Finisher, bookbinder, and imaging system

Single perforating unit is enabled to perforate for file binders and to cut milling grooves, while with a simple structure file-binder storage and booklet-binding can be carried out reliably. Configurations include: a convey-in path for sequentially transferring sheets; a stacker for collating into bundles sheets from the convey-in path; and an adhesive-layer applicator for adding an adhesive layer to the spine-closure edge of sheet bundles from the stacker. A perforating unit is provided in along the convey-in path, and a control unit for controlling position and/or number of perforations made by the perforating unit is provided with (1) a first operation mode in which it effects the punching of a predetermined number of holes in the edge of sheets, and (2) a second operation mode in which it effects the formation of a predetermined number of crenulated grooves in the edge of sheets.

BACKGROUND OF THE INVENTION

1. Technical Field

The present invention—involving finishing and bookbinding devices for collating and stacking, as well as binding into booklets, sheets onto which images have been formed by an imaging device—relates to improvements in mechanisms for perforating sheets with binder holes, and collating and stacking the sheets, as well as binding them into booklets.

2. Description of the Related Art

Widely known among finishing devices (finishers) as well as bookbinding devices (bookbinders) of this type are in general devices that sequentially stow into a storage stacker sheets fed from a printer, scanner, or like imaging device, as well as devices that collate sheets into bundles and bind them into booklets. With the former—finishing devices—incorporating a built-in mechanism for punching holes into sheets, later provided to binders, in the course of the sheets being conveyed out is known. Meanwhile, in the latter—bookbinding devices—mechanisms for applying adhesive, or adding on adhesive tape, to the spine-portion endface of collated and stacked sheet bundles, and binding them together are known.

For example, Japanese Unexamined Pat. App. Pub. No. 2007-276967 (FIG. 1) proposes: a bookbinder in which sheets from an imaging device are collated and stacked, and adhesive is applied to the sheets and they are bound together with a coversheet; and a system apparatus wherein, in a finisher provided in association with the bookbinder, punch holes are perforated in sheets from the imaging device, and the sheets are stored in a storage stacker.

The device as cited above (JP 2007-276967) is a system in which the bookbinder, which is disposed at a downstream side of the imaging device, and the finisher, which is disposed at a downstream side thereof, are linked. In a bookbinding mode, the sheets fed to a carry-in path are bound in a booklet by the bookbinder while in a finishing mode, the sheets fed to the carry-in path are forwarded to the finisher, where holes are punched, seals or stamps are applied, and a jog segmentation is also done. The sheets are then stored in a storage stacker.

After that, the spine-portion endface of the sheet bundle collated and stacked in the bookbinder is applied adhesive (or an adhesive tape) so as to bind together the sheets. In this case, roughening the spine-portion endface of the sheet bundle in an uneven shape (milling process) is known. By roughening the spine endface, this process causes the adhesive to permeate, in order to prevent sheets from coming loose.

Examples of a mechanism include that proposed in FIG. 9 and FIG. 11 of Japanese Unexamined Pat. App. Pub. No. 2007-062145, which provides a saw-toothed punching blade in a transport path of the sheets and roughens the edge of the sheets with the punching blade, at the time of applying a milling process to the sheets sequentially fed from the imaging device. In the mechanism as cited above (JP 2007-062145), the sheets moved along the transport path are roughened by pushing a punching blade by a driving cam. The sheets are roughened one by one or several sheets are roughened by piling them on top of one another.

As mentioned above, it is well known that at the time of binding the sheets transported from an imaging device, etc., into a booklet, the roughened notched grooves are formed on the spine-closure edge, and the sheets are bound together by the adhesive, etc. In particular, in the patent reference cited earlier (JP 2007-062145), there is proposed the formation of the roughened punch holes in one or several pages of sheets at the stage prior to collating and stacking the sheets.

In the mechanism proposed in the patent reference (JP 2007-062145), the saw-toothed punching blade is moved up and down by using a clank arm. When milling grooves are formed on the spine-closure edge on the transport path of the sheets in this way, the mechanism becomes simplified and compact, providing an affordable milling process. However, in this type of conventionally known milling mechanism, the punching blade is saw-tooth shaped. Due to this shape, a punching blade in a round blade shape generally used for file binders, for example, cannot be diverted for this milling mechanism. This necessitates expensive manufacturing of the punching blade, and if some defects, such as a blade is chipped, develop in the blade during usage, the entire blade has to be replaced.

In the device or the system configuration in which the finishing function of punching holes for a binder is combined with the bookbinding function of punching holes for milling, as cited in the above patent reference (JP 2007-276967), a punch unit for file binders and that for milling have to be provided separately. This necessitates a large device, which increases a cost for the punch unit. As a result, its maintenance also becomes complicated, which are shortcomings.

BRIEF SUMMARY OF THE INVENTION

Therefore, the inventor has conceived the idea of selectively perforating for file binders and cutting milling grooves by the punching blade in a round blade shape.

A first object of the present invention is to provide a finisher capable of surely binding together sheets at the time of binding them into a booklet with a simple structure by perforating for file binders and cutting milling grooves by single perforating means, and also capable of providing binding holes at predetermined positions for file-binder situations.

A second object of the present invention is to provide a bookbinder capable of surely bonding the sheets by a lesser number of uneven grooves formed on the spine-closure edge at the time of binding the sheets into a booklet.

To attain the aforementioned objects, the present invention is configured to comprise perforating means for forming circular punch holes (round holes) in a transport path of sheets is arranged, and control means for controlling perforating positions and/or the number of holes by the perforating means. The control means includes (1) a first operation mode for perforating a predetermined number of punch holes on the edge of the sheet and (2) a second operation mode for perforating a predetermined number of uneven grooves on the edge of the sheet. Thereby, in the first operation mode, punch holes for a binder are perforated, and in the second operation mode, roughening grooves for binding a booklet are perforated. The main configurations will be explained below.

