The present application claims priority to and incorporates by reference the entire contents of Japanese priority document 2007-306283 filed in Japan on Nov. 27, 2007 and Japanese priority document 2008-201912 filed in Japan on Aug. 5, 2008.
1. Field of the Invention
The present invention relates to a sheet finisher, an image forming apparatus including the sheet finisher, and a sheet processing method.
2. Description of the Related Art
With the development of multi-functional sheet finishers, sheet finishers with both a side-stitch function and a saddle-stitch function have appeared. In the saddle-stitch function, a set of sheet-like recording mediums (hereinafter, “sheets”) is stapled in the center and the stapled set of sheets is half-folded. Japanese Patent Application Laid-open No. 2001-163519 and Japanese Patent Application Laid-open No. 2001-206629 disclose examples of the sheet finishers with the saddle-stitch function. In most of the sheet finishers with the saddle-stitch function, a folding unit that folds the set of sheets includes at least one pair of rollers called pressure rollers and a plate member called folding plate. More particularly, the folding plate is aligned with a line to be folded of the set of sheets, and inserts the set of sheets into a nip between the pressure rollers. Thus, a crease is made along the line to be folded on the set of sheets with the nip.
Some folding units include a first pair of pressure rollers and a second pair of pressure rollers. The set of sheets is pressed twice with the first pressure rollers and the second pressure rollers, which makes a stronger crease. Japanese Patent No. 3566492 and Japanese Patent Application Laid-open No. 2001-19269 disclose examples of folding units including a plurality of pairs of pressure rollers. However, even when the set of sheets is pressed twice, it is difficult to make a crease strong enough due to a short pressing time and a low pressing force. Because a rotation axis of the pressure rollers runs parallel to a direction perpendicular to a sheet conveying direction, a folded side of the set of sheets is pressed in the nip between the pressure rollers only for a short time. Moreover, because the pressure rollers nip the entire folded side at the same time, the pressing force on the set of sheets is distributed, i.e., the pressing force per unit area is low.
Sheet finishers disclosed in Japanese Patent Application No. 3746472 and Japanese Patent Application Laid-open No. S62-16987 are similar to the sheet finishers disclosed in Japanese Patent Application Laid-open No. 2001-163519 and Japanese Patent Application Laid-open No. 2001-206629, except that the sheet finishers additionally include a slidable pressure roller to make a stronger crease. The slidable pressure roller is arranged near an ejection port downstream of the pressure rollers. Upon receiving the set of sheets from the pressure rollers, the slidable pressure roller re-presses the set of sheets while sliding on the folded side in the direction perpendicular to the sheet conveying direction, i.e., along the line of crease by an operation of a screw. This configuration makes it possible to a stronger crease.
Because the folded side is pressed with the slidable pressure roller sliding in the direction perpendicular to the sheet conveying direction, the pressing force is applied only at one point of the folded side making a contact with the slidable pressure roller at a time. Because the slidable pressure roller slides on the folded side, the entire folded side is pressed with the high pressing force. As a result, the strong crease is made on the set of sheets.
Moreover, because the slidable pressure roller slides by the rotation of the screw, the folded side is pressed with the pressing force high enough and the crease strong enough is made on the set of sheets. This also results in decreasing a thickness of the folded side. However, because the rotation of the screw is used to slide the slidable pressure roller, the sliding speed is slow, which results in low productivity.
It is an object of the present invention to at least partially solve the problems in the conventional technology.
According to an aspect of the present invention, there is provided an apparatus for folding a sheet including a folding unit that folds the sheet along a folding line thereby obtaining a folded sheet having a folded side; a pressing unit that presses the folded side of the folded sheet; a driving unit that causes the pressing unit to slide in a direction substantially perpendicular to a conveying direction of the sheet; and a control unit that independently sets number of slides at which the pressing unit is to slide on each of a plurality of sections of the folded side depending on a distance of each of the sections from a reference position, and controls the driving unit so as to slide in each of the sections for the number of slides set for that section.
According to another aspect of the present invention, there is provided an image forming apparatus that includes the above apparatus for folding a sheet.
