Document reader and image forming apparatus

A document size sensor is disposed on a document feed path at a location between a document tray and a juncture and on the front side in the primary scanning direction perpendicular to a document feed direction. The document size sensor is located between a sheet edge position for B4-size document sheet and a sheet edge position for A 4 -size document sheet, which are situated on the front side in the primary scanning direction. The document size sensor detects A3 - and B 4 -size document sheets but does not detect A 4 - or B5-size document sheet. Based on a detection signal from the document size sensor, judgment is made as to whether a document sheet fed from the document tray is a larger-sized document sheet or a smaller-sized document sheet.

CROSS REFERENCE

This Nonprovisional application claims priority under 35 U.S.C. § 119(a) on Patent Application No. 2004-303578 filed in Japan on Oct. 18, 2004, the entire contents of which are hereby incorporated by reference.

BACKGROUND OF THE INVENTION

The present invention relates to a document reader configured to feed plural document sheets placed on a document tray to a document read position one by one and read image information from each of the document sheets. The present invention also relates to an image forming apparatus configured to form an image on a recording medium based on image information read from a document sheet by the document reader.

Recent years have seen a progressing development of document readers of the type adapted to read image information from document sheets at a predetermined image read position during feeding of the document sheets one by one, as disclosed in Japanese Laid-open Patent Application No. H07-095364.

Such a document reader defines therein a document feed path extending from the document tray, through the image read position, to the delivery tray. The document tray is capable of receiving plural document sheets as stacked thereon. The delivery tray receives the document sheets as stacked thereon after the reading of image information therefrom.

The light-receiving surface of an image reading device faces the image read position on the document feed path either directly or via a deflecting mirror. Each document sheet under feeding on the document feed path travels in the secondary scanning direction with respect to the light-receiving surface of the image reading device. While the length of the document sheet from the leading edge thereof to the trailing edge thereof in the document feed direction passes through the image read position, the image reading device reads image information from the entire image bearing side of the document sheet.

However, a conventional document reader cannot read image information continuously from a series of differently sized document sheets including, as mixed, an A3-size document sheet and a B5-size document sheet for example, though can read image information continuously from a series of single-sized document sheets placed on the document tray.

The conventional document reader has a document sensor disposed on the document feed path at a location intermediate the document tray and the image read position for detecting the presence and absence of a document sheet so that an occurrence of a document feed failure is detected based on a detection signal from the document sensor. The document reader stops operating upon an occurrence of a change in duration of detection by the document sensor, which is regarded as an occurrence of a document feed failure. For this reason, when a change in document sheet size occurs during successive feeding of plural document sheets, a change in duration of detection by the document sensor occurs, which causes the document reader to stop operating. Thus, it becomes impossible to feed document sheets.

There exists no conventional document reader configured to determine the length of a document sheet in the primary scanning direction during feeding of the document sheet, though there exists a document reader of the type configured to determine the length of a document sheet placed on the document tray in the document feed direction (the direction perpendicular to the primary scanning direction).

Accordingly, even if plural document sheets of different sizes are fed successively by the neglect of the detection signal from the document sensor, image information reading from the same range as the dimension of a maximum-size document sheet is performed with respect to a document sheet of a smaller size in the primary scanning direction. This means that unnecessary image information from outside the image region of the smaller-sized document sheet is also read and processed. As a result, such a conventional document reader has the problem that the demand for higher-speed image reading cannot be satisfied.

Also, an image forming apparatus for forming an image on a recording medium with use of image information read by such a document reader performs image formation based on such unnecessary image information. Further, the image forming apparatus forms an image on a recording medium of an unnecessarily large size relative to the image information. Thus, the image forming apparatus has the problem that the demand for higher-speed image formation and resources saving cannot be satisfied.

A feature of the present invention is to provide a document reader capable of determining the length of a document sheet in the primary scanning direction immediately after start feeding of the document sheet to avoid reading of unnecessary image information from outside the image region of a smaller-sized document sheet, thereby continuously reading image information from a series of differently sized document sheets including mixed document sheets of different sizes. Another feature of the present invention is to provide an image forming apparatus capable of image formation based on image information continuously read from a series of such differently sized document sheets without waste.