In one aspect, the present invention is equipped with: a convey-in path for sequentially moving sheets; stacking means for collating the sheets from the convey-in path into bundles; and adhesive-layer forming means for adding an adhesive layer to a spine-closure edge of the sheet bundle from the stacking means; and further equipped with: perforating means disposed between the convey-in path or the stacking means, and the adhesive-layer forming means, for forming circular punch holes at one or a plurality of locations on the sheet; control means arranged in the perforating means, for controlling a perforating position and/or the number of perforations; and the control means including a first operation mode for perforating punch holes for a binder on the end of the sheet and a second operation mode for perforating crenellated notch-holes on the edge of the sheet.

The perforating means is disposed along the convey-in path, the convey-in path is installed consecutively to a bookbinding process path and a sheet-discharge process path, which are separated from the convey-in path, and at a downstream side of the bookbinding process path, the stacking means is disposed, and at a downstream side of the sheet-discharge process path, a storage stacker for stacking and storing the sheets is disposed, respectively. The control means is configured to move a perforated sheet along the sheet-discharge process path in the first operation mode and move the perforated sheet along the bookbinding process path in the second operation mode.

In another aspect, the present invention is equipped with: a convey-in path for sequentially conveying sheets; stacking means for collating the sheets from the convey-in path into bundles; adhesive-layer forming means for adding an adhesive layer to a spine-closure edge of the sheet bundle from the stacking means; cover binding means for binding together the sheet bundle from the adhesive-layer forming means and a coversheet; and a cover feed path for feeding the coversheet to the cover binding means, and further equipped with perforating means disposed between the convey-in path or the stacking means, and the adhesive-layer forming means, for forming punch holes at one or a plurality of locations on the sheet; control means arranged in the perforating means, for controlling a perforating position and/or the number of perforations; and the control means including a first operation mode for perforating punch holes for a binder on the end of the sheet and a second operation mode for perforating crenellated notch-holes on the edge of the sheet.

The convey-in path is connected to an inner-leaf transport path along which the sheet is moved to the stacking means, and the cover feed path, which are separated from the convey-in path, and a storage stacker for stacking and storing the sheets is disposed at a downstream side of the cover feed path. In the first operation mode, the control means is so configured that punch holes are perforate on the ends of a coversheet and an inner leaf supplied to the convey-in path, and the sheets are moved from the cover feed path to the storage stacker, and in the second operation mode, the control means is so configured that crenellated notch-holes are perforated on the edge of the inner leaf fed to the convey-in path and the inner leaf is moved to the inner-leaf transport path.

At the time of moving the sheet from the convey-in path to the stacking means, the control means is so configured that sheets to be perforated and those not to be perforated in the second operation mode are selectively fed.

The perforating means and the sheet fed to a perforating position of the convey-in path are configured to move relative to a transport direction position, and the control means is configured to adjust the size of notch holes perforated on the edge of the sheet in the second operation mode, in the second operation mode.

Positioning means for setting the sheet to a predetermined perforating position is arranged along the convey-in path, the positioning means is configured by regulating means for regulating the end of the sheets by pushing against the sheets, and roller means for transporting the sheets from the regulating means by a predetermined amount, and the control means adjusts the size of the notch holes perforated on the edge of the sheets by a transport amount of the roller means, in the second operation mode.

The control means is configured to set large or small of the size of the notch holes perforated on the edge of the sheet based on sheet information such as a sheet material quality, a sheet size, a sheet basis weight (grammage), and the number of sheets to be collated, in the second operation mode.

The perforating means is equipped with a plurality of perforating cutters for simultaneously perforating a plurality of punch holes in a sheet width direction, the plurality of perforating cutters are so configured that the number of punch holes can be selected, and the control means is configured to select the number of crenellated notch-holes formed on the edge of the sheet in the second operation mode.

The control means is configured to select the number of the notch holes perforated on the edge of the sheet based on sheet information such as a sheet material quality, a sheet size, a sheet basis weight, and the number of sheets to be collated, in the second operation mode.

In the second operation mode, the control means is configured to selectively perforate the notch holes in the sheets moved to the inner-leaf transport path.

In the second operation mode, the control means perforates the notch holes perforated in at least one set of two successive sheets so that (1) the number of holes, and/or (2) the size of the holes, and/or (3) hole position are differed, when perforating the notch holes in the sheets moved to the inner-leaf transport path.

An imaging system according to the present invention is configured by: an imaging device for sequentially imaging on sheets; and a bookbinder for collating sheets from the imaging device into a bundle and wrapping the collated sheets with a coversheet to form a booklet. The bookbinder is equipped with the aforementioned configuration.

The present invention is that which is so configured that along the transport path for the sheets to be fed toward the adhesive-layer forming (applying) means for binding sheets into a booklet, the perforating means for forming the circular punch holes is arranged, and the control means for controlling the perforating positions and/or the number of perforations by the perforating means is configured to control by: (1) the first operation mode for perforating a predetermined number of punch holes on the edge of the sheet; and (2) the second operation mode for forming a predetermined number of uneven grooves on the end of the sheet. Thus, the following remarkable effects are provided.

The punch holes for a binder and the uneven grooves for binding a booklet can be selectively formed by the circular punching blades, respectively, according to finishing conditions. Therefore, unlike in the conventional art where a perforating mechanism for the binder holes and that for binding a booklet need to be individually incorporated within the device, the device can be configured small and compact.

That is, when forming the punch holes at the time of stacking and storing the sheets forwarded along the convey-in path in the storage stacker, the binder holes can be formed by perforating a predetermined number of punch holes on edge of the distal end or the rear end of the sheet along the convey-in path. Also when binding the sheets from the convey-in path in a booklet, roughened uneven grooves are formed on the spine-closure edge by forming the notch holes in an uneven shape on the edge of the distal end or the rear end of the sheets along the convey-in path, and by the adhesive flown between the grooves, the sheets can be surely stitched together.

