The present invention relates to a sheet folding apparatus, a sheet folding method and an image forming apparatus.
In an image forming system, an optional sheet post-process apparatus can be connected to an image forming apparatus such as a multifunction peripheral. Recently, a sheet post-process apparatus is proposed which has a function that aligns ends of a stack of sheets printed by the multifunction peripheral are aligned in length (longitudinal) and width (lateral) directions, and performs saddle stitch binding of the stack of sheets to obtain a booklet.
As the sheet post-process apparatus, US Patent Application Publication No. 2004/0254054A1 discloses a sheet folding device that pushes out a folding plate in the direction perpendicular to a vertical sheet conveying path to insert the sheet or sheet stack between a pair of folding rollers and fold the sheet or sheet stack nipped and fed by the folding rollers. In the paper folding device, the rear ends (lower ends) of the sheets stacked between stack conveying guide plates present along a sheet conveying path are supported by a movable rear end fence and elevated along the sheet conveying path.
Conventionally, there is a known structure for stitch binding. In the structure, a stapling unit is disposed on an upper side of a pair of folding rollers along a sheet conveying path, and a pair of lateral alignment plates are disposed on an upper side of the stapling unit along the sheet conveying path. The lateral alignment plates are exposed in the same plane as a stack conveying guide, and include a pair of jogger fences which align the both side ends of the sheet stack. When the longitudinal center portion of the sheet stack is set to the processing position of the stapling unit, these lateral alignment plates perform a lateral aligning operation of moving in a width direction of the sheet stack so that both side ends of the sheet stack are temporarily aligned with the jogger fences.
In an example where the stapling unit is of a separated type including a driver unit and an anvil unit which are opposed on the both sides of the sheet conveying path, a sheet feeding guide is disposed between the folding unit and the stapling unit. The anvil unit causes the staple surface of the driver unit to sink together with the sheet stack by about 10 mm at the time of stapling. In view of this, the sheet feeding guide is disposed at a position lower than the staple surface by about 10 mm and has a portion which extends to the staple surface of the driver unit and is capable of being depressed.
If a step is present between the sheet feeding guide and the stack conveying guide located on a lower side of the folding unit, distortion of the sheet stack cannot be symmetric between the upper and lower sides. This raises a problem that the folding plate folds the sheet stack at a portion deviated from the longitudinal center portion of the sheet stack. That is, it is difficult to ensure folding position accuracy.
Further, the stack conveying guide has a bead structure that improves smooth movement of sheets. However, if the bead structure is applied to exposed surfaces of the lateral alignment plates, this raises a problem that the sheets tend to be caught on beads during the lateral alignment operation. To cope with this problem, the bead structure may not be applied to the lateral alignment plates. However, this raises another problem that the sheet stack is not conveyed from the processing position of the stapling unit to a folding position. That is, if static electricity applied during an electrophotographic printing process remains in the sheets, the sheet stack is adhered to the exposed surfaces of the lateral alignment plates due to the static electricity. The adhesion force is large enough to prevent the sheet stack from sliding down by its own weight when the position of the movable rear end fence is changed.
According to an exemplary embodiment, one aspect of the invention relates to a sheet folding apparatus comprising: a sheet position adjuster which supports a stack of sheets stacked on an inclined surface of a sheet path and adjusts a position of the stack of sheets along the inclined surface; a stapler which staples the stack of sheets set at a stapling position by the sheet position adjuster; a sheet folding unit which folds the stack of sheets moved downward from the stapling position and set at a folding position by the sheet position adjuster; and a sheet conveying guide provided between the stapler and the sheet folding unit; wherein the stapler includes a driver unit which ejects a staple from a staple surface by sinking from the inclined surface and an anvil unit which operates to sink the driver unit, the sheet folding unit includes a pair of folding rollers which rotate in contact with each other and a folding blade which inserts the stack of sheets into a nip between the pair of folding rollers, and the sheet conveying guide includes a sheet loading surface offset in a sinking direction toward a side of the pair of folding rollers from the staple surface by an amount of sinking of the driver unit, and an uprising member which is disposed on a part of the sheet loading surface to keep the stack of sheets symmetric with respect to the pair of folding rollers.
