a first conveyance roller pair configured to convey a sheet, a second conveyance roller pair disposed upstream of the first conveyance roller pair and configured to convey the sheet, a contact portion disposed downstream of the first conveyance roller pair and configured to contact the conveyed sheet, a third conveyance roller pair disposed downstream of the first conveyance roller pair and configured to convey the sheet with a skew having been corrected by contacting the contact portion, a separation unit configured to separate the first conveyance roller pair, and a control unit configured to control a conveyance speed of the sheet conveyed by the first conveyance roller pair, a conveyance speed of the sheet conveyed by the second conveyance roller pair, and the separation unit, wherein the control unit forms a loop of the sheet between the first conveyance roller pair and the second conveyance roller pair, and separates the first conveyance roller pair before a leading edge of the sheet reaches the contact portion.
Further features of the present invention will become apparent from the following description of exemplary embodiments with reference to the attached drawings.
Various exemplary embodiments, features, and aspects of the invention will be described in detail below with reference to the drawings.
First, an image forming unit will be described. The surfaces of four photosensitive drums 101a to 101d are uniformly charged by charging rollers 102a to 102d, respectively. To laser scanners 103a to 103d, image signals of yellow (Y), magenta (M), cyan (C), and black (B) are respectively input. According to the image signals, the drum surfaces are irradiated with laser beams, the electric charge is neutralized, and latent images are formed.
The latent images formed on the photosensitive drums 101a to 101d are developed with toner of yellow, magenta, cyan, and black by development units 104a to 104d, respectively. The toner developed on the respective photosensitive drums is sequentially transferred onto an intermediate transfer belt 106 that serves as an endless belt-shaped image bearing member by primary transfer rollers 105a to 105d. In this way, on the intermediate transfer belt 106, a full-color toner image is formed.
A sheet fed from any one of sheet feeding units including sheet cassettes 111 and 112, and a manual sheet feeding unit 113 is conveyed toward a third conveyance roller pair (registration roller pair) 120 by a second conveyance roller pair 114 and a first conveyance roller pair 115. The toner image on the intermediate transfer belt 106 is controlled so that no deviation occurs between the sheet conveyed by the third conveyance roller pair 120 and the image. The toner image is transferred onto the sheet by a secondary transfer outer roller 109. The toner image is then heated and pressed by a fixing device 110 and fixed onto the sheet. Thereafter, the sheet is discharged from a discharge unit 119a or 119b to the outside of the apparatus main unit.
From an operation unit 200 (illustrated in
Each of the sheet cassettes 111 and 112 includes a size detection unit 130 for detecting a size of a stored sheet and notifying the below-described control unit 50 of the image forming apparatus of the detected size. The size detection unit 130 includes a size detection lever that slides and comes in contact with a side regulating plate for regulating the position of the sheet in the width direction. The side detection lever can rotate in conjunction with the side regulating plate.
The size detection unit 130 includes a plurality of sensors or switches in an attachment portion in the apparatus main body to which the sheet cassette is to be attached. The sensors or switches are provided at positions corresponding to the size detection lever. If the user moves the side regulation plate to fit it to the side end portion of the sheet, the size detection lever rotates in conjunction with the movement. In response to the sheet cassette being attached to the image forming apparatus, the side detection lever selectively turns on or off detection elements of the sensors or the switches provided in the attachment portion of the apparatus main body. With this operation, signals of different patterns are sent from the sensors or switches to the image forming apparatus main body. Based on the signals, the information processing apparatus main body can recognize the size of the sheet stored in the sheet cassette. The manual sheet feeding unit 113 may be provided with a similar mechanism to the foregoing, as a size detection unit.
The side regulation plate can be moved along the side end portion of the sheet. This enables position adjustment of the sheet in the width direction with respect to the image forming unit. The side regulation plate is also effective to prevent a sheet skew caused during the sheet feeding operation at the conveyance rollers provided downstream of the sheet feeding rollers. In actual operations, however, a small space between the side regulation plate and the sheet may cause a skew of the sheet. In another case, the sheet conveyed from the sheet feeding unit may be skewed during the sheet conveyance operation.
To solve the problems, an image forming apparatus according to a first exemplary embodiment includes a sheet conveying apparatus 116 capable of correcting a skew of a sheet fed to the image forming unit.
With reference to
The first conveyance roller pair 115 provided in the conveyance path includes, as illustrated in
The second conveyance roller pair 114 provided upstream of the first conveyance roller pair 115 includes, similarly to the first conveyance roller pair 115, as illustrated in
The third conveyance roller pair 120 is provided downstream of the first conveyance roller pair 115, and serves as a contact portion where the leading edge of a conveyed sheet comes in contact therewith, for sheet skew correction. As illustrated in
The third conveyance lower roller 120b is a rubber roller. The third conveyance upper roller 120a and the third conveyance lower roller 120b are disposed to face each other. The third conveyance upper roller 120a is pressed against the third conveyance lower roller 120b by elastic force of a spring (not illustrated).