In particular, in the present invention, the crenellated notch-holes are formed by the perforating cutters for forming the circular punch holes on the spine-closure edge of the sheets when binding the sheets into a booklet, and thus, the positions of the perforating cutters relative to the sheet edge can be adjusted to change the size of the notch holes, e.g., a small size or a large size. Therefore, when the thickness of sheets to be bound into a booklet is large, e.g., sheet of 100 pages are bound into a booklet, the notch holes can be set large according to the specification of the device. This enables accurate bonding in which sheets do not come loose.

Further, in the present invention, the perforating means is configured to form a plurality of punch holes simultaneously, and in the aforementioned second operation mode, the size, the number, positions of the notch holes are changed according to a sheet material quality, a sheet size, a sheet basis weight, and the number of sheets to be collated. This enables the accurate binding of a sheet bundle into a booklet with a relatively lesser number of grooves.

Also, in the present invention, the sheets sequentially fed along the convey-in path are formed with the crenellated notch-holes so as to bind the sheets into a booklet. Thus, the number and positions of holes can be changed for each sheet to be collated. Thereby, the adhesive can be surely permeated through the sheets, which enables the more accurate binding of a sheet bundle into a booklet.

DETAILED DESCRIPTION OF THE INVENTION

The present invention will now be explained in detail based on the preferred embodiment provided below.FIG. 1is an explanatory view of the entire configuration of a bookbinder according to the present invention and an imaging system using the same.FIG. 2is a detailed explanatory view of the bookbinder.

As shown inFIG. 1, the imaging system according to the present invention is configured by an imaging device A and a bookbinder B. The imaging device A sequentially forms images on sheets. The bookbinder B collates sheets, which are connected to a sheet-discharge outlet14of the imaging device A and formed thereon with images, in a bundle. The sheets are then bound into a booklet. Thereafter, a bundle of sheets which are bound into a booklet is cut. The bookbinder inFIG. 1is further equipped with a finisher C at a downstream side of the bookbinder B. Detailed configuration of each device is explained later.

Imaging Device Configuration

Initially, the imaging device A can employ a variety of structures, such as a copier, printer or printing machine, but inFIG. 1, an electrostatic printing device is illustrated. The imaging device A is incorporated in the casing1with a paper-feeding section2, a printing section3, a sheet-discharge section4, and a control section. A plurality of cassettes5that correspond to sheet sizes is disposed in the paper-feeding section2; Sheets of the sizes instructed by the control section are kicked out and fed to the paper-feeding path6. A registration roller7is arranged in the paper-feeding path6to feed a sheet to the downstream printing section3at a predetermined timing after the leading edge of the sheet has been aligned.

A static-electric drum10is arranged in the printing section3. A print head9, a developer11, and a transfer charger12, etc., are disposed around this static-electric drum10. The print head9is composed of a laser emitter, for example. A latent image is formed on the static-electric drum10; the developer11adheres toner ink to the latent image; the image is printed onto the sheet by the transfer charger12. The image is fixed to the printed sheet by a fuser13, and is then conveyed out to a sheet-discharge path17. A sheet-discharge outlet14formed in the casing1and a sheet-discharge roller15are disposed in the sheet-discharge section4. Note that the symbol16in the drawing is a cycling path. Printed sheets from the sheet-discharge path17are turned over from front to back at a switchback path, then fed again to the registration roller7so that images can be formed on the backside of the printed sheet. In this way, sheets printed with images on the front side or on both sides can be conveyed out from the sheet-discharge outlet14by the sheet-discharge roller15.

Note that the symbol20in the drawings represents a scanner unit. This optically reads images on an original to be printed by print head9. The structure is widely known to be composed of a platen23where an original sheet is placed; a carriage21that travels along the platen23to scan the images on an original; and an optical reading means (such as a CCD device)22that photo-electrically converts the optical image from the carriage21. In the drawing, a document feeder25that automatically feeds original sheets to the platen is installed above the platen23.

Bookbinder Configuration

The following will now explain the bookbinder B that is attached to the imaging device A based onFIG. 2. The bookbinder B is composed of a stacking unit40that stacks and collates printed sheets in a bundle in the casing30; an adhesive application means55that applies adhesive paste to the sheet bundle conveyed from the stacking unit40; and cover binding means60that binds a coversheet to a sheet bundle that has been applied with adhesive.

Transport Path Configurations

The following will explain each sheet transport path. In the casing30, a convey-in path31having a convey-in inlet31aconnected to the sheet-discharge outlet14of the imaging device A is arranged from the convey-in path31, and a cover feed path34and an inner-leaf transport path32are linked via path switching flapper36. Also, the inner-leaf transport path32is installed consecutively to a bookbinding path (inner-leaf feed path; hereinafter, the same shall apply)33via the stacking unit40, and the cover feed path34is linked with a finishing path38. The bookbinding path33is disposed in a direction that traverses the device substantially vertically, and the cover feed path34is arranged in a direction that transects the device substantially horizontally.

The bookbinding path33and the cover feed path34intersect (perpendicular) to each other, and a process stage (cover binding position) F mentioned later is disposed in that intersection section. The convey-in path31configured as described above is connected to the sheet-discharge outlet14of the imaging device A to receive printed sheets from the imaging device A. In this case, printed sheets (inner leaves) Sn that are printed with content information and printed sheets (coversheet) Sh that are to be used as a front cover and printed with a title, etc., are conveyed out from the imaging device A. In this way, the carry-in path31is separated into the inner-leaf transport path32and the cover feed path34; these are interposed by a path switching flapper36. This selects the path to transport each printed sheet.

An inserter unit26is linked to the above-mentioned carry-in path31. This is configured to separate the coversheets Sh one by one that will not be printed at the imaging device A from a paper-feeding tray means26aand supply it to the convey-in path31. A kick roller26kand separating means26sare disposed in this paper-feeding tray means26a. Sheets on the tray are kicked out and fed by the kick roller26kafter which they are separated by the separating means26sand conveyed out one by one in the downstream side. A sheet feeding path27that continues to the carry-in path31is arranged at a downstream side of the separating means26s.