SUMMARY OF THE INVENTION

A document reader according to the present invention includes a document tray, a document feed path, an image reading device, at least one sensor, and a judgment section. The document tray is provided for document sheets of different sizes to be placed thereon. The document feed path feeds the document sheets one by one from the document tray. The image reading device is configured to read image information from each of the document sheets under feeding at an image read position on the document feed path. The sensor is configured to detect the presence or absence of a document sheet at a location on the document feed path between the document tray and the image read device, and between first and second positions on which respective edges of different-sized first and second document sheets to be placed on the document tray pass. The first and second positions are situated on at least one side of the document feed path in a direction perpendicular to a sheet feed direction. The judgment section is configured to judge which of the first and second document sheets is under feeding based on a result of detection by the sensor.

The foregoing and other features and attendant advantages of the present invention will become more apparent from the reading of the following detailed description of the invention in conjunction with the accompanying drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Hereinafter, preferred embodiments of document reader and image forming apparatus according to the present invention will be described in detail with reference to the accompanying drawings.

FIG. 1is a view showing the construction of image forming apparatus100according to an embodiment of the present invention. The image forming apparatus100includes an image read section110comprising an image reader1according to the present invention, an image forming section210, and a sheet feed section250and is provided with a post-processing device260and a multi-tier sheet feeder unit270.

Image data read from a document by the image read section110is transferred to the image forming section210. The image data thus transferred is subjected to predetermined image processing in an image processing section of the image forming section210and then temporarily stored in memory incorporated in the image processing section. In response to an instruction to output the stored image data, the image data is read out of the memory.

The image forming section210includes a rotatably supported photoreceptor drum222, and, around the photoreceptor drum222, an electrostatic charger223, a laser write unit227, a developing device224, a transfer device225, a peeler229, and a cleaner226.

The electrostatic charger223is configured to charge the surface of the photoreceptor drum222to a predetermined potential. The laser write unit227is configured to form an electrostatic latent image on the surface of the photoreceptor drum222by irradiating the surface of the photoreceptor drum222with laser light modulated according to image data. The developing device224is configured to supply toner onto the electrostatic latent image formed on the photoreceptor drum222to develop the latent image into a visible toner image. The transfer device225is configured to transfer the toner image formed on the surface of the photoreceptor drum222to a recording sheet. The peeler229is configured to release the recording sheet from the surface of the photoreceptor drum222. The cleaner226is configured to collect excess toner.

Instead of the laser write unit227, use may be made of an optical write head of the solid state scanning type employing a light-emitting device array comprising LEDs, ELs or the like.

Below the image forming section210is located the sheet feed section250which comprises a recording sheet tray251, a manual feed tray254and a reversing unit255. The multi-tier sheet feed unit270includes sheet feed trays252and253. The sheet feed section250defines a sheet feed path for transporting a recording sheet fed from any one of the trays251to254to an ejected-sheet tray219via a transfer position between the photoreceptor drum222and the transfer device225in the image forming section210.

The reversing unit255communicates with a switchback path221for turning a recording sheet front side back for formation of an image on the reverse side of the sheet. The reversing unit255is replaceable with a normal sheet tray. The image forming apparatus100can be fitted with a large-capacity sheet feed unit capable of holding several thousands of recording sheets.

On the ejection side of the image forming section210are provided a fixing unit217, the switchback path221, and the post-processing device260. The fixing unit217is configured to fix a toner image to a recording sheet by heating and pressurizing the recording sheet bearing the toner image transferred thereto. The switchback path221is configured to turn a recording sheet front side back for the formation of an image on the reverse side of the sheet. The post-processing device260is provided with an up-and-down tray261and performs stapling or other processing on recording sheets bearing respective images formed thereon. Each recording sheet bearing a toner image fixed thereto by the fixing unit217is guided to the post-processing device260by an ejection roller219optionally through the switchback path221, subjected to predetermined post-processing, and then ejected to the up-and-down tray261.

The image read section110includes a CCD (Charge Coupled Device) read unit11and is configured to perform image reading by using a light source unit13and a mirror unit14to focus an image of a document sheet placed flat on a first platen12onto the CCD read unit11. The CCD read unit11includes an imaging lens11A and a CCD image sensor corresponding to the image reading device defined by the present invention.

