Stapler system for an image forming apparatus

A stapler system for an image forming apparatus according to one example embodiment includes a housing and a mounting device for mounting the housing to the image forming apparatus. A staple head is positioned within the housing for stapling media. A media sheet path is disposed within the housing for directing media received from the image forming apparatus to the staple head for stapling. When the housing is mounted on the image forming apparatus, a portion of the housing extends above an output bin of the image forming apparatus to permit delivery of stapled media from the housing to the output bin of the image forming apparatus.

CROSS REFERENCES TO RELATED APPLICATIONS

REFERENCE TO SEQUENTIAL LISTING, ETC.

BACKGROUND

1. Field of the Disclosure

The present disclosure relates generally to the handling of printed media sheets by an image forming apparatus, and more specifically, to a stapler system for an image forming apparatus.

2. Description of the Related Art

An image forming apparatus may be equipped with a stapler system for stapling printed media sheets. Typically, such stapler systems are equipped with an output tray for collecting stapled media sheets separate from an output bin of the printer. An advanced image forming apparatus, such as a multi-function printer (MFP), may be equipped with copying and/or scanning functionality in addition to the printing functionality. In some MFPs, the output bin of the stapler system is on a top portion of the MFP above the output bin of the printer. This increases the overall height of the MFP and makes it undesirable for use in places with space limitations. Further, the increased height may also create accessibility problems for the stapled media sheets. Accordingly, it will be appreciated that a stapler system that does not increase the overall height of an MFP or create accessibility problems is desired.

SUMMARY OF THE DISCLOSURE

A stapler system for an image forming apparatus according to one example embodiment includes a housing and a mounting device for mounting the housing to the image forming apparatus. A staple head is positioned within the housing for stapling media. A media sheet path is disposed within the housing for directing media received from the image forming apparatus to the staple head for stapling. When the housing is mounted on the image forming apparatus, a portion of the housing extends above an output bin of the image forming apparatus to permit delivery of stapled media from the housing to the output bin of the image forming apparatus. In some embodiments, when the housing is mounted on a multi-function image forming apparatus having a base portion for printing, a scanner portion for scanning and a gap formed between the base portion and the scanner portion and having the output bin positioned in the gap, the portion of the housing extends into the gap and above the output bin.

Embodiments include those wherein the housing has a generally L-shaped structure formed by a first portion and a second portion extending in a generally orthogonal direction from the first portion. In such embodiments, the mounting device is positioned on the first portion and a media release mechanism is positioned on the second portion for delivering stapled media from the housing to the output bin of the image forming apparatus. The media release mechanism is positioned above the output bin of the image forming apparatus when the housing is mounted on the image forming apparatus.

In some embodiments, the mounting device includes a movable latch member for securing the housing to the image forming apparatus. The latch member is received by a corresponding opening in the image forming apparatus when the housing is mounted on the image forming apparatus. Some embodiments include a pin adjacent to the latch member for aligning the housing with the image forming apparatus. The pin is received by a corresponding hole in the image forming apparatus when the housing is mounted on the image forming apparatus. In some embodiments, the mounting device includes an actuating mechanism having a latch that is operatively coupled to the latch member. Pressing the latch releases the latch member from the locked position and permits removal of the housing from the image forming apparatus.

DETAILED DESCRIPTION

The following description and drawings illustrate embodiments sufficiently to enable those skilled in the art to practice it. It is to be understood that the disclosure is not limited to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. For example, other embodiments may incorporate structural, chronological, electrical, process, and other changes. Examples merely typify possible variations. Individual components and functions are optional unless explicitly required, and the sequence of operations may vary. Portions and features of some embodiments may be included in or substituted for those of others. The scope of the application encompasses the appended claims and all available equivalents. The following description is, therefore, not to be taken in a limited sense, and the scope of the present invention is defined by the appended claims.

Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless limited otherwise, the terms “connected,” “coupled,” and “mounted,” and variations thereof herein are used broadly and encompass direct and indirect connections, couplings, and mountings. In addition, the terms “connected” and “coupled” and variations thereof are not restricted to physical or mechanical connections or couplings.

The present disclosure provides a stapler system for an image forming apparatus, such as a printer. The stapler system of the present disclosure may be used in conjunction with a single function printer (SFP) or a multi-function printer (MFP). The stapler system shares an output bin of the image forming apparatus for collecting a stack of stapled media sheets therein.

