Patent Grant
7607648
Electronic document publishing often demands more than a stack of paper in an output tray of an office printer. Typically, a plurality of duplex printed sheets are bound into finished documents by a publishing system that prints and finishes books. Publishing systems perform operations such as collating, binding, folding, trimming, stapling, etc. These finishing operations are typically performed on all of the sheets in a book at one time, which generally requires the use of high forces and powerful motors. Consequently, the systems adapted to perform these functions are relatively expensive and often exceed the cost of other desktop or office printers. As such, known publishing systems are not generally well suited for use in low-cost desktop bookmaking.
Other typical publishing systems incorporate sheet-wise operations, which are performed on individual sheets that are subsequently accumulated or stacked and bound to form a bound document. However, since the entire stack of sheets must generally be accumulated before being stapled or otherwise bound, conventional finishing systems utilize high-force staplers configured to staple through an entire sheet stack in a single operation. More particularly, typical staplers require a high mechanical force to press staple legs through the sheet stack and bend the staple legs to bind the sheet stack. Since the sheet fibers are forced aside to allow passage of the staple legs, the required force to staple a document is relatively large and increases as the number of sheets in the sheet stack increases. Therefore, a need exists for a publishing system that decreases forces and motor power used to staple a bound document while providing a compact system suitable for use with office printers and for methods associated therewith.
One aspect of the present invention relates to a staple hole forming apparatus configured to facilitate binding a plurality of sheets with a staple having two legs. The staple hole forming apparatus includes a pair of pins and a pin receptor. The pair of pins are spaced from each other a distance substantially equal to a distance between the two legs of the staple. The pin receptor is positioned opposite the pair of pins relative to a sheet path through the staple hole forming apparatus. The pin receptor is positioned to mate with at least one of the pair of pins. One of the pair of pins and the pin receptor is configured to move towards and mate with the other of the pair of pins and the pin receptor causing the pair of pins to penetrate a sheet extending between the pair of pins and the pin receptor to form two holes in the sheet. Each of the two holes is configured to receive one of the two legs of the staple.
In the following Detailed Description, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. In this regard, directional terminology, such as “down,” “over,” “above,” etc., is used with reference to the orientation of the Figure(s) being described. Because components of embodiments of the present invention can be positioned in a number of different orientations, the directional terminology is used for purposes of illustration and is in no way limiting. It is to be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope of the present invention. The following Detailed Description, therefore, is not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims.
In one embodiment, bound document 14 is stapled along a spine 18 within finishing system 12 in a two part process to reduce the mechanical forces required for the stapling operation. In particular, in a first step, staple holes are punched, drilled, or otherwise formed in each sheet. In a subsequent step, the sheets are accumulated into a sheet stack, and the legs of the staples are inserted through the existing staple holes. The staples are secured about the sheet stack to form bound document 14. Accordingly, lower forces are utilized as compared to a single step stapling method, in which holes are formed in a sheet stack concurrently with the insertion of the staple legs through the sheet stack. The need for and use of reduced mechanical forces permits use of lower cost drives, motors, and overall system structure, which decreases the overall cost of finishing system 12. In addition, since lower forces can be used, the sheet capacity for bound documents may also increased. It should be noted that although primarily described herein as a sheet-wise operation forming staple holes in single sheets of bound document 14, in other embodiments, staple holes are simultaneously formed in more than one sheet at a time. Staple holes may be formed in any number of the plurality of sheets of to be included in bound document 14, including more than one sheet and up to all the sheets for bound document 14. In one embodiment, the number of sheets 20 is less than all of the sheets to be included in bound document 14.
During use and as indicated by arrow 26, one or more sheets 20 are received from printer 10 (illustrated in
In one embodiment, first finishing station 22 includes a fold blade 34, a carriage assembly 36, and a drive mechanism 38. Drive mechanism 38 is configured to move carriage assembly 36 toward fold blade 34 to fold and form holes in one or more sheets 20 (illustrated in
In one embodiment, fold blade 34 is made of metal or any other suitable material and is shaped as a substantially flat strip having a generally rectangular cross-sectional profile at its free edge 48. In other embodiments, fold blade 34 is formed having other cross-sectional profiles, such as a rounded, triangular, concave, or convex cross-sectional profile. In one embodiment, fold blade 34 is supported by a blade holder 50 and laterally extends in a direction substantially perpendicular to the longitudinal sheet path, which is generally indicated by arrow 52. In one embodiment, fold blade 34 is alternatively held by any other stabilizing structure or is manufactured with blade holder 50 as a unitary component.
Carriage assembly 36 extends substantially parallel to and above fold blade 34 Carriage assembly 36 is coupled with drive mechanism 38. Drive mechanism 38 is configured to selectively move carriage assembly 36 toward fold blade 34. In another embodiment, carriage assembly 36 is substantially stationary and fold blade 34 alternatively moves towards carriage assembly 36.