A separation unit 140 separates the first conveyance upper roller 115a from the first conveyance lower roller 115b. The separation of the first conveyance upper roller 115a from the first conveyance lower roller 115b can reduce the force of the first conveyance roller pair 115 for nipping the sheet to zero. The separation unit 140 includes a first conveyance upper roller separation motor 145, an input gear 144, a driven shaft 143 for supporting the first conveyance upper roller 115a, and a separation lever front 142f and a separation lever rear 142r for separating the first conveyance upper roller 115a from the first conveyance lower roller 115b. An output gear of the first conveyance upper roller separation motor 145 engages with the input gear 144. The input gear 144 is fixed to an end portion of the driven shaft 143. The separation lever front 142f and the separation lever rear 142r fixed to the driven shaft 143 come in contact with the shaft of the first conveyance upper roller 115a from the under side.
With the mechanism, rotating the first conveyance upper roller separation motor 145 to the left in
In
With reference to
A skew correction operation to be performed when the sheet is skewed to the left side (front side) with respect to the conveyance direction, as illustrated in
First, the sheet fed from the sheet cassette 111 or 112 is nipped by the second conveyance roller pair 114, and conveyed toward the first conveyance roller pair 115. The sheet conveyed by the second conveyance roller pair 114 is then nipped by the first conveyance roller pair 115, and conveyed toward the third conveyance roller pair 120.
In this operation, the conveyance speed of the first conveyance roller pair 115 is set to a speed lower than the conveyance speed of the second conveyance roller pair 114. Consequently, as illustrated in
In the first exemplary embodiment, the conveyance distance L from the first conveyance roller pair 115 to the third conveyance roller pair 120 is set to 15 mm to 30 mm in view of the stability in the conveyance of the separated sheet after the separation.
In the first exemplary embodiment, depending on the information about the sheet input by the user to the operation unit 200, the control unit 50 appropriately adjust the conveyance speed difference between the first conveyance roller pair 115 and the second conveyance roller pair 114. That is, the control unit 50 acquires the information about the sheet to be conveyed, and based on the acquired information about the sheet, the control unit 50 determines the speed difference between the conveyance speed of the sheet by the first conveyance roller pair 115 and the conveyance speed of the sheet by the second conveyance roller pair 114.
For example, in the first exemplary embodiment, a speed difference for a sheet having a large grammage to be conveyed is set to a value larger than a speed difference for a sheet having a small grammage to be conveyed. This is because, for the sheet having the large grammage, the sheet may slip at the nip portion of the second conveyance roller pair 114, and thus it is difficult to form a loop.
Through this adjustment, in the first exemplary embodiment, a loop can be appropriately formed depending on the type of the sheet to be conveyed.
Then, as illustrated in
The first conveyance roller pair 115 is thus separated, so that the sheet is conveyed by the force of the sheet to return from the loop state to a flat state (hereinafter, referred to as loop resistance) and the conveyance force of the second conveyance roller pair 114.
In the conveyance, the left side (front side) of the sheet advancing ahead comes in contact with the nip portion of the third conveyance roller pair 120 earlier than the right side (rear side). At the time, the rotation of the third conveyance roller pair 120 is being stopped. Then, the right end portion advancing behind comes in contact with the nip portion of the third conveyance roller pair 120 and the skew of the sheet is corrected. The sheet is conveyed while being twisted in the loop, thereby correcting the skew.
Then, the third conveyance roller pair 120, which is in a non-rotating state, starts the rotation, and as illustrated in
For a sheet having a large grammage (a sheet having large stiffness, for example, thick paper), the loop formation force necessary to start forming a loop from a flat state is considerably large as compared to that of plain paper. If the loop formation force exceeds the sheet nipping force of the second conveyance roller pair 114, the sheet slips at the nip portion of the second conveyance roller pair 114, and this may cause a decrease in the conveyance amount of the second conveyance roller pair 114, and a failure in the formation of a loop of a desired size of the sheet.
If the loop formation operation by the second conveyance roller pair 114 is continued until the desired loop is formed, the stop time of the third conveyance roller pair 120 (the time period for which the sheet stops at the nip portion of the third conveyance roller pair 120) increases, making it difficult to achieve high-productivity of the image formation.
Increasing the conveyance speed of the second conveyance roller pair 114 during the loop formation can reduce the loop formation time. However, this causes the leading edge of the sheet to come in contact with the nip portion of the third conveyance roller pair 120 at high speed. That is, this may increase the sound generated at the contact operation, or may cause damages such as a bend at the leading edge of the sheet. Consequently, during the loop formation, it is desirable to set the conveyance speed of the second conveyance roller pair 114 at a low speed.