A transport roller31bis disposed along the carry-in path31whereas a transport roller32ais disposed along the inner-leaf transport path32. Gripping transport means47, bundle posture-reorienting means64that is described later, and a sheet-discharge roller (sheet-discharge means)66are disposed along the bookbinding path33. A transport roller34aand a transport roller38aare disposed along the cover feed path34and the finishing path38, respectively. They are also respectively linked to driving motors.

Carry-In Path Configuration

Along the carry-in path31, an aligning mechanism (positioning means: hereinafter, the same shall apply)35for aligning the sheets from the carry-in inlet31a, and a punch unit80are disposed.FIG. 2shows the overall configuration, andFIG. 5shows the detailed configuration. The aligning mechanism35is disposed along the convey-in path31, and the punch unit80is disposed at a downstream side of the aligning mechanism35. The sheets from the carry-in inlet31aare aligned by the aligning mechanism35, and punch holes (file-binder holes and milling grooves in the present invention) are formed into the sheets. The inner leaves Sn moved to the inner-leaf transport path32, and the coversheet Sh is moved to the cover feed path34. Note that in the present invention, the sheets perforated with the binder holes are transferred via the cover feed path34to the finishing path38. This control is described later.

The aligning mechanism35is arranged along the carry-in path31. This mechanism is configured by; a nipping claw (regulating means: hereinafter, the same shall apply)35athat locks the rear end of the coversheet Sh; an aligning member35bthat offsets the coversheet Sh held by the nipping claws35ain a transport-orthogonal direction; and a forward and reverse rotating roller (roller means)35rwhich is switched back so as to push against the coversheet Sh sent to the cover feed path34by the nipping claw35a. The forward and reverse rotating roller35ris configured such that it can elevate from the coversheet Sh to a waiting position evacuated in the upward direction.

The above-mentioned forward and reverse rotating roller35ris configured by the roller means for moving the sheets to the punch unit80disposed at a downstream side of the aligning mechanism35. Accordingly, after the rear end position of the sheet is regulated by the aligning mechanism35, positions at which the punch holes are perforated are set by a transfer amount of the roller35r. That is, the transfer amount of the forward and reverse rotating roller35rdetermines whether holes are to be perforated from the rear end of the sheet in predetermined binder-holes positions or whether crenellated notch-holes (concave grooves) are to be perforated on the rear edge of the sheets.

After the rear end of the coversheet Sh conveyed along the carry-in path31passes through the aligning mechanism35, it is switched back and then transported by the reverse rotation of the forward and reverse rotating roller35r. When this happens, the rear end of the sheet is pushed against the nipping claw35a, and it undergoes skew (oblique) correction. In this state, the nipping claw35aholds the rear end of the sheet and the aligning member35bon which the nipping claw35ais mounted is pulled over in the transport-orthogonal direction. The coversheet Sh undergoes skew correction in the back-and-forth transport directions, and the position in the width direction (transport-orthogonal direction) is to be corrected (lateral-edge position is corrected). Thus, the coversheet Sh that has undergone the aligning correction is set to be transported by the forward and reverse rotating roller35rto a process stage F at a downstream side. The setting and feeding to the process stage F is done by transporting a predetermined amount of coversheets Sh from the aligning position. Moreover, in a case of the coversheet Sh, holes are not perforated by the punch unit80at a downstream side of the aligning mechanism35.

Punch Unit Configuration (Cf.FIGS. 4 and 5)

The configuration of the punch unit80is described based onFIGS. 5A and 5B. The punch unit80is configured by: a lower frame83on which the sheets are mounted, an upper frame84which has a small gap with the lower frame83, a punch member81that is disposed on the upper frame84, and the driving cam85that moves the punch member81up and down.

A punch driving motor MP and a driving axis86that is linked to the punch driving motor MP are disposed on the upper frame84, as shown inFIG. 5A. The punch member81is fitted and supported to the upper frame84such that it can freely slide up and down. The punch member81is appropriately disposed on a plurality of locations. As shown inFIG. 5A, first to fourth punch members81a,81b,81c, and81dare disposed at predetermined intervals on four locations.

The punch member81is formed of SUS steel, etc., and a perforating cutter81X is formed at the front end. A guard flange87is provided on the axis of the punch member81, and a reversion spring88is disposed on the guard flange87. As shown inFIG. 5B, the driving cam85is attached to the above-mentioned driving axis86. A first driving cam85ais disposed in the position opposite the first punch member81a, and a second driving cam85bis disposed in the position opposite the second punch member81b. Likewise, a third driving cam85cand a forth driving cam85dare disposed.FIG. 5Balso illustrates positional relationships of the punch members81ato81dcorresponding to the driving cams85ato85dcomposed of an eccentric cam axially supported by the driving axis86.

A first cam face85X is formed in one location in the first and fourth driving cams85aand85d, respectively. The first cam face85X and a second cam face85Y are each formed in two locations in the second and third driving cams85band85c, respectively. For each of the driving cams85ato85d, the first cam face85X is substantially simultaneously engaged with heads of the first to fourth punch members81ato81d, in the driving axis86. Accurately speaking, these perforating positions are engaged after waiting for a very small time difference (phase difference) in the order of the first punch member81a, the second punch member81b, the third punch member81c, and the fourth punch member81d. This is for lessening the perforation load exerted on the punch driving motor MP.

If the driving axis86is rotated clockwise at a predetermined angle (e.g., 90 degrees) from a home position as shown inFIG. 5B, the first, second, third, and fourth punch members81ato81dmove in the perforating direction to perforate four holes in the sheet. On the other hand, if the driving axis86is rotated counterclockwise at a predetermined angle (e.g. 90 degrees), and when it is rotated at a predetermined angle (e.g. 90 degrees) at the position of the first cam face85X, the second and third punch members81band81cperforate two holes in the sheet. After the perforation, each punch member81ato81dreturns to its original position by the reversion spring88. Although not shown, an encoder and an encode sensor are disposed in the punch driving motor MP, and a position sensor is disposed at the home position of the driving axis86. Accordingly, the two perforations or the four perforations are selected by angular control of the driving cam85, based on rotation control of the punch driving motor MP, and as a result, punch holes are perforated at predetermined positions on the sheet by each punch member81ato81d. Note that the symbol82in the drawings denotes a waste box.