Another aspect of the invention relates to a sheet folding method comprising: supporting a stack of sheets stacked on an inclined surface of a sheet path; adjusting a position of the stack of sheets along the inclined surface; stapling the stack of sheets set at a stapling position, by using a stapler; and folding the stack of sheets moved downward from the stapling position and set at a folding position, by using a sheet folding unit; the method further comprising: providing a sheet conveying guide between the stapler and the sheet folding unit; constituting the stapler by a driver unit which ejects a staple from a staple surface by sinking from the inclined surface and an anvil unit which operates to sink the driver unit; constituting the sheet folding unit by a pair of folding rollers which rotate in contact with each other and a folding blade which inserts the stack of sheets into a nip between the pair of folding rollers; offsetting a sheet loading surface offset in a sinking direction toward a side of the pair of folding rollers from the staple surface by an amount of sinking of the driver unit; and providing an uprising member on a part of the sheet loading surface of the sheet conveying guide to keep the stack of sheets symmetric with respect to the pair of folding rollers.
Another aspect of the invention relates to an image forming apparatus comprising: a printer which prints an image on a sheet; a finisher device which sorts or staples sheets; a sheet folding apparatus which performs bookbinding of sheets; and a conveying mechanism which conveys the sheets to a selected one of the finisher device and the sheet folding apparatus; the sheet folding apparatus including: a sheet position adjuster which supports a stack of sheets stacked on an inclined surface of a sheet path and adjusts a position of the stack of sheets along the inclined surface; a stapler which staples the stack of sheets set at a stapling position by the sheet position adjuster; a sheet folding unit which folds the stack of sheets moved downward from the stapling position and set at a folding position by the sheet position adjuster; and a sheet conveying guide provided between the stapler and the sheet folding unit; wherein the stapler includes a driver unit which ejects a staple from a staple surface by sinking from the inclined surface and an anvil unit which operates to sink the driver unit, the sheet folding unit includes a pair of folding rollers which rotate in contact with each other, and a folding blade which inserts the stack of sheets into a nip between the pair of folding rollers, and the sheet conveying guide includes a sheet loading surface offset in a sinking direction toward a side of the pair of folding rollers from the staple surface by an amount of sinking of the driver unit, an uprising member which is disposed on a part of the sheet loading surface to keep the stack of sheets symmetric with respect to the pair of folding rollers.
Additional objects and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objects and advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out hereinafter.
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments, and together with the general description given above and the detailed description of the embodiments given below, serve to explain the principles of the invention.
Hereinafter, a sheet post-process apparatus of an embodiment will be described with reference to the accompanying drawings. This sheet post-process apparatus is optionally connected to a multifunction peripheral 1001 as an image forming apparatus, and has a function in which ends of a stack of sheets printed by the multifunction peripheral 1001 are aligned in length (longitudinal) and width (lateral) directions, a longitudinal center of the stack of sheets is stapled, and folding is further performed at the longitudinal center portion, and by this, the stack of sheets is bound as a booklet. In this function, stapling is performed at, for example, two places along a folding axis.
The sheet folding apparatus PS1 includes a stack plate 1, a stapler 2, a sheet folding unit 3, a sheet pressing unit 4, a sheet position adjuster 5, a lateral alignment unit 6, and a belt conveying section 7. The stack plate 1 has a sheet loading surface 101 which is disposed as an inclined surface of a sheet path. The sheet loading surface 101 is inclined to form a large angle with respect to the horizontal plane. The stapler 2 is disposed along the sheet path and above the sheet folding unit 3. The stapler 2 and the sheet folding unit 3 may constitute a saddle stitch binding process section. The lateral alignment unit 6 is disposed along the sheet path and above the stapler 2. The sheet pressing unit 4 is disposed at a lower part of the stack plate 1. The sheet position adjuster 5 is disposed along the sheet path and below the sheet folding unit 3. The stapler 2 and the sheet folding unit 3 served as the saddle stitch binding process section perform a saddle stitch binding process for the stack of sheets in a state where the stack of sheets is pressed by the sheet pressing unit 4.
The belt conveying section 7 includes a sheet conveying belt 7A to drive rollers to convey sheets sequentially discharged as printed materials from the multifunction peripheral 1001 through a sheet conveying path 107, and a conveying motor 7B to drive the sheet conveying belt 7A. The sheet conveying path 107 ejects the sheets successively to the sheet path on the stack plate 1. The sheets slide down successively along the stack plate 1.
The sheet position adjuster 5 includes a stacker 5A, a conveying belt 5B and a conveying motor 5C.
The stacker 5A may be a pair of hooks. The stacker 5A supports the sheets sequentially sliding down along the stack plate 1 and stacked on the stack plate 1. The stacker 5A regulates the lower end position of the stack of sheets SP.