The light source unit13includes a light source for emitting document-illuminating light, a reflector for gathering document-illuminating light emitted from the light source at a predetermined image read position on the first platen12, a slit allowing only reflected light from the document sheet to pass therethrough, and a mirror for deflecting the optical path of the reflected light having passed through the slit by 90°. The mirror unit14includes a pair of mirrors for deflecting the optical path of light from the light source unit13by 180°.

In a stationary document read mode, the light source unit13and the mirror unit14reciprocate below the first platen12in the secondary scanning direction at a predetermined velocity of V and a velocity of V/2, respectively, thereby guiding reflected light from the entire image bearing surface of the document sheet on the first platen12to the CCD read unit11with the optical path length kept constant.

The CCD read unit11may be structured to reciprocate a unit of an optical read system for reduced-size reading or actual-size reading comprising a CCD image sensor, an imaging lens and a light source below the first platen12at a velocity of V in the stationary document read mode.

The image read section110further includes a second platen16spaced a predetermined distance apart from the first platen12in the secondary scanning direction. In a feed-and-read mode in which the document reader1is used, the light source unit13is held stationary at image read position P1opposed to the second platen16.

FIG. 2is a view showing the construction of document reader1according to an embodiment of the present invention.FIG. 3is a view showing an outward appearance of the document reader1with its cover open. The document reader1is positioned above the image read section110so as to be capable of covering and exposing the top surfaces of the first and second platens12and16.

The document reader1includes a document tray2, a delivery tray3, and a switchback tray8. The document tray2holds plural document sheets as stacked thereon. The delivery tray3receives, as stacked thereon, document sheets having been subjected to image information reading. The switchback tray8temporarily receives a document sheet having been subjected to image information reading from one side thereof in a double side read mode.

A document feed path H1is defined to extend from the document tray2to the delivery tray3through the image read position P1. The document feed path H1is provided with a pickup roller4, a feed roller5A, a separating roller5B, and transport rollers R1to R5. Also, a secondary feed path H2is defined to connect the switchback tray8to a juncture P2located intermediate the document tray2and the image read position P1on the document feed path H1. The secondary feed path H2is provided with a delivery roller R6and a transport roller R7.

A cover member9supports the pickup roller4, feed roller5A and separating roller5B. The cover member9is hinged on the left-hand side inFIG. 2for pivotal movement to expose and cover an upper portion of the document feed path H1.

In a one-side document read mode for reading image information from only one side of each document sheet, a document sheet is paid out by rotation of the pickup roller4abutting against the topmost surface of a stack of document sheets placed on the document tray2and then guided into the document feed path H1by rotation of the feed roller5A. At that time, the separating roller5B rotating in the same direction as the feed roller5A pushes back document sheets other than the topmost document sheet onto the document tray2, so that only the topmost document sheet is fed into the document feed path H1.

The document sheet fed from the document tray2is transported on the document feed path H1toward the image read position P1with predetermined timing by the transport rollers R1and R2rotating. As the document sheet passes through the image read position P1, image information is read by the CCD read unit11of the image read section110including the light source unit31held stationary below the image read position P1. The document sheet having been subjected to image information reading is delivered onto the delivery tray3by the transport rollers R4and R5rotating.

In a double-side document read mode for reading image information from the both sides of each document sheet, a single document sheet fed into the document feed path H1is subjected to image information reading from one side thereof as in the one-side document read mode, guided into the secondary feed path H2by the transport roller R4, and then transported onto the switchback tray8by rotation of the delivery roller R6. The delivery roller R6rotates backwardly with the trailing edge of the document sheet nipped thereby. Then, the document sheet is turned front side back and transported on the secondary feed path H2toward the juncture P2by the delivery roller R6and transport roller R7rotating.

The document sheet transported on the secondary feed path H2to the juncture P2is then transported on the document feed path H1toward the image read position P1again. At the image read position P1, the reverse side of the document sheet, which is opposite from the side from which the image information has already been read, faces the light source unit13held stationary below the image read position P1so as to be subjected to image information reading. The document sheet having been subjected to image information reading from its both sides is delivered onto the delivery tray3by the transport rollers R4and R5rotating.

A document sensor6is disposed on the document feed path H1at a location immediately downstream of the juncture P2. The document sensor6is configured to detect a document sheet passing through the document feed path H1from the document tray2or the switchback tray8.