In one embodiment, carriage assembly 36 includes a housing 60, fold rollers 62, and one or more pinch foot 64. Housing 60 is configured to retain fold rollers 62 and at least one pinch foot 64 and is coupled with drive mechanism 38. In one embodiment, housing 60 extends parallel to fold blade 34 and is made of any suitable material, such as metal or plastic.
Fold rollers 62 are rotatably attached to an interior portion of housing 60. At least two sets of parallel fold rollers 62 are included in the embodiment of carriage assembly 36 illustrated in
Each pinch foot 64 is configured to clamp against fold blade 34, and is resiliently mounted to an internal portion of housing 60. For example, each pinch foot 64 is attached to housing 60 with a pinch spring 66 as illustrated in
As illustrated in
In one embodiment, each pinch foot 64 defines one or more pin receptor 42. Each pin receptor 42 is a void or other area extending from pinch groove 68 in a substantially linear direction relative to and away from fold blade 34. In one embodiment, each pin receptor 42 extends in a direction substantially parallel to and in line with the extension of fold blade 34 from blade holder 50. Each pin receptor 42 is positioned to laterally and longitudinally align with at least one corresponding pin 40. Accordingly, as carriage assembly 36 is moved toward fold blade 34, each pin receptor 42 receives at least one corresponding pin 40.
In one embodiment, punch apparatus 32 is collectively formed by fold blade 34 and carriage assembly 36, and includes male portions or pins 40 and female portions or pin receptors 42. In one embodiment, pins 40 extend from fold blade 34 toward carriage assembly 36. Pins 40 are each any suitable pin or die configured to punch or otherwise form a hole in one or more sheets 20. More particularly, in one embodiment, each pin 40 is generally cylindrical with a pointed tip. However, use of pins having other cross-sectional shapes are also contemplated. Pins 40 are each formed of a relatively rigid material, such as metal. In one embodiment, pins 40 have a cross-sectional size substantially the same as a cross-sectional size of the staple legs intended to be inserted through holes formed by pins 40. In one embodiment, pins 40 have a cross-sectional size smaller than a cross-sectional size of the staple legs intended to be inserted through holes formed by pins 40. In one embodiment, pins 40 have a cross-sectional size larger than a cross-sectional size of the staple legs intended to be inserted through holes formed by pins 40.
In one embodiment, pins 40 are arranged into at least one pair of pins 40. Each pair of pins 40 is configured to form a pair of staple holes in sheet 20 configured to receive opposing legs of a staple. Accordingly, pins 40 defining a pair of pins 40 are spaced from each other a distance substantially equal to a distance between the two legs of a staple. In one embodiment, more than one staple is used to bind the document, such that more than one pair of pins 40 are used to form staple holes. When more than one pair of pins 40 are used to form staple holes, each pair of pins 40 is spaced from other pairs of pins 40 a distance substantially equal to a distance desired for spacing staples along a spine 18 of bound document 14 (illustrated in
Once again referring to
In one embodiment, as carriage assembly 36 progresses further toward fold blade 34, each pinch foot 64 is forced back into housing 60 against springs 66, while maintaining pressure on sheet 20 against fold blade 34 due to the action of pinch springs 66. In one embodiment, when sheet 20 is clamped between fold blade 34 and pinch grooves 68, sheet 20 is secured relative to first finishing station 22 to define a fold position and to ensure proper alignment of sheet 20 relative to fold blade 34.
In one embodiment, a fold line is formed in sheet 20 by moving fold rollers 62 relative to fold blade 34 such that fold blade 34 and sheet 20 pass between fold rollers 62. For example, housing 60 moves toward fold blade 34 such that sheet 20 is deformed between fold blade 34 and opposing fold rollers 62 to fold sheet 20. In one embodiment, fold rollers 62 are biased toward each other with the use of any springs or other bias mechanism or material. By pressing and rolling fold rollers 62 against sheet 20 and fold blade 34, a portion of sheet 20 conforms to the shape of fold blade 34 and thus the fold is defined in sheet 20.
Upon folding sheet 20, drive mechanism 38 or other biasing force moves carriage assembly 36 away from fold blade 34, which also rolls fold rollers 62 away from fold blade 34. Therefore, each pinch foot 64 with pin receptors 42 is translated away from fold blade 34, pins 40, and sheet 20 (i.e., punch assembly 32 is transitioned from the mated position back to the unmated position). Although described above as translating carriage assembly 36 relative to fold blade 34, in other embodiments, fold blade 34 is alternatively translated relative to carriage assembly 36 to fold and punch holes in sheet 20.
In one embodiment, the position of pins 40′ and/or pin receptors 42′ are adjustable along and over fold blade 34′, such that the position of any holes 78 in sheets 20 can be adjusted dependent upon the desired characteristics of bound document 14. In one embodiment, more pin receptors 42′ are formed in fold blade 34′ as compared to the number of pins 40′ included in first finishing system 22′ where each pin receptor 42′ corresponds with a different available position for a pin 40′.