The conveying belt 5B is coupled to the stacker 5A. The conveying motor 5C drives the conveying belt 5B in order to lift up and down the stacker 5A along the sheet path. The stacker 5A aligns the lower end of the stack of sheets SP, and moves up and down along the stack plate 1 to set a center of the stack of sheets SP to a stapling position and a folding position. The center of the stack of sheets SP at the stapling position faces a staple supported by a driver unit 2A of the stapler 2. The center of the stack of sheets SP at the folding position faces a folding blade 3C of the sheet folding unit 3.
The stack plate 1 is partially opened so that the sheet folding unit 3 and the stapler 2 are exposed in the sheet path.
Incidentally, for example, as shown in
The upper part of
A snapshot P1 indicates the sheet pressure plate 4A at the standby position. The sheet pressure plate 4A has an angle against the stack plate 1 at P1. The sheet pressure plate 4A may be in a substantially vertical state at the standby position.
A snapshot P2 indicates the sheet pressure plate 4A moving in parallel to approach the stack plate 1 from the standby position after the instant indicated by the snapshot P1. The sheet pressure plate 4A may move in a direction indicated by a broken arrow 502 perpendicular to the stack plate 1. The sheet pressure plate 4A may shift horizontally as indicated by a solid arrow 501. The sheet pressure plate 4A may shift may move in parallel posture with the posture at the standby position.
A snapshot P3 indicates the lower part of the sheet pressure plate 4A contacting with the stack plate 1 after the instant indicated by the snapshot P2. The sheet pressure plate 4A may rotate in a direction indicated by a rounded solid arrow 503. The sheet pressure plate 4A may rotate about the lower part (base axis on the lower end side, for example) so that the upper part moves toward the stack plate 1.
A snapshot P4 indicates the sheet pressure plate 4A at the sheet pressing position after the instant indicated by the snapshot P3. The upper part of the sheet pressure plate 4A arrives at the stack plate 1 to contact in substantially parallel with the stack plate 1. By this, the sheet pressure plate 4A presses the stack of sheets SP.
On the other hand, the lower part of
A snapshot P5 indicates the upper part of the sheet pressure plate 4A getting away from the stack plate 1 after the instant indicated by the snapshot P4. The sheet pressure plate 4A may rotate in a direction indicated by a rounded solid arrow 504. The sheet pressure plate 4A may rotate about the lower part (base axis on the lower end side, for example) so that the upper part moves against the stack plate 1. The sheet pressure plate 4A may rotate about the lower part to take a posture in parallel with the posture at the standby position. A snapshot P6 indicates the sheet pressure plate 4A moving in parallel to separate from the stack plate 1 after the instant indicated by the snapshot P5. The sheet pressure plate 4A may move in a direction indicated by a broken arrow 505 perpendicular to the stack plate 1. The sheet pressure plate 4A may shift horizontally as indicated by a solid arrow 506. The sheet pressure plate 4A may shift may move in parallel posture with the posture at the standby position indicated by a snapshot P7. By this, the pressure of the stack of sheets SP is released.
In the case of pressing the stack of sheets SP, the lower end of the sheet pressure plate 4A first contacts the stack of sheets SP, and next, the upper end of the sheet pressure plate 4A contacts the stack of sheets SP. The sheet pressure plate 4A serves to eliminate buckling and curl of the stack of sheets SP by pressing the stack of sheets SP first from the lower end side.
After Act 7 or Act 8, the stack of sheets SP is conveyed to the folding position at Act 9. Specifically, the sheet position adjuster 5 is driven to lift down the stacker 5A. Act 10, it is repeatedly checked whether (longitudinal center of) the stack of sheets SP is present at the folding position. This is confirmed in a manner that the stacker 5A is detected, for example, by a sensor disposed according to the sheet size. Upon confirmation, a sheet pressing process is performed at Act 11. In this sheet pressing process, the sheet pressing unit 4 is driven to obtain the movement of the sheet pressure plate 4A shown in the upper part of
Incidentally, in the above-mentioned bookbinding process, the sheet size in which the sheet pressure plate 4A can be used may have such a condition that when the stack of sheets SP is set to the stapling position, the lower end of the stack of sheets SP is below the upper end of the sheet pressure plate 4A. When the sheet folding apparatus handles only sheets having such a size that the sheet pressure plate 4A can be used at the stapling position, above mentioned Act 4 and Act 8 are omitted. Further, when the sheet folding apparatus handles only sheets having such a size that the sheet pressure plate 4A can not be used at the stapling position, above mentioned Act 4 to Act 7 are omitted.