In view of the foregoing, in the first exemplary embodiment, before the leading edge of the sheet comes in contact with the third conveyance roller pair 120, a loop is formed during the conveyance between the first conveyance roller pair 115 and the second conveyance roller pair 114. During the conveyance, the loop formation is performed taking advantage of a conveyance speed difference between the conveyance speed of the first conveyance roller pair 115 and that of the second conveyance roller pair 114. Consequently, the loop can be gradually formed during the conveyance. As described above, according to the first exemplary embodiment, for thick paper, a desired loop can be formed without extending the stop time of the third conveyance roller pair 120, and thus the skew correction ability for thick paper can be increased.
Further, in the first exemplary embodiment, before the leading edge of the sheet comes in contact with the nip portion of the third conveyance roller pair 120, the first conveyance roller pair 115 is separated. This can weaken the force of the sheet in coming in contact with the nip portion of the third conveyance roller pair 120, and prevent the leading edge of the sheet from being stuck into the nip portion. This is because the sheet comes in contact with the nip portion of the third conveyance roller pair 120 in the looped state by forming the loop of the sheet between the second conveyance roller pair 114 and the first conveyance roller pair 115, and separating the first conveyance roller pair 115. On the other hand, in the state where the first conveyance roller pair 115 is being pressed, the sheet is linearly conveyed and the force of the third conveyance roller pair 120 in coming in contact with the nip portion is large.
With reference to
In step 5101, a user executes a print job from the operation unit 200 of the image forming apparatus or the computer 201 connected directly or via a network to the image forming apparatus. In this operation, the user can specify the number of sheets to be printed and sheet information about the sheet to be used. Further, by the size detection unit 130, the sheet information can be detected.
In step 5102, in response to the execution of the print job, the sheet feeding operation is started. In step S103, based on the sheet information specified by the user, whether to change the conveyance speed of the first conveyance roller pair is determined.
In step S104, when feeding thin paper or plain paper that can be easily looped, the control unit 50 sets the speed so that the conveyance speed difference between the first conveyance roller pair 115 and the second conveyance roller pair 114 is small. On the other hand, when setting a conveyance speed for thick paper that is hard to be looped, the control unit 50 sets the speed so that the conveyance speed difference between the first conveyance roller pair 115 and the second conveyance roller pair 114 is large. In step S105, the sheet is conveyed to the second conveyance roller pair 114, the first conveyance roller pair 115, and then to the third conveyance roller pair 120 while a loop is formed between the first conveyance roller pair 115 and the second conveyance roller pair 114.
In step S106, the registration sensor 141 detects the conveyed sheet, and after a predetermined period of time has passed, in step S107, the separation unit 140 separates the first conveyance roller pair 115.
After the first conveyance roller pair 115 is separated, in step S108, the sheet comes in contact with the nip portion of the third conveyance roller pair 120 which is in a non-rotating state, so that the skew is corrected. In step S109, the rotation of the third conveyance roller pair 120 in the non-rotating state is restarted. In step S110, the sheet is conveyed to a secondary transfer unit located downstream of the roller pair while the state where the skew has been corrected is maintained, and an image transfer operation and a sheet discharge operation are performed.
In step S111, the controller 50 determines whether a subsequent sheet exists. If a subsequent sheet exists (YES in step S111), in step S112, after the trailing edge of the preceding sheet passed through the first conveyance roller pair 115, and before the leading edge of the subsequent sheet reaches the first conveyance roller pair 115, the first conveyance roller pair 115 is pressed to contact. If a subsequent sheet does not exist (NO in step S111), the print job ends.
Next, the loop formation success rate in the first exemplary embodiment will be described.
In a skew correction sequence in the comparative example, the leading edge comes in contact with the third conveyance roller pair 120, and a loop of the sheet is formed in a state where the leading edge is stopped. As described above, it is desirable that the conveyance speed of the second conveyance roller pair 114 for bringing the leading edge of the sheet into contact with the third conveyance roller pair 120 is set to a low speed.
That is, the productivity depends on the stop time of the third conveyance roller pair 120. It is necessary to stop the rotation of the third conveyance roller pair 120 after the preceding sheet is conveyed and before the leading edge of the subsequent sheet reaches the roller pair. Considering the characteristics of the motors during this operation, there is a limit to enhance the productivity by increasing the conveyance speed of the third conveyance roller pair 120 after the formation of the loop.
In the first exemplary embodiment, as indicated by the solid lines in
In the first exemplary embodiment, by adjusting the speed difference during the conveyance in which there is no limitation in the increase and decrease of the speed, the apparatus can handle various types of media. Further, in a state where the loop is formed in advance, the leading edge of the sheet is caused to hit the nip portion of the third conveyance roller pair 120, and by the loop resistance of the sheet to return to the flat state, the entire sheet leading edge portion is brought into contact with the nip portion.