Although the use and methods are described herein primarily with respect to first finishing system 22, it will be understood that first finishing station 22′ or other suitable devices, such as a hole drilling apparatus, may additionally or alternatively be used to form staple holes in sheet 20.
As generally illustrated in
Once all of sheets 20 have been accumulated, the legs of staples 80 are inserted through each pair of staple holes 78. In particular, as illustrated, in one embodiment, each staple 80 includes a cross member 82, a first leg 84, and a second leg 86. Legs 84 and 86 extend from opposite ends of cross member 82 in a substantially perpendicular manner. In one embodiment, staples 80 are metal staples. Each staple 80 is positioned relative to staple holes 78 such that first leg 84 is positioned to align with one staple hole 78 and second leg 86 is positioned to align with a second staple hole 78. Staples 80 are inserted through sheet stack 74 in any suitable method such as, for example, with a conventional power or manual stapler. More particularly, legs 84 and 86 are inserted to extend through each of the corresponding staple holes 78 in sheet stack 74, and upon insertion, each staple 80 interacts with staple saddle 72.
Upon interaction with staple saddle 72, which is generally a rigid material such as metal or other material sufficiently rigid to deform staple legs 84 and 86, each staple leg 84 or 86 is bent or otherwise deformed to clasp the innermost sheet 20 of sheet stack 74, thereby, securing staple 80 to sheets 20 and binding document 14. Although described above with respect to
Since staple holes 78 are formed in an operation separate from the insertion of staples 80, the overall forces utilized to insert legs 84 and 86 through sheets 20 to bind document 14 are significantly diminished. In particular, since staple holes 78 are formed in individual ones or portions of sheets 20, less force is required to form holes 78 than is required to punch holes through the entire sheet stack 74 at one time as in conventional systems. Such insertion forces are substantially less than the force required in conventional finishing systems to concurrently punch holes through a sheet stack, position the staple legs through the sheet stack, and to deform the staple legs to bind the sheet stack. Use of reduced forces permits use of lower cost drives, motors, and overall system structure, which decreases the overall cost of finishing system 12. In addition, since lower forces can be used, the sheet capacity for bound documents may also increased. Use of reduced overall forces also permits a wider range of sheet types to be used to form bound document 14. For example, thicker sheets or coated sheets, such as photo paper, etc., can be bound within finishing system 12 without generally requiring the relatively large forces typically used to bind such sheet types.
As generally indicated by exit arrow 28, once sheets 20 are stapled, the plurality of sheets 20 exit second finishing station 24 as bound document 14. In one embodiment, bound document 14 exiting second finishing station 24 is forwarded to another finishing station or output tray 16 (illustrated in
At operation 106, it is determined if all sheets 20 to be included in bound document 14 have been punched with staple holes 78. If all sheets 20 have not been punched, operation 102 is repeated as needed until all sheets 20 have been punched. If all sheets 20 have been punched, method 100 continues to operation 108. In one embodiment, it is desired that less than all of sheets 20 are punched prior to insertion of staples 80 (illustrated in
Additionally referring to
At operation 110, staples 80 are inserted through staple holes 78 as previously described with respect to
Once a hole is punched within individual sheet 20, sheet 20 is forwarded from punching station 152 to folding station 154 as generally indicated by arrow 162. Folding station 154 is configured to fold each sheet 20. In one embodiment, folding station 154 includes a fold blade, a pinch foot, and/or fold rollers similar to those described above with respect to first finishing station 22 (illustrated in
Upon stapling, bound document 14 is forwarded from stapling station 156 to a subsequent finishing station, such as a trimming station, etc., or is otherwise fed to output tray 16 (illustrated in
Moreover, although primarily described above as staple hole punching and folding sheets 20 in a sheet-wise manner, in other embodiments, portions or fractions of the plurality of sheets 20 to be included in bound document 14 are punched and folded at one time. In particular, a portion of the plurality of sheets 20 including more than one and less than all of sheets 20 is folded and stapled at one time. In this respect, although the forces used to fold and punch each portion of sheets 20 may be greater than the forces used to staple and punch a single sheet 20, the forces are still generally smaller than that would be used to fold and punch all of sheets 20 included in bound document 14 in a single operation. In addition, upon entering any of finishing stations 22, 24, 152, 154, and 156, sheet 20 or the plurality of sheets 20 are generally jogged and/or aligned in any suitable method to facilitate proper placement of fold lines, staple holes, and staples throughout each sheet 20 within the finished bound document 14.
Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a variety of alternate and/or equivalent implementations may be substituted for the specific embodiments shown and described without departing from the scope of the present invention. This application is intended to cover any adaptations or variations of the specific embodiments discussed herein. Therefore, it is intended that this invention be limited only by the claims and the equivalents thereof.
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