A document size sensor7, which corresponds to the sensor defined by the present invention, is disposed on the document feed path H1at a location intermediate the document tray1and the juncture P2and on the front side in the primary scanning direction perpendicular to the document feed direction. The document size sensor7is configured to detect an edge position of a document sheet fed from the document tray2in the primary scanning direction.

FIG. 4is a schematic diagram illustrating the location of the document size sensor7included in the aforementioned document reader1. The document reader1according to the present embodiment is capable of feeding a document sheet of A3 size or smaller. The CCD image sensor11A of the CCD read unit11included in the image read section110of the image forming apparatus100is configured to read image information from a range L1which is slightly longer than the length of A3-size document sheet D1in the primary scanning direction (Y-Y direction) perpendicular to the sheet feed direction.

The document size sensor7is located between sheet edge position D2A for B4-size document sheet D2smaller than A3-size document sheet D1and sheet edge position D3A for A4-size document sheet D3smaller than B4-size document sheet D2, the sheet edge positions D2A and D3A being situated on the front side in the primary scanning direction. Accordingly, the document size sensor7can detect A3-size document sheet D1(which is meant to include an A4-size document sheet placed in portrait orientation) and B4-size document sheet D2((which is meant to include an A5-size document sheet placed in portrait orientation) but cannot detect A4-size document sheet D3or B5-size document sheet D4.

Thus, it is possible to judge whether a document sheet fed from the document tray2is a larger-sized document sheet (A3- or B4-size document sheet) or a smaller-sized document sheet (A4- or B5-size document sheet) according to whether or not the document size sensor7has detected the document sheet.

It should be noted that in the document reader1each document sheet is fed as centered on a center position in the primary scanning direction.

Additional document size sensor7may be disposed on the rear side in the primary scanning direction at a location between a sheet edge position for B4-size document sheet D2and a sheet edge position for A4-size document sheet D3. In the primary scanning direction it is possible to further provide additional document sensor7at either or both of a location between the front-side sheet edge position for A3-size document sheet D1and the front-side sheet edge position for B4-size document sheet D2and a location between the rear-side sheet edge position for A3-size document sheet D1and the rear-side sheet edge position for B4-size document sheet D2, or at either or both of a location between the front-side sheet edge position for A4-size document sheet D3and the front-side sheet edge position for B5-size document sheet D4and a location between the rear-side sheet edge position for A4-size document sheet D3and the rear-side sheet edge position for B5-size document sheet D4.

Further, the document size sensor7may be disposed so as to be movable in the primary scanning direction. In this case the document size sensor7can be fixed at any one of the aforementioned locations selectively. Alternatively, such an arrangement is possible that the location of the document size sensor7in the primary scanning direction can be changed with a change in the position of a document guide2A defining a sheet edge position of a document sheet placed on the document tray2in the primary scanning direction.

FIG. 5is a block diagram illustrating the configuration of control section30included in the image forming apparatus100and the configuration of control section20included in the document reader1. The control section20of the document reader1comprises a CPU21including ROM22and RAM23, the CPU21being connected to the document sensor6, document size sensor7, CCD image sensor11A and other components. The CPU21constituting the control section20of document reader1is connected to a CPU31constituting the control section30of the image forming apparatus100.

The control section30of the image forming apparatus100comprises CPU31including ROM32and RAM33, the CPU31being connected to input/output devices including image processing section34, operating panel controller35, image read section loading equipment36, image forming section loading equipment37, sheet feed section loading equipment38, and the like.

In the control section20of the document reader1the CPU21outputs image information read from a document sheet by the CCD image sensor11A to the CPU31.

Also, the CPU21judges whether or not a document feed failure has occurred based on a detection signal from the document sensor6. If it is judged that the document feed failure has occurred, the CPU21outputs feed failure information to the CPU31. Because the CPU21recognizes a proper duration of a document detecting state of the document sensor6from the size of a document sheet being fed and the document feed speed, the CPU21judges that the document feed failure has occurred if the duration of the detection signal from the document sensor6is different from the proper duration.