Referring now toFIGS. 1 through 3, perspective views of a stapler system10mounted on image forming apparatuses1000and2000are shown. As illustrated inFIG. 1, image forming apparatus is a single function printer (SFP)1000and inFIGS. 2 and 3image forming apparatus is a multi-function printer (MFP)2000. Stapler system10includes a housing100. Housing100includes a first portion100A and a second portion100B that extends generally orthogonally from, and is integral with, first portion100A. Accordingly, first and second portions100A,100B form a generally L-shaped structure.

With reference toFIG. 1, image forming apparatus1000includes a housing1001formed by a front wall1002, a first side wall1003, a second side wall (not shown) and a rear wall (not shown). Housing1001also includes a top portion1004and a bottom portion (not shown). Top portion1004includes an output bin1012for collecting printed media sheets from image forming apparatus1000. Housing100of stapler system10is carried by housing1001of image forming apparatus1000. First portion100A of housing100mounts on at least one of the walls of image forming apparatus1000. In the example embodiment illustrated, first portion100A mounts on the rear wall of image forming apparatus1000as will be explained in greater detail herein. However, it will be appreciated that first portion100A may mount on one or both of the side walls or front wall1002of image forming apparatus1000. Further, second portion100B of housing100may mount to a section of top portion1004as desired. Second portion100B of housing100extends directly above output bin1012of image forming apparatus1000to permit delivery of stapled media sheets from stapler system10to output bin1012as will be explained in greater detail herein. Second portion100B of housing100includes a media release mechanism800positioned above output bin1012when housing100is mounted on image forming apparatus1000that releases stapled media from housing100and delivers it to output bin1012as will be explained in greater detail herein.

With reference toFIGS. 2 and 3, image forming apparatus2000includes a is housing2001formed by a front wall2002, a first side wall2003, a second side wall2004, a rear wall2005, a top portion2006and a bottom portion (not shown). Image forming apparatus2000includes a base portion2008for printing media sheets and a scanner portion2010positioned above base portion2008for scanning media sheets. An output bin2012is located in a gap2014between base portion2008and scanner portion2010for collecting printed media sheets from base portion2008. In the example embodiment illustrated, a first window2016extends through front wall2002to allow access to the printed media sheets. Alternatives include those wherein window2016extends through one of side walls2003,2004or rear wall2005.

Housing100of stapler system10is carried by housing2001of image forming apparatus2000. First portion100A of housing100mounts on at least one of the walls of image forming apparatus2000. In the example embodiment illustrated, first portion100A mounts on rear wall2005as will be explained in greater detail herein. However, it will be appreciated that first portion100A may mount on one or both of side walls2003,2004or front wall2002of image forming apparatus2000. Second portion100B of housing100extends through a second window in housing2001directly above output bin2012of image forming apparatus2000to permit delivery of stapled media sheets from stapler system10to output bin2012as will be explained in greater detail herein. In the example embodiment illustrated, second portion100B extends through a second window positioned opposite window2016through rear wall2005. However, second portion100B may extend through a window in any of walls2002,2003,2004,2005. Further, second portion100B may mount to a portion of housing2001inside gap2014. In this embodiment, media release mechanism800is positioned in gap2014above output bin2012when housing100is mounted on image forming apparatus2000.

Referring toFIGS. 4 and 5, housing100includes a front portion101, a rear portion102, a pair of side portions103(FIG. 2),104, a top portion105and a bottom portion106. Housing100also includes a media sheet entrance107A and a media sheet exit107B. When housing100is mounted on image forming apparatus1000,2000, front portion101faces a wall, such as the rear wall, of housing1001,2001of image forming apparatus1000,2000and rear portion102faces away from housing1001,2001. A mounting device108is positioned on front portion101for mounting housing100on housing1001,2001of image forming apparatus1000,2000. Mounting device108includes a pair of pins109A,109B and a pair of latch members110A,110B each disposed at opposite ends of front side101of housing100. Pins109A,109B are received by corresponding holes in housing1001,2001and align housing100of stapler system10relative to housing1001,2001of image forming apparatus1000,2000. In the example embodiment illustrated, pins109A,109B are generally cylindrical members each having a tapered end portion to ease the insertion of pins109A,109B into the corresponding holes of housing1001,2001. Latch members110A,110B are received by corresponding openings, such as slots, in housing1001,2001of image forming apparatus1000,2000and secure housing100of stapler system10to housing1001,2001. To mount housing100on housing1001,2001, a user aligns pins109A,109B and latch members110A,110B with the corresponding holes and slots in housing1001,2001and simply pushes housing100toward housing1001,2001until a pair of catches of housing1001,2001engage latch members110A,110B. The engagement between latch member110A,110B and the catches of housing1001,2001secures housing100of stapler system10to housing1001,2001of image forming apparatus1000,2000. Biasing members112A,112B bias latch members110A,110B to a locked position wherein latch members110A,110B are engaged with and retained by the catches. In the example embodiment illustrated, biasing members112A,112B are torsion springs; however, any suitable biasing member may be used as desired including, for example, compression springs.