Stacking Unit Configuration

A stacking tray41disposed in the sheet-discharge outlet32bof the above-mentioned inner-leaf transport path32stacks and stores the sheets from the sheet-discharge outlet32bin a bundle. As shown inFIG. 2, the stacking tray41is configured by a tray member disposed at a substantially horizontal posture, and a forward and reverse rotating roller42aand a carry-in guide42bare provided above. The printed sheets from the sheet-discharge outlet32bare guided onto the stacking tray41by the carry-in guide42b, and stored by the forward and reverse rotating roller42a. By a forward rotation, the forward and reverse rotating roller42amoves the printed sheets to the front end side of the stacking tray41, and by a reverse rotation, it regulates them by pushing the rear end of the sheet against a regulating member43disposed at the rear end of the tray (the right edge ofFIG. 2). Sheet-side aligning means not shown is arranged in the stacking tray41, and the edges on the both sides of the printed sheets stored on the tray are pulled over and aligned to a reference position. With such a configuration, the printed sheets from the inner-leaf transport path32are piled on top of one another on the stacking tray41, and then, collated in a bundle.

Sheet-bundle-thickness identifying means not shown is disposed in the above-mentioned stacking tray41so that the thickness of the sheet bundle stacked on the tray is detected. In this configuration, for example, a paper contact segment that contacts the topmost sheet is arranged on the tray so that a position of the paper contact segment is detected by a sensor, thereby identifying the thickness of the sheet bundle. Another example of the sheet-bundle-thickness identifying means includes that in which the sheets discharged onto the stacking tray are detected from a sheet-discharge sensor Se3, for example, a counter for counting the signals from the sheet-discharge sensor Se3is arranged, and the average sheet thickness is multiplied by the total number of sheets counted by a job ending signal from the imaging device A.

Sheet-Bundle Transport Means Configuration

Along the bookbinding path33, gripping transport means47for moving the sheets from the stacking tray41to an adhesive-layer forming position E at the downstream side is disposed. The gripping transport means47reorients the sheet bundle stacked in the stacking tray41as shown inFIG. 2from a horizontal posture to a vertical posture, and sets to transport the sheet bundle to the adhesive-layer forming position E along the bookbinding path33disposed substantially vertically. Due to this, the stacking tray41is moved from a stacking position (solid lines inFIG. 2) to a hand-over position (dotted lines inFIG. 2), and hands over the sheet bundle to the gripping transport means47that is prepared at this hand-over position.

Adhesive Application Section Configuration

Adhesive application means (adhesive-layer forming means; hereinafter, the same shall apply)55is disposed in the adhesive-layer forming position along the bookbinding path33. As shown inFIG. 3A, the adhesive application means55is configured by a glue container56containing hot-melt adhesive, an applying roll57, and a roll rotating motor MR. The glue container56is sectioned into a liquid-adhesive containing chamber (hereinafter, referred to as liquid-agent containing chamber)56aand a solid-adhesive containing chamber (hereinafter, referred to as a solid-agent containing chamber)56b. The applying roll57is incorporated in the liquid-agent containing chamber56asuch that it can rotate freely. A glue sensor56S (seeFIG. 2) that detects a residual amount of the adhesive is disposed in the liquid-agent containing chamber56a. The illustrated glue sensor56S serves also as a temperature sensor for adhesive, and detects the temperature of the adhesive that has liquefied within the liquid-agent containing chamber56a, and at the same time, detects the residual amount of adhesive by a temperature difference of a region immersed with adhesive. Heating means50such as an electric heater is buried in the glue container56. This glue sensor56S and the heating means50are wired-connected to a control CPU75described later, and they adjust the temperature of the adhesive within the liquid-agent containing chamber56ato a predetermined melting temperature. The applying roll57is composed of a heat-resistant porous material so that when it is impregnated with glue, a glue layer is heaped up around the roll.

The glue container56thus configured is reciprocated along the sheet bundle.FIG. 3Billustrates a conceptual diagram thereof. The glue container56is so formed that the length (dimension) is shorter than the lower edge (spine cover at the time of bookbinding) Sd of the sheet bundle. The glue container56is supported by a guide rail52of the device frame such that it can move, together with the applying roll57incorporated therein, along the lower edge Sd of the sheet bundle. This glue container56is linked to a timing belt53attached to the device frame. The driving motor MS is linked to this timing belt53.

The glue container56is reciprocated between the home position HP and the return position RP (from which the return operation is started along the sheet bundle) by means of the driving motor MS. Each position is set according to the positional relationship shown inFIG. 3B, and the return position RP is set by size information about a sheet width. When the power supply of the device is inputted (at an initial time), the glue container56is set to the home position HP. For example, the glue container56moves from the home position HP toward the return position RP after a predetermined time (estimated time at which the sheet bundle reaches the adhesive-layer forming position E) elapses from a sheet grip signal of the grip sensor Sg that is arranged in the gripping transport means47arranged before. Along with this movement, the applying roll57starts rotating by the roll rotation motor MR. Note that Sp inFIG. 3Bdenotes a home position sensor of the glue container56. The adhesive application means55thus configured glue starts moving the glue container56along the guide rail52, from the left side to the right side ofFIG. 3B, by the rotation of the driving motor MS. The transport amount of the gripping transport means47is so adjusted by an elevator motor not shown that on the forward path, the applying roll57is pressed against the sheet bundle so that the sheet ends are unbound while on the return path to return from the return position RP to the home position HP, a predetermined gap is formed with the sheet ends so that the adhesive can be applied therebetween.