As described above, the document sensor6is disposed on the document feed path H1at a location immediately downstream of the juncture P2with the secondary feed path H2. For this reason, it is possible for the CPU21to judge whether or not the document feed failure has occurred not only after feeding of a document sheet from the document tray2but also after feeding of a document sheet from the switchback tray8based on the detection signal from the document sensor6.

The CPU21judges the size of a document sheet placed on the document tray2based on a detection signal from a sensor provided on the document tray2, and stores document size information on the size thus judged while outputting it to the CPU31of the image forming apparatus100.

In reading image information from a series of differently sized document sheets including mixed document sheets of different sizes (differently-sized document read mode), the CPU31outputs smaller document size information to the CPU31based on the detection signal from the document size sensor7. Specifically, when the document size sensor7changes from a document detecting state where the document size sensor7is detecting a larger-sized document sheet fed from the document tray2at a preceding feed into a document non-detecting state where the document size sensor7is not detecting any document sheet at a next feed, the CPU21judges the document sheet just fed from the document tray2as being a smaller-sized document sheet and then outputs smaller document size information to the CPU31.

In the control section30of the image forming apparatus100the operating panel controller35inputs operation data on a key switch41provided on the operating panel of the image forming apparatus100to the CPU31and causes a display42of the operating panel to display indication data outputted from the CPU31.

The CPU31establishes image forming conditions based on the operation data on the key switch41inputted from the operating panel controller35. Such image forming conditions include a document sheet size, a recording sheet (recording medium) size, an image forming magnification, an image density, an image forming mode, and a like condition. When two of the document sheet size, recording sheet size and image forming magnification are established by operation on the key switch41, the remaining one is automatically established. The image forming mode is either a one-side image forming mode for forming an image on only one side of a recording sheet (recording medium) or a double-side image forming mode for forming images on both sides of a recording sheet.

When the differently-sized document read mode is selected at the operating panel, the CPU31outputs to the CPU21differently-sized document information informing that a series of differently sized document sheets including mixed document sheets of different sizes is placed on the document tray2.

When smaller document size information is inputted to the CPU31, the CPU31changes the currently established recording sheet size based on the smaller document size information and the previously established image forming magnification. Also, the CPU31changes the developing bias value or the quantity of light for exposure based on information on an image density established as one of the image forming conditions.

The CPU31causes the image processing section34to perform predetermined image processing on image information inputted from the CPU21. The image information is temporarily stored as image data in memory included in the image processing section34and then transferred to the laser write unit227included in the image forming section loading equipment36with predetermined timing.

The image forming section loading equipment36includes, in addition to the laser write unit227including a semiconductor laser and a mirror motor, a main motor for generating rotational force for the photoreceptor drum222, a power source circuit for applying a developing bias to the developing roller of the developing unit224, and other components.

The sheet feed section loading equipment37includes a clutch for transmitting rotation to the transport rollers and the like on the sheet feed paths, a solenoid for operating a flapper, and other components.

When the CPU31receives feed failure information inputted from the CPU21, the CPU31causes the motor, solenoid, clutch and the like included in the image forming section loading equipment36and sheet feed section loading equipment37to stop operating.

FIG. 6is a flowchart of process steps performed by the control section20of the above-described document reader1. When a document is placed on the document tray2(step S1), the CPU21of the document reader1waits for a document read request to be inputted from the CPU31of the image forming apparatus100(step S2). When a start key on the operating panel of the image forming apparatus100is operated to cause the CPU31to input the document read request to the CPU21, the CPU21causes the pickup roller4and the feed roller5A to rotate thereby starting feeding of document sheets from the document tray2(step S3).

Then, the CPU21judges whether or not differently-sized document information has been inputted from the CPU31(step S4). If the differently-sized document information has been inputted from the CPU31by selection of the differently-sized document read mode at the operating panel of the image forming apparatus100, the CPU21judges whether or not the document size sensor7has detected a document sheet at the time of passage of the leading edge of the document sheet fed from the document tray2through the location of the document size sensor7(step S5).

If it is judged that the document size sensor7has detected the document sheet, then the CPU21judges the document sheet fed from the document tray2as being a larger-sized document sheet and selects range L1inFIG. 4as the reading range of the CCD image sensor11A (step S6). The CPU21starts image information reading from the document sheet at the time the leading edge of the document sheet reaches the image read position P1(step S7). When the document size sensor7assumes a non-detecting state where any document sheet is undetected, the CPU21judges whether or not any document sheet is present on the document tray2(step S8→S13).