Mounting device108further includes a pair of actuating mechanisms113A,113B operatively coupled to latch members110A,100B for releasing latch members110A,110B and thereby releasing housing100from housing1001,2001. Actuating mechanisms113A,113B include latches114A,114B, respectively, disposed on side portions103,104, respectively, of housing100. Latches114A,114B are operatively coupled to latch members110A,110B. In the example embodiment illustrated, latches114A,114B are positioned within recesses115A,115B, respectively, and face housing1001,2001when housing100is mounted thereon. This configuration achieves an ergonomic effect in that as a user removes housing100from housing1001,2001, latches114A,114B are positioned to be conveniently accessible to the user's fingertips. Alternatives include those wherein latches114A,114B face in opposite directions from each other from sides103,104and those wherein latches114A,114B face away from housing1001,2001. Pressing latches114A,114B causes latch members110A,110B to rotate about a pivot point ‘P’ in order to provide clearance for latch members110A,110B to clear the catches of housing1001,2001and to allow removal of housing100.

With reference toFIGS. 4 and 6, in the example embodiment illustrated, is stapler system10receives electrical power directly from a power supply (not shown). Alternatives include those wherein stapler system10receives electrical power from image forming apparatus1000,2000. In the example embodiment illustrated, power is supplied to stapler system10via a power cord150(FIG. 6) from the power source through an inlet in bottom portion106. Alternatives include those wherein the inlet for power cord150is on one of side portions103,104, rear portion102or top portion105. In the example embodiment illustrated, electrical power received from cord150is split between stapler system10and image forming apparatus1000,2000. Alternatives include those wherein image forming apparatus1000,2000has its own power supply. A power cord152transfers electrical power from an outlet on bottom portion106to an inlet on image forming apparatus1000,2000. Alternatives include those wherein the outlet for power cord152is on one of side portions103,104, rear portion102or top portion105of housing100.

Housing100includes a retaining member154for retaining power cord150on housing100. Retaining member154is composed of a flexible material such as, for example, rubber. Retaining member154includes an opening156therein, such as a slit, for receiving power cord150. A first end154A of retaining member154is attached to bottom portion106of housing100. A second end154B of retaining member154is removably attached to rear portion102of housing100. Second end154B includes an opening158therein for receiving a peg160extending from rear portion102to attach second end154B to housing100. Alternatives include those wherein peg160extends from bottom portion106or one of side portions103,104and second end154B of retaining member154attaches to bottom portion106or one of side portions103,104.

Housing100also includes a data bus170(FIG. 4) for exchanging data between stapler system10and image forming apparatus1000,2000as is known in the art. In some embodiments, stapler system10includes a controller (not shown) for controlling the operation of stapler system10. Alternatives include those wherein a controller of image forming apparatus1000,2000controls the operation of stapler system10.

Referring now toFIG. 7, stapler system10includes a plurality of guiding elements to guide media sheets received from image forming apparatus1000,2000, particularly printed media sheets, within housing100. Specifically, the plurality of guiding elements operatively mount within housing100and guide the printed media sheets along a media sheet path210(shown with a dashed line) within housing100. For example, as shown inFIG. 7, the plurality of guiding elements includes a diverter202for diverting media traveling along a media sheet path within image forming apparatus1000,2000into media sheet entrance107A of stapler system10(FIG. 4). In some embodiments, diverter202is mounted on housing100of stapler system10. Alternatives include those wherein diverter202is mounted on housing1001,2001of image forming apparatus1000,2000. The guiding elements also include a pair of feed rollers204and an exit roller206for advancing media along media sheet path210within housing100.