Cover Binding Means Configuration

The cover binding means60is disposed in a process stage F of the above-mentioned bookbinding path33. As shown inFIG. 2, the cover binding means60is configured by a back support plate61, a spine folding plate62, and a folding roll63. The cover feed path34is disposed in the process stage F so that the coversheet Sh is fed from the imaging device A or the inserter unit26. The back support plate61is composed of a plate like member that backs up the coversheet Sh, and is disposed to retract freely along the bookbinding path33. An inner leaf bundle Sn is joined in an inverted T-letter shape to the coversheet Sh supported by the back support plate61. The spine folding plate62is configured by a pair of right and left press members. The pair is so configured to keep closely to and apart from each other by driving means not shown in order to fold the spine of the coversheet joined in an inverted T-letter shape. The folding roll63is configured by a pair of rollers for compressing the sheet bundle of which the spine is folded to finish the folding.

Bundle Posture-Reorienting Means Configuration

Subsequently, the finishing process of the sheet bundle bound into a booklet (as mentioned above) will now be explained. This finishing process involves trimming 3 sides for alignment excluding the spine of the sheet bundle that has been made into a booklet. Due to this, the bundle posture-reorienting means64that reorients the vertical direction of the sheet bundle and trimming means65that trims the edges of the sheet bundle are disposed in a trimming position G positioned at a downstream side of the folding roll63. The bundle posture-reorienting means64reorients the sheet bundle of which the cover is provided from a cover binding position F in a predetermined direction (posture) and feeds it to the trimming means65or a storage stacker67at a downstream side. This trimming means65trims and aligns the edges of the sheet bundle. Due to this, the bundle posture-reorienting means64is equipped with rotation tables64aand64bfor holding and rotating the sheet bundle forwarded from the folding roll63. As shown inFIG. 2, these rotation tables64aand64bare arranged in a unit frame64xthat is attached to the device frame in a freely elevated manner. A pair of rotation tables64aand64bare each axially supported to rotate freely across the bookbinding path33in the unit frame64x. One movable rotation table64bis supported to move freely in a sheet bundle-thickness direction (in a direction orthogonal to the bookbinding path33). A swing motor not shown is arranged in the bookbinding path33in each of the rotation tables64aand64bso as to reorient the posture of the sheet bundle.

Trimming Means Configuration

Trimming means65is disposed at a downstream side of the bundle posture-reorienting means64. As shown inFIG. 1, this trimming means65is configured by a trimming edge press member65bthat pressingly supports the trimmed edges of the sheet bundle to a blade bearing member65a, and a trimming blade unit65c. The trimming edge press member65bis disposed in a position opposite the blade bearing member65adisposed along the bookbinding path33, and is composed of a pressurizing member that moves in a direction orthogonal to the sheet bundle by means of driving means not shown. The trimming blade unit65cis configured by a chopping blade (with a flat blade)65xand a cutter motor MC that drives it. Thus, by using the thus-configured trimming means65, the edges (excluding the spine) of the sheet bundle that has been made into a book are cut and aligned in a predetermined amount.

The sheet-discharge roller (sheet-discharge means)66and the storage stacker67are disposed at a downstream side of the trimming position G. This storage stacker67stores the sheet bundle in an upright posture, as shown inFIG. 1. As shown inFIG. 1, the storage stacker67is disposed in the casing30in a drawer-like fashion, can be pulled out to the front side of the device (front side ofFIG. 1), and can be viewed from top by a user when it is pulled out to the front side of the device.

Finisher Configuration

The finisher C is disposed in the bookbinder B, and the finishing path38that continues to the cover feed path34is provided in this finisher C. Finishers such as a staple unit and a stamp unit are disposed in the finishing path38. Printed sheets from the imaging device A are received via the cover feed path34, and they are conveyed out to the paper-discharge tray37after staples, and stamps and seals are applied to the printed sheets. It is also possible to not apply any finishing process on printed sheets and to store them in the sheet-discharge tray37directly from the imaging device A.

Control Means Configuration

Next, based onFIG. 9, the configuration of the control means in the above-mentioned device will now be explained.FIG. 9is a control block diagram. As shown inFIG. 1, in the system that links the imaging device A and the bookbinder B, the control panel71and mode setting means72are arranged to the control CPU70provided on the imaging device A. A control CPU75is equipped in the control section of the bookbinder B. This control CPU75calls up a bookbinding execution program from the ROM76and executes each process in the bookbinding path33.

This control CPU75receives a finishing mode instruction signal, a job end signal, sheet size information, and other information and command signals required in the bookbinding process from the control CPU70of the imaging device A. Sheet sensors Se1to Se6for detecting the sheets (sheet bundle) to be transported are disposed in the carry-in path31, the bookbinding path33, and the cover feed path34, respectively, at the positions illustrated inFIG. 2. Detection signals of the sheet sensors Se1to Se6are transmitted to the control CPU75. The control CPU75is furnished with “perforation control means78”, a “stacking unit control section75a”, an “adhesive-application-means control section75b”, a “cover-binding-means control section75c”, a “trimming means control section75d”, and a “stacker control section75e”. Perforation-operation-execution-controlling-data storing means (RAM)78ais provided in the perforation control means78.

In the aforementioned device configuration and the control configuration of the present invention, holes are punched in the sheets conveyed from the imaging device A to the carry-in path31in a subsequent first operation mode and second operation mode.

Perforation Control Means Configuration (Cf.FIG. 9)

The aforementioned punch unit80is controlled in the following first operation mode and second operation mode.

First Operation Mode

This operation mode is used for perforating the punch holes for a binder in the sheets from the carry-in path31. The punch holes for a binder are perforated in the rear end of the sheets on which images are formed. For this, when a “binder-holes perforating mode” is selected by the mode setting means72, the perforation control means78controls the forward and reverse rotating roller35rso that the rear end of the sheets conveyed to the carry-in path31is positioned at the rear end position by the aligning mechanism35. These sheets are moved from a positioning position Pa to a punch position Pb (shown inFIG. 4) by a predetermined length (L1). In this movement control, the number of power source pulses supplied to the driving motor (PWM control) that rotates the forward and reverse rotating roller35ris controlled so as to set a transport length L1. The transport length L1in the first operation mode is set in advance and stored in a RAM78a. The perforation control means78rotates counterclockwise the driving cam85that elevates the punch member81in a case of the two perforations (FIG. 5B) while rotates it clockwise in a case of the four perforations. This is to be done by rotation control of the punch driving motor Mp that is linked to the rotation axis85.