In the example illustrated in
For example, in the comparative example, it is assumed that the conveyance speed of the second conveyance roller pair 114 before the speed reduction is 650 mm/s, and the conveyance speed of the second conveyance roller pair 114 after the speed reduction (speed at the loop formation) is 120 mm/s. In this case, the time necessary to form a loop with a loop amount of 5 mm starting from a position upstream of the third conveyance roller pair 120 by 20 mm and to start the rotation of the third conveyance roller pair 120 is about 82 ms.
Meanwhile, in the first exemplary embodiment, it is assumed that the conveyance speed of the first conveyance roller pair 115 is 430 mm/s, and the conveyance speed of the second conveyance roller pair 114 is 650 mm/s, and the speed difference between the roller pairs is 220 mm/s. Further, it is assumed that the distance between the nips of the first conveyance roller pair 115 and the second conveyance roller pair 114 is 20 mm. In this case, the time necessary to form a loop with a loop amount of 5 mm starting from the nip position of the first conveyance roller pair 115 and to start the rotation of the third conveyance roller pair 120 is about 56 ms.
As described above, in the first exemplary embodiment. the time necessary for the loop formation can be substantially reduced.
Next, a second exemplary embodiment will be described.
In the second exemplary embodiment, as a skew correction configuration of the third conveyance roller pair, a shutter mechanism is used. The shutter member 121 is rotatably disposed in a stop orientation (
The first conveyance lower roller 115b and the registration lower roller 120b are driven by the same drive source (the registration motor 61).
Next, as illustrated in
As illustrated in
The leading edge of the sheet is conveyed toward the shutter member 121 by the loop resistance and the conveyance force of the second conveyance roller pair 114.
First, the left end portion of the sheet advancing ahead comes in contact with the shutter member 121, and then, the right end portion of the sheet advancing behind comes in contact with the shutter member 121, and the entire leading edge portion of the sheet fits along the shutter member 121 to correct the skew. The twist generated due to the turn of the leading edge of the sheet is absorbed in the space of the loop formed in advance.
Then, as illustrated in
The separation timing of the first conveyance roller pair 115 by the separation unit 140 can be any timing while the urging force of the urging unit 122 for urging the shutter member 121 to remain at the stop position is acting. The range in which the urging force of the urging member 122 acts is set to a range in which the leading edge of the sheet is located upstream of the nip portion of the third conveyance roller pair 120.
In the skew correction configuration with the shutter member 121, after the leading edge of the sheet hits against the shutter member 121 held by a predetermined urging force, a loop of the sheet is formed, thereby correcting the skew of the sheet. Then, when the force of the leading edge of the sheet pressing the shutter member 121 exceeds the above-described urging force, the sheet turns the shutter member 121 to pass therethrough. The strength of the force of the leading edge of the sheet pressing the shutter member 121 differs between thin paper and thick paper. The pressing force of thin paper is weak while the pressing force of the thick paper is strong. Consequently, since the force necessary to urge the shutter member 121 differs between thin paper and thick paper, it is difficult to perform the skew correction on various types of media.
In view of the foregoing, in the second exemplary embodiment, when thick paper is conveyed, before the leading edge portion of the sheet hits against the shutter member 121, a loop of the sheet is formed, and the first conveyance roller pair 115 is separated. By the operation, the force of the thick paper pressing the shutter member 121 can be weakened. Further, when thin paper is conveyed, if the force to press the shutter member 121 is to be ensured, the separation of the first conveyance roller pair 115 can be omitted. That is, the control unit 50 can acquire the information about the sheet to be conveyed, and based on the acquired information about the sheet, the control unit 50 can determine whether to perform separation of the first conveyance roller pair 115 by the separation unit 140.
While the present invention has been described with reference to exemplary embodiments, it is to be understood that the invention is not limited to the disclosed exemplary embodiments. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions.
This application claims the benefit of Japanese Patent Application No. 2013-152793 filed Jul. 23, 2013, which is hereby incorporated by reference herein in its entirety.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2013-152793 | Jul 2013 | JP | national |
| Number | Name | Date | Kind |
|---|---|---|---|
| 20020076250 | Johnson et al. | Jun 2002 | A1 |
| 20050206072 | Tanabe | Sep 2005 | A1 |
| 20080251998 | Muneyasu et al. | Oct 2008 | A1 |
| 20110316226 | Karikusa et al. | Dec 2011 | A1 |
| Number | Date | Country |
|---|---|---|
| 6-336353 | Dec 1994 | JP |
| 9-183539 | Jul 1997 | JP |
| Number | Date | Country | |
|---|---|---|---|
| 20150028532 A1 | Jan 2015 | US |