Diverter202directs the printed media sheets either toward media sheet path210or toward an output bin of an image forming apparatus, such as output bin1012of image forming apparatus1000. Specifically, diverter202may be instructed to block media sheet path210when an image forming apparatus, such as image forming apparatus1000,2000, is instructed to perform only a printing function. Otherwise, when the image forming apparatus is instructed to perform a stapling function along with the printing function, diverter202is positioned to allow the printed media sheets to leave image forming apparatus1000,2000from an opening in a wall, such as, for example, the rear wall, of housing1001,2001and enter media sheet entrance107A through front portion101of first portion100A of housing100and move along media sheet path210for stapling by stapler system10. Once diverter202directs the printed media sheets toward media sheet path210, feed rollers204and exit roller206advance the printed media sheets along media sheet path210. In the example embodiment illustrated, media sheet path210is a generally C-shaped path.

Stapler system10further includes a pass through sensor220mounted along media sheet path210. In the example embodiment illustrated, pass through sensor220is a photosensor mounted along media sheet path210between feed rollers204and exit roller206. Alternatives include those wherein pass through sensor220is a mechanical flag sensor. Pass through sensor220determines positions of the printed media sheets along media sheet path210. Specifically, pass through sensor220detects when leading and trailing edges of the printed media sheets arrive at or leave from pass through sensor220. Based on the values of pass through sensor220, i.e., determination of the leading edges and/or the trailing edges, stapler system10may operate in a predetermined sequential order, which will be explained in greater detail later herein. Pass through sensor220may also determine if a jam of a printed media sheet on media sheet path210has occurred.

As shown inFIG. 7, stapler system10also includes a first alignment mechanism300for laterally aligning the printed media sheets. First alignment mechanism300is operatively mounted within housing100. Specifically, as shown inFIG. 7, first is alignment mechanism300is mounted on a portion118of housing100such that first alignment mechanism300is positioned above an output bin of an image forming apparatus. For example, as shown inFIG. 1, portion118of housing100positioned above output bin1012may support first alignment mechanism300.

Referring now toFIGS. 8 and 9, one example embodiment of first alignment mechanism300is shown in greater detail. However, it will be appreciated that alternative designs may be used to laterally align the media as desired.

As shown inFIG. 9, first alignment mechanism300includes a support frame302. Support frame302mounts within housing100. For example, support frame302may be mounted on portion118of housing100. First alignment mechanism300also includes a pair of spaced apart and parallel support shafts310,312carried by support frame302. Specifically, support shaft310mounts between side flanges304A,304B of support frame302while support shaft312mounts between side flanges306A,306B.

First alignment mechanism300also includes a pair of spaced apart and parallel arms320,322each slidably carried by support shafts310,312. Specifically, arms320,322each include a pair of sliding connectors slidably coupled with support shafts310,312. For example, arm320includes a pair of sliding connectors324,326slidably carried on one end of support shafts310,312, respectively. Similarly, arm322includes a pair of sliding connectors328,330slidably carried on the other end of support shafts310,312, respectively. Each arm320,322also includes a tamper portion coupled to the pair of sliding connectors thereof. For example, arm320includes a tamper portion332coupled to sliding connectors324,326and arm322includes a tamper portion334coupled to sliding connectors328,330.

First alignment mechanism300further includes a pair of motors340,342, each of which may be, for example, a stepper motor. Motors340,342mount on a top surface308of support frame302. Motors340,342may mount on top surface308with the help of mounting brackets376,378, respectively, and attachment means, such as nuts and bolts. Motors340,342are operatively coupled with arms320,322, respectively, for slidably moving arms320,322along support shafts310,312. In the example embodiment illustrated, first alignment mechanism300includes belt and pulley arrangements350,352which operatively couple respective motors340,342with respective arms320,322.

Belt and pulley arrangement350includes a belt354and a pulley356and belt and pulley arrangement352includes a belt358and a pulley360. Pulleys356,360are is rotably mounted on top surface308of support frame302. Pulley356rotably mounts on top surface308between side flanges304A,306A of support frame302. Similarly, pulley360rotably mounts on top surface308between side flanges304B,306B of support frame302.

Belts354,358of belt and pulley arrangements350,352operatively couple pulleys356,360with motors340,342, respectively. Specifically, belt354encircles pulley356and rotably couples with a drive shaft of motor340such that when the drive shaft of motor340rotates, belt354moves linearly and pulley356rotates. Similarly, belt358encircles pulley360and rotably couples with a drive shaft of motor342allowing belt354to move linearly and pulley356to rotate when the drive shaft of motor342rotates.