The above and other objects, features, advantages and technical and industrial significance of this invention will be better understood by reading the following detailed description of presently preferred embodiments of the invention, when considered in connection with the accompanying drawings.
Exemplary embodiments of the present invention are described in detail below with reference to the accompanying drawings.
The sheet finisher PD is attached to a side of the image forming apparatus PR. A sheet ejected from the image forming apparatus PR is conveyed to the sheet finisher PD. The sheet passes through a conveyer path A for single-sheet processing (e.g., a punching unit 100 is located near the conveyer path A). After that, the sheet is conveyed by the operation of switching claws 15 and 16 to any one of a conveyer path B connecting to an upper tray 201, a conveyer path C connecting to a shift tray 202, a conveyer path D connecting to a side-stitch tray F for alignment and stapling.
The image forming apparatus PR includes, although not shown in the drawings, an image processing circuit for converting received image data into printable image data, an optical writing device that writes a latent image with a light on a photosensitive element based on an image signal received from the image processing circuit, a developing device that develops the latent image to a toner image, a transferring device that transfers the toner image onto a sheet, and a fixing device that fixes the tonner image on the sheet. The image forming apparatus PR sends the sheet with the fixed toner image to the sheet finisher PD. Upon receiving the sheet from the image forming apparatus PR, the sheet finisher PD performs a certain post-processing with the sheet. Although the above explanation is made assuming that the image forming apparatus PR is an electrophotographic machine, the image forming apparatus PR can be any type of image forming apparatus such as an inkjet machine or a thermal-transfer machine.
After the alignment and stapling is performed at the side-stitch tray F with the sheet that has been passed through the conveyer paths A and D, the sheet is conveyed by the operation of a guiding member 44 to either the conveyer path C connecting to the shift tray 202 or a saddle-stitch tray G for saddle-stitch and folding. If the sheet is conveyed to the saddle-stitch tray G, the sheet is folded or the like at the saddle-stitch tray G. The folded sheet is conveyed to a conveyer path H and ejected onto a lower tray 203. The conveyer path D is provided with a switching claw 17 that keeps a position as shown in
An entrance sensor 301 that detects the sheet coming from the image forming apparatus PR, a pair of entrance rollers 1, the punching unit 100, a punch-waste hopper 101, a pair of conveyer rollers 2, and the switching claws 15 and 16 are arranged near the conveyer path A in this order, with the entrance sensor 301 being closest to the image forming apparatus PR. The switching claws 15 and 16 keep positions as shown in
When the sheet is to be conveyed to the conveyer path B, the solenoids are kept OFF, and thereby the switching claws 15 and 16 are in the positions shown in
The sheet finisher PD can perform various sheet processing including punching using the punching unit 100, alignment and side stitch using a pair of jogger fences 53 and a side-stitch stapler S1, alignment and saddle stitch using an upper saddle-stitch jogger fence 250a, a lower saddle-stitch jogger fence 250b, and a saddle-stitch stapler S2, sorting using the shift tray 202, half-folding using a folding plate 74 and a pair of first pressure rollers 81. Moreover, the sheet finisher PD can perform slide-pressing as a subsequent process of the half-folding to make a crease on the folded sheet set stronger.
As show in
The reverse roller 13 is made of sponge. When the sheet is ejected by the ejection rollers 6, the reverse roller 13 comes in contact with the sheet so that the back end of the sheet abuts against an end fence, which makes the sheets stacked on the shift tray 202 aligned.
The reverse roller 13 rotates by the rotation of the ejection rollers 6. There is a lift-up stop switch (not shown) near the reverse roller 13. When the shift tray 202 lifts up and pushes the reverse roller 13 up, the lift-up stop switch turns ON and a shift-tray lifting motor (not shown) stops. Thus, the shift tray 202 cannot move up beyond a predetermined position.
The sheet sensor 330 is arranged near the reverse roller 13. The sheet sensor 330 detects a position of the top one out of sheets stacked on the shift tray 202. When it is determined using the sheet sensor 330 that the position of the top sheet reaches a predetermined height, the shift tray 202 moves down by a predetermined amount by the action of the shift-tray lifting motor so that the position of the top sheet is always at the same level.