Further, when any of the above-mentioned sheet conditions is not detected, the sheet pressure plate 4A is moved at Act 26 to the sheet pressing position in a normal manner by the high-speed operation of the sheet pressure plate drive device. At Act 22 subsequent to Act 25 or Act 26, it is repeatedly checked whether the sheet pressure plate 4A is arrived at the sheet pressing position. When the arrival at the sheet pressing position is detected, the sheet pressure plate drive device is deactivated at Act 23 to keep the sheet pressure plate 4A at the sheet pressing position. The process is ended with the execution of Act 23.
Incidentally, the lateral alignment operation of the lateral alignment plates 6A and 6B can be performed by driving the lateral alignment motor 6C to align the side ends of the stack of sheets SP before the stapling and before the sheet folding. However, in this case, it is preferable to optimize the drive start timing of the sheet pressure plate drive motor 4C of the sheet pressure plate 4A with respect to the lateral alignment motor 6C.
When the stack of sheets SP is located at the stapling position shown in
For stapling, the lateral alignment motor 6C drives the lateral alignment plates 6A and 6B. The lateral alignment motor 6C starts to slow at an instant indicated by a broken line 221. The lateral alignment motor 6C stops after a predetermined time elapses from an instant indicated by a broken line 221.
The sheet pressure plate drive motor 4C starts and accelerates to drive the sheet pressure plate 4A from an instant indicated by a broken line 220. The sheet pressure plate drive motor 4C drives beyond the instant indicated by the broken lines 224, 221 and 222. The sheet pressure plate drive motor 4C stops at an instant indicated by a broken line 223 after a period for slowing.
The sheet pressure plate 4A may be at the standby position indicated as P1 in
The sheet pressure plate 4A may move in parallel to approach the stack plate 1 from the standby position after the sheet pressure plate drive motor 4C starts to drive. The sheet pressure plate 4A may move beyond the position indicated as P2 in
The lower part of the sheet pressure plate 4A may contact with the stack plate 1 after an instant indicated by a broken line 224, but the sheet pressure plate 4A may still not contact with the stack of sheet until an instant indicated by a broken line 222. The sheet pressure plate 4A may rotate beyond the position indicated as P3 in
The sheet pressure plate 4A may contact with the stack of sheet after the instant indicated by a broken line 222. The sheet pressure plate 4A may be at the sheet pressing position indicated as P4 in
The anvil unit 2B starts to move toward the driver unit 2A at the instant indicated by a broken line 223.
The sheet pressure plate 4A does not press the stack of the sheets during a term indicated by an arrow 211. The sheet pressure plate 4A may keep off from the stack of the sheets during a term indicated by an arrow 211.
The sheet pressure plate 4A contacts with the stack plate 1 during a term indicated by an arrow 213.
The sheet pressure plate 4A press the stack of the sheets during a term indicated by an arrow 212.
On the other hand, for folding, the lateral alignment motor 6C starts to slow at an instant indicated by a broken line 221 as same as for stapling.
The sheet pressure plate drive motor 4C starts and accelerates to drive the sheet pressure plate 4A from an instant indicated by a broken line 221 at the time as same as the lateral alignment motor 6C starts to slow. The sheet pressure plate drive motor 4C drives beyond the instant indicated by the broken lines 222 and 223. The sheet pressure plate drive motor 4C stops after a period for slowing. The folding blade 3c starts proceeding to insert the stack of sheets between the pair of folding rollers 3A and 3B after the sheet pressure plate drive motor 4C stops.
An arrow 214 in
An arrow 215 in
That is, the sheet pressure plate 4A starts proceeding at stapling earlier that at folding by a term indicated by a arrow 219.
Although driving of the sheet pressure plate drive motor 4C of the sheet pressure plate 4A is started almost at the same time as the stop of the lateral alignment motor 6C in pressing the stack of sheets SP for sheet folding, it is started before the stop of the lateral alignment motor 6C in pressing the stack of sheets SP for stapling. By such control, the time required for pressing the stack of sheets SP can be shortened.
The axis of the wind-up roll 4F may set lower than an upper end of the stack of sheets SP supported by the stacker 5A. The sheet pressure film 4D may curl upwardly. The wind-up roll 4F may wind out the sheet pressure film 4D to raise a top of a curl portion of the sheet pressure film 4D. The contact area of the sheet pressure film 4D with the stack of sheets SP may increase according to rising the top of the curl portion of the sheet pressure film 4D. The wind-up roll 4F may wind up the sheet pressure film 4D to lower the top of the curl portion of the sheet pressure film 4D. The contact area of the sheet pressure film 4D with the stack of sheets SP may decrease according to lowering the top of the curl portion of the sheet pressure film 4D. The sheet pressure film 4D is apart from the stack plate 1 each time the stacker 5A receives a sheet. The sheet pressure film 4D presses the sheet after the longitudinal center of the sheet arrives at the stapling position. Further, the sheet pressure plate 4A is again returned to the standby position after execution of stapling, and is again set to the sheet pressing position after the longitudinal center of the stack of sheets SP is arrived at the folding position. Even when the sheet pressure film 4D is used as stated above, the stack of sheets SP can be pressed similarly to the sheet pressure plate 4A.