Belt and pulley arrangements350,352also include belt tension springs362,364, respectively, carried by belts354,358, respectively. Belt tension springs362,364respectively tension belts354,358to reduce slack and prevent slipping of belts354,358.

As explained herein, belt and pulley arrangements350,352couple motors340,342with arms320,322, respectively. Arm320operatively couples with motor340via belt354and arm322operatively couples with motor342via belt358. In the example embodiment illustrated, arm320includes a clamp336that is slidably carried by support shaft310and coupled to sliding connector324, as shown inFIG. 9. Clamp336is further coupled to a portion of belt354such that when belt354is moved linearly due to the rotation of the drive shaft of motor340, sliding connector324slides on support shaft310slidably moving arm320on support shaft310transverse to the media feed direction indicated by arrow M. Similarly, arm322includes a clamp338coupled to sliding connector328and belt358for slidably moving arm322on support shaft310transverse to the media feed direction M when belt358is moved linearly by motor342.

First alignment mechanism300also includes sensors370,372carried by arms320,322, respectively, on sliding connectors326,330, respectively. Sensors370,372are communicably coupled with pass through sensor220mounted on media sheet path210. Sensors370,372determine the positions of arms320,322on support shafts310,312, which will be explained in greater detail later herein.

First alignment mechanism300of stapler system10laterally aligns the printed media sheets. Specifically, arms320,322each may slidably move towards each other for laterally aligning the printed media sheets on a collection tray120(shown inFIGS. 7 and 8) of housing100. For example, when the printed media sheets follow media is sheet path210(as explained in conjunction withFIG. 7), the printed media sheets may be partially received on collection tray120and partially received on tamper portions332,334of arms320,322. Specifically, when the leading edge of a printed media sheet is detected by pass through sensor220, arms320,322slidably move toward each other from a home position to a standby position to allow tamper portions332,334to partially receive the printed media sheet thereon.

Referring now toFIG. 10, a top view of first alignment mechanism300is shown.FIG. 10also depicts the sequential positions of arms320,322for laterally aligning the printed media sheets on collection tray120.FIG. 10depicts reference lines A1and A2, showing the home position of arms320,322, respectively. In the home position A1, A2, the distance between arms320,322is wider than the largest desirable media such that when arms320,322are in the home position A1, A2, finished media may be passed between tamper portions332,334to the output bin. Reference lines B1and B2show a standby position of arms320,322, respectively. References lines C1and C2show a stapling position of arms320,322, respectively. In the standby and stapling positions B1, B2and C1, C2, the distance between arms320,322is slightly larger than the width of the printed media sheets in order to laterally align the media sheets for stapling. Accordingly, it will be appreciated that the standby and stapling positions B1, B2and C1, C2depend on the size of the media.

When the leading edge of a printed media sheet is detected by pass through sensor220, the controller directs arms320,322to laterally slide from the home position A1, A2to the standby position B1, B2to receive the printed media sheet. It will be appreciated that the distance from the home position A1, A2to the standby position B1, B2is dependent upon the size of the media. For example, the distance from the home position A1, A2to the standby position B1, B2for A4 size media is greater than for A3 size media. In one example embodiment, in the case of letter size media, arms320,322each travel about 37.5 mm toward each other on support shafts310,312, respectively, to reach the standby position B1, B2from the home position A1, A2. In some embodiments, after each media sheet is received by arms320,322, arms320,322laterally slide toward each other until the distance between arms320,322is approximately equal to the width of the media and then slide away from each other to the standby position B1, B2in order to laterally align the stack of printed media sheets. Alternatives include those wherein only one arm320or322laterally slides toward the other and then returns to the standby position in order to align the media. In the example embodiment illustrated, sliding connector324includes a spring374(FIG. 8) that allows arm320to over-tamper the media. In this embodiment, after each media sheet is received by arms320,322, sliding connector324travels slightly further than is required to laterally slide arm320a distance from arm322equal to the width of the media. Spring374permits arm320to travel far enough to laterally align the printed media sheets but prevents arm320from compressing the media. It will be appreciated that sliding connector326may also include a spring to permit over-tampering as desired.