The ejection rollers 6 are formed with a driving roller 6a and a driven roller 6b. The driven roller 6b is arranged upstream of the driving roller 6a, and is rotatably attached to a free end of an open/close guiding plate. The open/close guiding plate is attached to the sheet finisher PD rotatably around the other end, arranged with the free end being closer to the shift tray 202. The driven roller 6b comes in contact with the driving roller 6a under the weight of the driven roller 6b or by a biasing force, and the sheet is ejected through between the driving roller 6a and the driven roller 6b. When stapled sheets are to be ejected, the open/close guiding plate moves up to a predetermined position, and then moves down at predetermined timing decided based on a detection signal from an ejection sensor 303. The predetermined position is decided based on a detection signal from a guiding-plate open/close sensor (not shown). The open/close guiding plate moves up, driven by a guiding-plate open/close motor (not shown).
When the sheet is conveyed to the side-stitch tray F by the rotation of the stapled-sheet conveyer rollers 11, the sheet is stacked on the side-stitch tray F. More particularly, the sheet goes backward by rotation of a reverse roller 12 in the vertical direction (i.e., the sheet conveying direction), and abut against an end fence 51, which makes the sheets stacked on the side-stitch tray F aligned. A direction perpendicular to the sheet conveying direction (i.e., the sheet-width direction) is aligned with the jogger fences 53. When it is determined based on a staple signal from a control circuit 350 that a last one of a set of sheets is stacked on the side-stitch tray F, the side-stitch stapler S1 stapes the set of sheets. A sheet pressing member 110 presses a side of the set of sheets when the side-stitch stapler S1 staples the sheets.
A home position (HP) of a lifting claw 52a is detected with an ejection-belt HP sensor 311. The ejection-belt HP sensor 311 turns ON/OFF by operation of the lifting claw 52a attached to a lifting belt 52. Two lifting claws 52a are attached to an outer surface of the lifting belt 52, with the lifting claws 52a being opposed to each other. The two lifting claws 52a alternately lift the set of sheets out of the side-stitch tray F.
The lifting belt 52 rotates between a driving pulley and a driven pulley along a center line of the aligned sheet width. A plurality of lifting rollers 56 are attached rotatably to a driving shaft, working as driven rollers. The lifting rollers 56 are arranged symmetric to each other with respect to the lifting belt 52.
The reverse roller 12 swings around a fulcrum 12a by a tapping solenoid, which causes the back end of the sheets stacked on the side-stitch tray F to abut against the end fence 51. The reverse roller 12 rotates counterclockwise. The pair of jogger fences 53 is arranged so that both width-direction sides of the stacked sheets put between them. The jogger fences 53 slide in the sheet-width direction back and forth via a timing belt (not shown) by positive-driving or negative-driving of a jogger motor (not shown). The side-stitch stapler S1 moves to a target position in the sheet-width direction via a timing belt (not shown) by positive-driving or negative-driving of a stapler moving motor (not shown) to staple the target position of the sheet side. As shown in
A saddle-stitch mechanism related to the slide-pressing process is explained below. A side-stitch mechanism is not explained, because the side-stitch mechanism is not a feature of the sheet finisher PD.
It is assumed that the sheet is conveyed to the conveyer path D by the operation of the switching claws 15 and 16, and then is conveyed to the side-stitch tray F by the operation of the conveyer rollers 7, 9, and 10, and the stapled-sheet conveyer rollers 11. At the side-stitch tray F, the sheet is aligned with the stapled-sheet conveyer rollers 11 both in the saddle-stitch mode and the side-stitch mode (see
After a set of sheets (hereinafter, “sheet set S”) is roughly aligned at the side-stitch tray F, the sheet set S is lifted up with the lifting claw 52a. As shown in
In the saddle-stitch tray G, the sheet set S is conveyed with a pair of upper conveyer rollers 71 and a pair of lower conveyer rollers 72 to a position at which the front end of the sheet set S abuts against the movable backend fence 73 as shown in
The sheet set S, the movable backend fence 73, and the relative members shown in
As shown in
In this manner, the stapled sheet set S is lifted up to the position for folding without fails only by the movement of the movable backend fence 73.