The transport length L1is set in advance according to the binder file standard, etc. AsFIG. 6illustrates the positional relationship of the punch holes (C1: 4 holes) and (C2: 2 holes), a hole position d1from the edge of the sheet is set according to the standard and stored in the RAM78a. After perforating binder holes H1(2 holes or 4 holes) in the sheets conveyed to the carry-in path31, the control CPU75feeds these sheets to the cover-transport path34by the flapper36. These sheets are then transported via this path to the finishing path38of the finisher C disposed at the downstream side. In this finisher C, the sheets on which binder holes have been perforated are collated in a bundle, bound together by staples, and then stored in the paper-discharge tray37.

Second Operation Mode

This operation mode is used for forming crenellated notch-holes (roughening grooves: hereinafter referred to as a milling process) on the edge of the sheets from the carry-in path31. For this, when a “bookbinding processing mode” is selected by the mode setting means72, the perforation control means78controls the forward and reverse rotating roller35rso that the rear end position of the sheets conveyed to the carry-in path31is positioned by the aligning mechanism35. These sheets are moved from the positioning position Pa to the punch position Pb by a predetermined length (L2or L3). In this movement control, the number of power source pulses supplied to the driving motor (PWM control) that rotates the forward and reverse rotating roller35ris controlled so as to set a transport length L1. The transport length L2or L3in the first operation mode is set in advance and stored in the RAM78a. The perforation control means78rotates the driving cam85that elevates the punch member81in a counterclockwise direction (FIG. 5B). This is to be done by rotation control of the punch driving motor Mp that is linked to the rotation axis85. On performing this operation, four holes are perforated in the sheet.

The aforementioned transport length L2or L3, a distance d2and a distance d3shown inFIG. 6Dare stored in a RAM86ain advance. In either case, the transport length L2(or L3) is so set that crenellated notch-holes H2are formed on the edge of the sheets. A method for perforating the notch holes H2is described later.

As described above, after the notch holes (milling holes) H2are perforated in the sheets conveyed to the carry-in path31, the control CPU75feeds these sheets to the inner-leaf transport path34by the flapper36. After that, along this path, the adhesive is applied to the spine-closure edge on which the notch holes (milling holes) have been formed. The procedure for applying the adhesive is as described above. After the adhesive is applied, the control CPU75binds together the sheet bundle and the coversheet, and stores it in the stacker67.

Thus, the present invention is characterized in that: in the “binder-hole perforating” mode, two or four punch holes are formed by the punch unit80in the hole positions according to the standard on the image-formed sheets conveyed to the carry-in path31, and the sheets are then stored in the paper-discharge tray37that is disposed at a downstream side of the carry-in path31; and at the same time, in the “bookbinding process” mode, crenellated notch-holes (milling holes) are formed on the edge of the sheets, and the sheets are then conveyed out to the inner-leaf transport path32that is positioned at a downstream side.

Now, a mode for forming the crenellated notch-holes H2(hereinafter referred to as a “milling process”) will be described below.

First Milling Process Method

This is a method for forming perforating distances (d2and d3) for the crenellated notch-holes H2in previously set fixed positions. The transport length L2is set to a constant value, and stored in the RAM86ain advance. Thereby, uneven grooves having a predetermined number of holes (four holes inFIG. 6) are formed on all the sheets transported to the inner-leaf transport path32. These sheets are collated and stacked in the stacking tray41, and the adhesive is applied to the spine-closure edge of the sheets perforated with the notch holes H2at a glue applying position E. At this time, the adhesive strength increases because the uneven grooves are formed on the sheet bundle.

Second Milling Process Method

Size of holes in the crenellated notch-holes H2is adjusted based on sheet information such as the material quality of sheet paper, paper size, basis weight of the sheets, and the number of sheets to be collated. In this case, the perforation control means68is so configured to set the transport lengths L1and L2depending on the following information: (1) size information of the sheet transferred from the imaging device A; (2) information regarding the material quality of sheet paper, (3) basis weight of the sheet, and (4) the number of sheets to be collated (thickness of the bundle), entered by the user, for example. At this time, when the sheet size is large, the hole position d is set larger as compared to a case that the sheet size is small. Due to this, the depth of the uneven grooves increases, which further increases the adhesive strength. When the sheet material quality makes the adhesion difficult, e.g., in a case of a coating sheet, the hole position d is set larger as compared to standard paper that relatively facilitates the adhesion. Also, when the basis weight of the sheet (the thickness of the sheet) is large, the hole position d is set larger as compared to a smaller basis weight. When the number of sheets to be collated is large, the hole position d is set larger as compared to a smaller number. Due to this, the depth of the uneven grooves increases, which further increases the adhesive strength.

Third Milling Process Method

The number of the crenellated notch-holes H2is adjusted (whether to increase or decrease the number) based on the sheet information such as the material quality of the sheet, paper size, the basis weight of the sheet, and the number of sheets to be collated. Similar to the second milling method, the number of notch holes is adjusted so that two or four holes are formed. Its control method is similar to that described above. The number of holes is set large in the following cases: the sheet size is large, the sheet material quality makes the adhesion difficult, the sheet basis weight is large, the number of sheets to be collated is large. In doing so, the number of holes of uneven grooves increases, which increases the adhesive strength.

Fourth Milling Process Method

Positions and/or the number of the crenellated notch-holes H2are so set that they are differ for each collated and stacked sheets. For example, the hole positions (or the number of holes) on the first sheet are set differently from the hole positions (or the number of holes) on the second sheet. As a result, the sheets in which the positions of holes or the number of holes are differed are piled on top of one another along the spine-closure surface of the sheet bundle, and the adhesive is applied. Likewise, holes are not perforated on the first sheet but they are perforated on the second sheet. Thus, as shown inFIG. 6D, sheets on which the milling process has been applied as well as sheets on which the milling process has not been applied are piled on top of one another on the spine-closure surface of the sheet bundle, and in this, state, the adhesive is applied to the piled sheets. Note that in this case, the collated and stacked sheets do not need to be differed alternately in the positions of holes, the number of holes, whether perforated or not perforated, but may be differed for each few sheets, for example.