Once the stack of printed media sheets is ready for stapling, arms320,322laterally slide in parallel from the standby position B1, B2to the stapling position C1, C2. In one example embodiment, in the case of letter size media, arms320,322slide 10 mm from the standby position B1, B2to the stapling position C1, C2. When stapling is complete, arms320,322laterally slide away from each other to the home position A1, A2in order to drop the stapled media to the output bin, such as output bin1012of image forming apparatus1000, which will be explained in greater detail later herein.

Referring now toFIG. 11, one example embodiment of a second alignment mechanism400of stapler system10for longitudinally aligning the printed media sheet is shown. However, it will be appreciated that alternative designs may be used to longitudinally align the media as desired. Second alignment mechanism400operatively mounts within housing100, best shown inFIG. 7. As shown inFIG. 11, second alignment mechanism400includes a first shaft410extending transversely across a portion of media sheet path210. First shaft410rotably mounts within housing100, as shown inFIG. 8. Second alignment mechanism400also includes flexible paddle elements420and422carried by first shaft410. Paddle elements420,422are positioned above collection tray120of housing100, as shown inFIG. 8. Paddle elements420,422rotate with the rotation of first shaft410.

Second alignment mechanism400includes a motor440and a first drive transmission428that operatively couples motor440to second alignment mechanism400. First drive transmission428includes a first set of gears430,432,434and436and first shaft410, as shown inFIG. 11. First set of gears430,432,434,436operatively couples with first shaft410. Specifically, gear436is carried by first shaft410, such that rotation of gear436rotates first shaft410. As illustrated, motor440is a stepper motor. Motor440operatively couples with first set of gears430,432,434,436. Specifically, gear430is mounted on a shaft (not shown) of motor440. Therefore, motor440rotates first shaft 41° through first set of gears430,432,434,436. Specifically, rotation of the shaft of motor440rotates gear430, which in turn rotates gears432,434,436for rotating first shaft410. It will be appreciated that the number and orientation of the gears of first drive transmission428illustrated and described herein is meant to serve as an example and is not intended to be limiting.

Rotation of first shaft410allows paddle elements420,422to longitudinally align the media sheets on collection tray120of housing100. More specifically, once a media sheet is laterally aligned by first alignment mechanism300(as explained in conjunction with theFIGS. 9 and 10), thereafter the media sheet is longitudinally aligned on collection tray120by second alignment mechanism400, which will be explained in greater detail later herein. Second alignment mechanism400also includes a first one way clutch450carried by first shaft410, as shown inFIG. 11. Alternatives include those wherein first one way clutch450is positioned on one of the first set of gears430,432,434,436. When motor440is rotating in a first direction, first one way clutch450engages and allows the rotation of first shaft410. When motor440is rotating in a second direction, first one way clutch450disengages and restricts the rotation of first shaft410.

Motor440rotates in the first direction (clockwise inFIG. 11), which rotates first shaft410in a first direction (counter-clockwise inFIG. 11) due to a rotation provided by first set of gears430,432,434,436. Further, rotation of first shaft410in the first direction rotates paddle elements420,422in the first direction. The rotation of paddle elements420,422in the first direction allows paddle elements420,422to contact the surface of a printed media sheet placed on collection tray120. The contact of paddle elements420,422moves the media sheet rearward, such that a trailing edge of the media sheet touches a wall122(shown inFIG. 7) of collection tray120. As a result, the printed media sheet is longitudinally aligned by second alignment mechanism400on collection tray120.

Accordingly, subsequent printed media sheets may be laterally and longitudinally aligned by first alignment mechanism300and second alignment mechanism400for configuring a stack of aligned media sheets on collection tray120. Further, it will be appreciated by those skilled in the art that printed media sheet may be initially longitudinally aligned by second alignment mechanism400on collection tray120and thereafter laterally aligned by first alignment mechanism300.

Referring back toFIG. 8, stapler system10also includes staple head500for stapling the stack of laterally and longitudinally aligned printed media sheets. Staple head500is mounted within housing100and positioned along a side of housing100. As shown inFIG. 8, staple head500is slidably received by a side slot130of housing100. Thereafter, staple head500is mounted within side slot130with the help of a mounting bracket510and attachment means, such as screws (not shown). Further, staple head500may be mounted within side slot130of housing100such that staple head500is aligned to the reference line C1(shown inFIG. 10) to allow staple head500to staple the stack of media sheets after being laterally and longitudinally aligned by first alignment mechanism300and second alignment mechanism400, respectively.