As shown in
The CPU 360 controls those components by reading program codes from a read only memory (ROM)(not shown), loading the program codes on a work area of a random access memory (RAM)(not shown), and executing the loaded program codes.
The half-folding mechanism includes a half-folding unit including the first pressure rollers 81 and the folding plate 74, the slide-pressing unit 525 including the slidable pressure roller 520, and the second pressure rollers 82. The slide-pressing unit 525 includes the slidable pressure roller 520, a compression spring 521, and a slider 522. The slider 522 is attached to a pair of guiding rods 526, slidable along them. The guiding rods 526 are arranged between a front plate and a back plate parallel to the direction perpendicular to the sheet conveying direction. The slidable pressure roller 520 slides in the rotating manner, while pressing with a predetermined force.
The slide-pressing unit 525 performs the slide-pressing by using the slidable pressure roller 520 sliding on the crease of the sheet set S in the direction perpendicular to the sheet conveying direction. More particularly, the slidable pressure roller 520 is pressed by an elastic force of the compression spring 521, and the slider 522 with the pressed slidable pressure roller 520 slides along the guiding rods 526 on the crease of the sheet set S. Thus, the elastic force of the compression spring 521 makes the crease stronger. The slidable pressure roller 520 presses the sheet set S against a sheet supporting plate 528, which makes it possible to nip the sheet set S with the predetermined pressure.
A driving mechanism 501 arranged over the slide-pressing unit 525 drives the slidable pressure roller 520 and the lower conveyer rollers 72. The driving mechanism 501 includes a pressure-release motor 510, a pressure-release gear 512, a slidable pressure-roller driving gear 519 shown in
As shown in
As shown in
With this configuration of the half-folding mechanism, the lower conveyer roller 72b moves close to or apart from the lower conveyer roller 72a. When the sheet set S is to be conveyed through the saddle-stitch tray G, the nipped sheet set S is released. The slidable pressure roller 520 presses the sheet set S while sliding in the direction perpendicular to the sheet conveying direction. In other words, the lower conveyer roller 72b moves, as described above with reference to
In this manner, the lower conveyer roller 72b and the slidable pressure roller 520 receive the driving force of the pressure-release motor 510 via the driving-force transmission belt 515 and the driving-force transmission gear 511, and move by the received driving force. The received driving force is transmitted to the pressure-release gear 512 and the slidable pressure-roller driving gear 519 via the transmission gear 513. The driving force is further transmitted to the slidable pressure-roller driving pulleys 514 via the slidable pressure-roller driving belt 517, and thus the slidable pressure-roller sliding belt 516 rotates. As a result, the slidable pressure roller 520 is driven by the rotation of the slidable pressure-roller sliding belt 516.
When the slidable pressure roller 520 is at the HP, the lower conveyer roller 72b is apart from the lower conveyer roller 72a. This configuration is effective to prevent a sheet jam, because the slidable pressure roller 520 keeps out of an area in which the sheet set S is to be conveyed while the first pressure rollers 81 presses the sheet set S.
After the crease is made on the center of the sheet set S by the first pressure rollers 81, the sheet set S is conveyed with the folded side being ahead and is stopped when the folded side is on a line along which the slidable pressure roller 520 slides. The slidable pressure roller 520 slides on the folded side in the direction to the sheet conveying direction as shown in
If the number of sheets of the sheet set S is small, a thickness of the folded side of the sheet set S decreases enough after the slide-pressing by the slidable pressure roller 520;
As shown in
If the number of sheets of the sheet set S is large or each sheet is thick, one slide is not enough to decrease the thickness of the folded side to a desired level and to fold the sheet set S accurately. If the slidable pressure roller 520 slides on the entire folded side in the sheet-width direction several times, the thickness of the folded side decreases to the desired level and the sheet set S is folded accurately. However, it takes a longer time, which results in decreasing of productivity by the amount of the increased time.