Explanation of Punch Perforating Operation Procedure

Control of the perforation control means (control CPU75) will now be explained based on a flowchart shown inFIG. 10.FIG. 10Ashows the first operation mode andFIG. 10Bshows the second operation mode. In the imaging device A, along with setting the imaging conditions, a punch processing mode (first operation mode) in which the binder holes are formed and a milling processing mode (second operation mode) in which the bookbinding process is performed are selectively set.

When the first operation mode is set, sheets on which images are formed by the imaging device A (St01) are conveyed out to the carry-in path31. The perforation control means78positions the rear end of the sheets by the aligning mechanism35(St03). In this positioning, the forward and reverse rotating roller35ris rotated in a direction opposite to the transport direction so as to push the sheets against the regulating means (nipping claws)35a, whereby the sheets are aligned. After the rear end position is aligned, the perforation control means78rotates the forward and reverse rotating roller35rin the transport direction for a predetermined amount, and moves the rear end of the sheet from the regulated position Pa to the perforated position Pb. In this way, the rear end of the sheet is set and positioned to the perforated position Pb (St04). Next, the perforation control means78rotates and drives the punch driving motor Mp of the punch unit to perforate the binder holes. In the 2-hole perforation mode, the driving axis86shown inFIG. 5is rotated counterclockwise, and in the 4-hole perforation mode, the driving axis86is rotated clockwise (St05).

Next, the control CPU75activates the path switching flapper36(St06) to move the sheets to the cover-transport path34(St07). The finishing path38and the paper-discharge tray37of the finisher C are disposed at a downstream side of the cover-transport path34. The control CPU75feeds the sheets from the cover-transport path34to the finishing path38(St08). After that, in the finishing path38, the finish process is applied such as seals or stamps are applied, the sheets are bound by staple, etc. (St09). Thereafter, the sheets are stored in the paper-discharge tray37.

On the other hand, when the second operation mode is set, the sheets on which images are formed (St01) by the imaging device A are conveyed out to the carry-in path31, as shown inFIG. 10B. The perforation control means78positions the rear end of the sheets by the aligning mechanism35(St03). In this positioning, the forward and reverse rotating roller35ris rotated in a direction opposite to the transport direction so as to push the sheets against the regulating means (nipping claws)35a, whereby the sheets are aligned. After the rear end position is aligned, the perforation control means78rotates the forward and reverse rotating roller35rin the transport direction for a predetermined amount, and moves the rear end of the sheets from the regulated position Pa to the perforated position Pb. In this way, the rear end of the sheets is set and positioned to the perforated position Pb (St04). Setting of the sheet to the punching position at this time is executed according to the milling methods (first or fourth methods) described above. Next, the perforation control means78rotates and drives the punch driving motor Mp of the punch unit to perforate the milling holes. At this time, the driving axis86shown inFIG. 5is rotated clockwise to provide the 4-hole perforation (St05).

Next, the control CPU75determines whether the sheets conveyed to the carry-in path31are the inner leaves or the coversheet (St11). When the sheets are inner leaves, the path switching flapper36is actuated (St12) to move the sheets to the inner-leaf transport path32(St13). The sheets are then collated in a bundle in the stacking tray41(St14), and transported in a bundle to the adhesive applying position E. Thereafter, as shown inFIG. 7A, the adhesive is applied to the sheet bundle (St15). On the other hand, when it is determined that the sheet is the coversheet at the step11, the path switching flapper36is actuated to transport the sheets to the cover feed path34, and set to the cover binding position. As shown inFIG. 7BandFIG. 8A, the book is made (St017) by wrapping the inner leaves (to which the adhesive has been applied) with the coversheet at the cover binding position F so that a book is made. After that, the control CPU75moves the sheet bundle in which the cover is bound to the trimming position at a downstream side of the cover binding position, and three directions of the sheet bundle are trimmed by a trimming blade (St18). The sheet bundle in a booklet that undergoes the bookbinding process (shown inFIG. 8B) is stored in the stacker37(St19).

In the present invention, it has been depicted that in the punch unit80, the four punch members81are disposed for perforating four holes. However, the punch members may also be disposed for perforating four holes or more. As shown inFIG. 11, when the punch member81and the sheet are moved relative to a sheet-width direction, a large number of notch holes can be perforated by using a lesser number of punch members.

The device inFIG. 11will now be described. The configuration of the punch unit is the same as that in the device inFIG. 5, and thus, like reference numerals are allotted to like parts to omit the duplicated description. In the punch unit80shown inFIG. 11, a pair of transport rollers89that move the sheet in the width direction are disposed in the left and right, and driving motors not shown are linked to these rollers. The perforation control means78perforates 4-hole uneven holes, for example, on one end side in the width direction of the sheet, and then rotate the roller89by a predetermined amount to shift the sheet in the width direction. After this sheet is shifted in the width direction, the punch driving motor Mp is again rotated and driven to perforate the other end side of the sheet. As a result, a plurality of crenellated notch-holes H2is formed as shown inFIG. 11B.

In the present invention, the perforating means for perforating the binder holes or the notch holes in the sheet is described. In this case, indicated generally in the right portion ofFIG. 12, the perforation is done one sheet by one sheet that has been conveyed to the sheet carry-in path. Alternatively, a perforating means, according to the present invention, for perforating binder holes or notch holes may also be utilized, as indicated generally in the left portion ofFIG. 12, on sheet bundles into which sheets have been collated in a bundle. For a device configuration (perforating means) for perforating the sheet bundle, that which is disclosed in Japanese Unexamined Pat. App. Pub. No. 2002-326196 is known, for example.

This application claims priority rights from Japanese Pat. App. No. 2007-314808, which is herein incorporated by reference.