Referring now toFIG. 12, a perspective view of an ejection mechanism600of stapler system10is shown along with second alignment mechanism400. Ejection mechanism600includes a second shaft610that rotably mounts within housing100. Ejection mechanism600includes spaced apart ejector belts620and622rotably mounted on second shaft610with pulley members630A,630B that are mounted on housing100. Pulley members632A,632B are respectively aligned with pulley members630A,630B. Ejector belt620mounts on pulley members630A,632A while ejector belt622mounts on pulley members630B,632B. Rotation of second shaft610rotates ejector belts620,622.

Ejector belts620,622move along collection tray120of housing100along30media sheet path210. Collection tray120may have longitudinal channels124(shown inFIG. 8), which facilitate the movement of the pair of ejector belts620,622along collection tray120. Parallel longitudinal channels124A,124B receive projections624and626(shown inFIG. 12) on the outer surface of ejector belts620,622.

Ejection mechanism600also includes a second drive transmission638that operatively couples ejection mechanism600with motor440of second alignment mechanism400. Second drive transmission638includes a second set of gears640,642and644and second shaft610. Second set of gears640,642and644are operatively coupled to second shaft610. Specifically, gear644is carried by second shaft610. Second shaft610is rotated by motor440through the second set of gears640,642,644. Specifically, gear640meshes with gear432for receiving torque from motor440. It will be appreciated that the number and orientation of the gears of second drive transmission638illustrated and described herein is meant to serve as an example and is not intended to be limiting.

Ejection mechanism600also includes a second one way clutch650carried by second shaft610. Alternatives include those wherein second one way clutch650is positioned on one of the second set of gears640,642,644. When motor440is rotating in the first direction (clockwise direction inFIGS. 11 and 12), second one way clutch650disengages and restricts rotation of second shaft610in a first direction. When motor440is rotating in the second direction (counter-clock direction inFIGS. 11 and 12), second one way clutch650engages and allows rotation of second shaft610in a second direction.

Ejection mechanism600facilitates moving the stapled media sheets from collection tray120towards first alignment mechanism300, particularly towards tamper portions332,334of arms320,322, respectively. Specifically, when motor440rotates in the second direction (counter-clockwise direction shown with an arrow inFIGS. 11 and 12), second shaft610also rotates (counter-clockwise shown with an arrow inFIGS. 11 and 12) due to a rotation provided by the second set of gears640,642,644. Due to rotation of second shaft610, ejector belts620,622also rotate which moves projections624,626in the media feed direction M to move the stack of stapled media sheets from collection tray120towards tamper portions332,334of arms320,322. Specifically, projections624,626move within their respective channels124A,124B of collection tray120for moving the stack of stapled media sheets from collection tray120towards tamper portions332,334of first alignment mechanism300.

The stack of stapled media sheets is now received on tamper portions332,334of first alignment mechanism300for being collected into an output bin of an image forming apparatus, such as output bin1012of image forming apparatus1000. More specifically, when ejection mechanism600moves the stack of stapled media sheets towards tamper portions332,334of arms320,322, arms320,322are allowed to move away from each other. For example, arms320,322are allowed to attain the home position (shown with the reference lines A1and A2), thereby allowing tamper portions332,334of arms320,322to leave the stack of stapled media sheets allowing the stapled media sheet to fall into an output bin of an image forming apparatus, such as output bin1012of image forming apparatus1000. Accordingly, in the example embodiment illustrated, arms320,322, and more specifically tamper portions332,334, serve as media release mechanism800(FIG. 9) that delivers stapled media from housing100to the output bin of the image forming apparatus. However, it will be appreciated that any suitable device for releasing stapled media from housing100and delivering it to the output bin may be utilized such as, for example, a conventional exit nip formed between a pair of exit rollers or a device similar to ejection mechanism600.