In the present embodiment, the folded side parallel to in the direction perpendicular to the sheet conveying direction is divided into three sections X1, X2, and X3, and the number of slides at which the slidable pressure roller 520 slides on each of the sections X1, X2, and X3 is decided independently. With this configuration, the slidable pressure roller 520 can slide on each section at only required times, which decreases the slide-pressing time.
The folded side of the sheet set S is divided into the sections X1, X2, and X3 in this order with respect to the direction perpendicular to the sheet conveying direction, with the section X1 being closest to one end of the folded side. If a length of the section X1 is equal to that of the section X3, a gap between thicknesses of both ends of the sheet set S is suppressed. If the length of the sections X1 and X3 is shorter than that of the section X2, the decrease in productivity is suppressed. In other words, it is preferable that the length of the sections X1 and X3 is equal (i.e., X1=X3) and the length of the section X1 is smaller than that of the section X2 (i.e., X1≦X2). The length of the sections X1 and X3 is, more preferably, one quarter of the entire length or larger (i.e., X1≧L/4, where L=X1+X2+X3). Still preferably, the length of the section X1 is between the quarter to one third of the entire length (i.e., L/3≧X1≧L/4), although this preferable range is regardless of a staple position.
It has been known that an area near a staple is likely to be thick. Therefore, it is preferable to the sections where the slidable pressure roller 520 slides more times include staple positions SN1 and SN2.
An operator (user) can set the length of each of the sections X1, X2, and X3 with the operation panel 380 shown in
The operator can set the number of slides (number of switchbacks) at each section in addition to the number of sections and the length of each section. The number of slides affects the pattern of sliding by the slidable pressure roller 520.
After the half-folding, the sheet set S is either ejected onto the lower tray 203 as the processed copy set or conveyed to the subsequent post-processing device such as the cutting device as described with reference to
When the half-folded sheet set S is ejected out as the processed copy set, the number of slides on the section X2 is increased to decrease the thickness of the folded side as shown in a pattern (3) of
The operator selects the desired sliding pattern taking various conditions into consideration, for example, stapling, number of sheets, thickness of each sheet, size of sheet, and presence of the subsequent post-processing device, thereby independently setting the number of slides on each section to a required value. The operator sets those settings with the operation panel 380 shown in
The sheet after image forming is conveyed from the image forming apparatus PR to the side-stitch tray F of the sheet finisher PD, and is aligned with other sheets as the sheet set S. The saddle-stitch tray G receives the sheet set S (Step S100). It is determined whether the sheet set S is to be stapled in the center (Step S101). When the sheet set S is to be stapled in the center (Yes at Step S101), it is determined whether the number of sheets is equal to or larger than a first threshold (Step S102). The first threshold is assumed to be five. When the sheet set S is not to be stapled (No at Step S101) or when the number of sheets is smaller than the first threshold (No at Step S102), the pattern (1) shown in
When the number of sheets is equal to or larger than the first threshold (Yes at Step S102), it is determined whether the size of sheet is equal to or smaller than a predetermined size, for example, B4 (Step S103). It has been known that if the size of sheet is small, a week crease is likely to be made on the sheet set S and the thickness of the folded side increases. It means that if two sets having the same number of sheets but different in size are folded in the same pattern, the thickness of the folded side of the large-size set is lower than that of the small-size set. Therefore, the process control branches based on a result of determination whether the size of sheet is equal to or smaller than the predetermined size, i.e., B4.
When the size of sheet is larger than B4 (No at Step S103), it is determined whether the number of sheets is equal to or larger than a second threshold (Step S105). The second threshold is assumed to be 15. When the number of sheets is smaller than the second threshold (No at Step S105), it is determined whether each sheet is thick (Step S106). It is assumed that weight per area is equal to or heavier than 100 g/m2, each sheet is determined to be thick.