Hereinafter, merits obtained in this embodiment will be described.
Sheets sequentially ejected from the belt conveying section 7 are slid down along the inclined stack plate 1 by their own weight at the time of stacking, and stacked on the stack plate 1 as a stack of sheets SP supported by the stacker 5A. This stack of sheets SP is lifted up and down by the stacker 5A at the time of sheet conveying. At the time of sheet stacking or sheet conveying, for example, the sheet pressure plate 4A is located at the standby position sufficiently apart from the sheet loading surface 101, thereby securing a wide sheet path between the sheet loading surface 101 and the sheet pressure plate 4A. This makes defective conveying such as a sheet jam difficult to occur at the time of sheet conveying. As a result of securing the wide sheet path, buckling of the stack of sheets SP at the time of sheet stacking becomes liable to occur. However, since the sheet pressure plate 4A is set to the sheet pressing position after the sheet stacking, the buckling of the stack of sheets SP can be eliminated. Further, even if sheets which are liable to be curled are stacked as a stack of sheets SP, this curl can be eliminated. When the buckling or curl is eliminated as stated above, the position accuracy of the stack of sheets SP moved to the stapling position or the folding position can be improved. Further, since the stack of sheets SP is pressed by the sheet pressure plate 4A before the stapling or the sheet folding, these processes can be stably performed. Further, since the sheet pressure plate 4A starts to press the stack of sheets SP from its lower end side, the buckled or curled stack of sheets SP can be finely extended without generating wrinkles. Moreover, the sheet pressure plate 4A can be driven by the simple drive device.
As shown in
Even if the sheet size allows the stack of sheets SP to be pressed in any of the stapling position and the sheet folding position by the sheet pressure plate 4A, after the start of the sheet pressure plate drive motor 4C of the sheet pressure plate 4A, there occurs a difference in the time required for the sheet pressure plate 4A to actually contact the stack of sheets SP. Since this time difference can be previously calculated from the sheet size, in view of the free running time of the sheet pressure plate 4A corresponding to the position of the stack of sheets SP, control is performed to optimize the drive start timing of the sheet pressure plate drive motor 4C of the sheet pressure plate 4A with respect to the lateral alignment motor 6C. That is, the drive timing of the sheet pressure plate drive motor 4C is made early by the free running time of the sheet pressure plate 4A which is increased when the stack of sheets SP set at the stapling position is pressed, and wasteful time consumption is reduced. Accordingly, the time required for pressing the stack of sheets SP can be shortened.
The pair of uprising members GA makes the height conditions of the stack of sheets SP at the upper side and the lower side of the sheet folding unit 3 substantially equal to each other, and this uniforms the asymmetric distortion of the stack of sheets SP generated by the step between the sheet loading surface of the sheet conveying guide G and the sheet loading surface 101. In addition, since the stapler 2 and the sheet folding unit 3 can be disposed to be close to each other, the sheet folding apparatus can be constructed to be very compact.
The lateral alignment unit 4 has the structure in which the support base members BM of the lateral alignment plates 6A and 6B are disposed at the back of the stack plate 1, or the arch-shaped conductive member BMX is disposed to stride the support base members BM of the lateral alignment plates 6A and 6B disposed to be exposed on the sheet loading surface 101. When the support base members BM are at the back of the stack plate 1, the support base members BM do not contact the stack of sheets SP in the lateral alignment operation. Further, the arch-shaped conductive members BMX contact only a part of the stack of sheets SP. Accordingly, sliding of the stack of sheets SP is improved and adhesion by static electricity can be removed.
Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details and representative embodiments shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents.
This application claims the benefit of U.S. Provisional Applications No. 60/952,836 filed Jul. 30, 2007; No. 60/968,541 filed Aug. 28, 2007; No. 60/968,853 filed Aug. 29, 2007; No. 60/969,126 filed Aug. 30, 2007; No. 60/969,148 filed Aug. 30, 2007; and No. 60/980,727 filed Oct. 17, 2007.
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