Stapler system10of the present disclosure also includes sensors for detecting a height of the stack of printed media sheets to be collected on tray120and a height of the stack of stapled media sheets to be collected in an output bin, such as output bin1012. For example, stapler system10includes sensors702,704positioned on housing100, as shown inFIG. 7. Sensor702detects a height of a stack of printed media sheets on tray120. Sensor704detects a height of a stack of media sheets in an output bin, such as output bin1012(FIGS. 4 and 8). In the example embodiment illustrated, sensor704is an optical sensor that includes a transmitter and a receiver that form an optical path S therebetween. The transmitter and the receiver are positioned on opposite portions119A,119B of housing100, respectively. In the example embodiment illustrated, portions119A,119B are positioned in a stationary manner beneath arms320,322, respectively.FIG. 13shows output bin1012having printed media therein. In some instances, printed media may tend to curl as shown inFIG. 13. If the height of the stack of media in output bin1012gets too high, it may interfere with the movement of arms320,322. Accordingly, sensor704detects whether the stack of media sheets in an output bin, such as output bin1012, exceeds a predetermined height that could restrict the movement of arms320,322. If sensor704detects the presence of media, the image forming apparatus indicates to the user that the media in the output bin needs to be removed. This indication may be in the form of a message on a display screen of the image forming apparatus, such as a display device2020of image forming apparatus2000(FIG. 2), or a signal from an indicator light (not shown).

Referring now toFIG. 7, in use, initially, diverter202allows a printed media sheet (not shown) to enter housing100of stapler system10. Thereafter, feed rollers204guide the printed media sheet along media sheet path210. Once pass through sensor220detects a leading edge of the printed media sheet, first alignment mechanism300and second alignment mechanism400are triggered by pass through sensor220. Specifically, in one embodiment, when the leading edge of the printed media sheet moves 160 mm in about 542 ms (millisecond), arms320,322move from the home position (shown with reference lines A1, A2inFIG. 10) to the standby position (shown with reference lines B1, B2inFIG. 10). Thereafter, when a trailing edge of the printed media sheet is detected by pass through sensor220, the printed media sheet is allowed to move along the media sheet path210for about 91 ms. This allows the printed media sheet to be received on collection tray120. Once the printed media sheet is received on collection tray120, second alignment mechanism400is allowed to operate for about 172 ms. Specifically, motor440is allowed to rotate first shaft410for about 172 ms, thereby allowing paddle elements420,422to move the printed media sheet rearwardly for contacting wall122of collection tray120. This allows the printed media sheet to be longitudinally aligned in collection tray120. Further, arms320,322move towards each other from the standby position (shown with reference lines B1, B2inFIG. 10) for laterally aligning the media sheet on collection tray120. Specifically, after 129 ms, when the printed media sheet is longitudinally aligned, arms320,322move towards each other, for example with reference to theFIG. 10, arms320,322move 5 mm towards each other for laterally aligning the media sheet on collection tray120. Accordingly, the printed media sheet is laterally and longitudinally aligned on collection tray120by first alignment mechanism300and second alignment mechanism400.

Once the printed media sheet is laterally and longitudinally aligned on collection tray120, arms320,322move away from each other, particularly towards the standby position (shown with reference lines B1, B2inFIG. 10). Thereafter, a next printed media sheet is allowed to move along the media sheet path210for being collected on collection tray120, thereafter next printed media sheet is laterally and longitudinally aligned on collection tray120by first alignment mechanism300and second alignment mechanism400. Accordingly, subsequent printed media sheets are received on collection tray120and thereafter laterally and longitudinally aligned for configuring a stack of aligned printed media sheets on collection tray120.

Once the stack of aligned printed media sheets is configured on collection tray120, arms320,322move from the standby position (shown with reference lines B1, B2inFIG. 10) to the stapling position (shown with reference lines C1, C2inFIG. 10). Thereafter, staple head500is actuated to perform the stapling function for stapling the stack of aligned printed media sheets. Next, arms320,322move away for each other, i.e., from the stapling position towards the standby position. Thereafter, ejection mechanism600is triggered for moving the stack of stapled media sheets towards tamper portions332,334of arms320,322. Finally, arms320,322move from the standby position to the home position allowing the stack of stapled media sheets to collect into an output bin of an image forming apparatus, such as output bin1012of image forming apparatus1000.

The present disclosure provides a stapler system, such as the stapler system10, for an image forming apparatus, such as a SFP and a MFP. The stapler system of the present disclosure obtains an aligned stack of stapled media sheets. The stapler system mounts on a conventional image forming apparatus. The stapler system shares an existing output bin of an image forming apparatus thereby avoiding the need for a separate tray for collecting the stack of stapled media sheets. The stapler system of the present disclosure conveniently mounts on a MFP without increasing a distance between a scanner portion and a base portion of the MFP.

The foregoing description of several embodiments of the present disclosure has been presented for purposes of illustration. It is not intended to be exhaustive or to limit the present disclosure to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. It is intended that the scope of the present disclosure be defined by the claims appended hereto.