When each sheet is not thick (No at Step S106), it is determined whether the sheet set S is to be conveyed to the subsequent post-processing device, for example, the cutting device (step S107). When the sheet set S is to be conveyed to the cutting device (Yes at Step S107), the slide-pressing process in the pattern (2) shown in
When the size of sheet is equal to or smaller than B4 (Yes at Step S103), it is determined whether the number of sheets is equal to or larger than a third threshold (Step S104). The third threshold is assumed to be 10. When the number of sheets is equal to or larger than the third threshold (Yes at Step S104), when the number of sheets is equal to or larger than the second threshold (Yes at Step S105), or when each sheet is thick (Yes at Step S106), it is determined whether the sheet set S is to be conveyed to the cutting device (step S108). When the sheet set S is to be conveyed to the cutting device (Yes at step S108), a pattern (4) shown in
When the sheet set S is not to be conveyed to the cutting device (No at step S108), a pattern (5) shown in
In the pattern (5), after the slidable pressure roller 520 slides to the position Z4 in the same manner as the pattern (3), the slidable pressure roller 520 returns to the position Z1. As a result, the number of slides on each section is increased by one compared with the pattern (3). In other words, if two slides are added to the number of slides on the section X2 in the normal pattern to decrease the thickness of the folded side, the pattern (5) is implemented.
Instead of automatically selecting the appropriate pattern, the operator can manually select the desired pattern with the operation panel 380. When a manual mode is selected (Step S109), the pattern specified by the operator is selected even when the sheet set S does not satisfy the conditions for the specified pattern.
Although various patterns are made by changing the number of slides on each section as shown in
In the patterns (2′) and (4′), to flatten the both ends, the number of slides on the sections X1 and X3 is increased and the sliding speed at the sections X1 and X3 is a low speed V1 while the sliding speed at the section X2 is a high speed V2.
On the other hand, in the patterns (3′) and (5′), to flatten the center, the number of slides on the section X2 is increased and the sliding speed at the section X2 is the low speed V1 while the sliding speed at the sections X1 and X3 is the high speed V2.
In this manner, the slidable pressure roller 520 slides on a priority section at the low speed while sliding on the other sections at the high speed as shown in the patterns (1′) to (5′), which makes it possible to make the crease strong enough with the short slide-pressing time.
Although the sheet is divided into the sections with separation positions that are measured from the end of the sheet as the reference position in the embodiment, it is possible to use another position as the reference position instead of the end of the sheet.
The number of sheets, the thickness of each sheet, the size of sheet, and the type of subsequent post-processing device that are used in the explanation are examples. Those values or types are variable depending on the hardware structure, the applications, or the like.
According to the embodiment, the folded sheet set is unevenly pressed by the slidable pressure roller sliding in the direction perpendicular to the sheet conveying direction by dividing the entire length into a plurality sections and setting the number of slides on each section independently. This makes it possible to reduce the slide-pressing time and suppress decrease in productivity.
Moreover, it is possible to produce the appropriately folded sheet-set by switching sliding patterns of the slidable pressure roller without making the system complicated.
Furthermore, it is possible to reduce the thickness of the folded sheet-set while suppressing decrease in productivity.
Moreover, it is possible to flatten the both ends of the folded sheet-set while suppressing decrease in productivity, which increases accuracy at the subsequent post-processing step.
Furthermore, it is possible to flatten the folded side with respect to the direction perpendicular to the sheet conveying direction.
Moreover, it is possible to independently adjust each section of the folded side as appropriately and perform proper processing.
Furthermore, it is possible to convey to the subsequent post-processing device the sheet set that is properly processed based on a type of the subsequent post-processing device.
According to an aspect of the present invention, a slidable pressure member presses a folded sheet-set while unevenly sliding on a folded side by dividing the folded side into a plurality of sections with separation positions measured from an end of the folded side and setting the number of slides on each section independently. This reduces a thickness of the folded side, while suppressing decrease in productivity.
Although the invention has been described with respect to specific embodiments for a complete and clear disclosure, the appended claims are not to be thus limited but are to be construed as embodying all modifications and alternative constructions that may occur to one skilled in the art that fairly fall within the basic teaching herein set forth.
Number | Date | Country | Kind |
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2007-306283 | Nov 2007 | JP | national |
2008-201912 | Aug 2008 | JP | national |