If it is judged that the document size sensor7has not detected any document sheet in step S5, the CPU21judges the document sheet fed from the document tray2as being a smaller-sized document sheet, selects range L2inFIG. 4as the reading range of the CCD image sensor11A (step S9), and then outputs smaller document size information to the CPU31(step S10). Subsequently, the CPU21starts image information reading from the document sheet at the time the leading edge of the document sheet reaches the image read position P1(step S11). When the document sensor6assumes a non-detecting state where any document sheet is undetected, the CPU21judges whether or not any document sheet is present on the document tray2(step S12→S13).

If the differently-sized document information has not been inputted in step S4, the CPU21establishes a reading range of the CCD image sensor11A based on document size information (step S14) and then starts image information reading from the document sheet at the time the leading edge of the document sheet reaches the image read position P1(step S15). Thereafter, when the document size sensor7assumes a non-detecting state where any document sheet is undetected, the CPU21judges whether or not any document sheet is present on the document tray2(step S16→S13).

The process returns to step S3if any document sheet is present in step S13, and the CPU21performs the process steps S3to S13repeatedly until completion of image information reading from all the document sheets placed on the document tray2.

The CPU21outputs to the CPU31image information read in any one of the steps S7, S11and S15.

As can be understood from above, the CPU21of the document reader2corresponds to the judgment section defined by the present invention. If a series of differently sized document sheets including mixed document sheets of different sizes is placed on the document tray2with the differently-sized document read mode selected, the CPU21judges whether a document sheet fed from the document tray2is a larger-sized document sheet of A3- or B4-size or a smaller-sized document sheet of A4- or B5-size based on the detection signal from the document size sensor7, and then establishes a proper image information reading range of the CCD image sensor11A based on the judgment made.

Thus, if the document sheet fed from the document tray2is a smaller-sized document sheet, the reading range of the CCD image sensor11A can be reduced to avoid reading of and image processing on unnecessary image information from outside the document region.

FIG. 7is a flowchart of process steps performed by the control section30of the image forming apparatus100. When the start key on the operating panel is operated, the CPU31of the image forming apparatus100waits for an input of image information (steps S21and S22). When the image information is inputted from the CPU21, the CPU31performs image processing on the image information inputted and stores the processed image information as image data into memory (steps S23and S24). Subsequently, the CPU31determines a size of a recording sheet to be fed (step S25), feeds the recording sheet of the size determined with predetermined timing (steps S26and S27), and then starts image formation based on the image data stored in the memory (step S28). The CPU31performs the process steps S25to S28repeatedly until the image data in the memory runs out (step S29).

In step S25the CPU31determines a recording sheet size from, for example, an image forming magnification established through the operating panel and document size information inputted from the CPU21. If smaller document size information is inputted from the CPU21in the differently-sized document read mode, the CPU31modifies document size information from A3 or B4 size to A4 size and then determines a fresh recording sheet size from the modified document size information and the image forming magnification established. The CPU31feeds a recording sheet of the size determined at the time of image formation based on the image information associated with the smaller document size information. When the input of small document size information is stopped, the CPU31restores the initial document size information.

The above-described process enables image formation based on image information read from a smaller-sized document sheet in the differently-sized document read mode to be performed on a recording sheet of the size suited not to a larger-sized document sheet but to a smaller-sized document sheet, thereby effectively utilizing resources.

If a smaller-sized document sheet is fed from the document tray2in the differently-sized document read mode, image information inputted from the CPU21of the document reader1does not include unnecessary image information from outside the document region and, therefore, the image processing section34can be prevented from performing image processing on such unnecessary image information.

It is to be noted that the image forming apparatus100may have a scanner and facsimile function such as to output image information read by the image read section110to an external device, in addition to the copy function of forming an image on a recording sheet fed from the sheet feed section250at the image forming section210based on image information read by the image read section110.

The foregoing embodiments are illustrative in all points and should not be construed to limit the present invention. The scope of the present invention is defined not by the foregoing embodiment but by the following claims. Further, the scope of the present invention is intended to include all modifications within the meanings and scopes of claims and equivalents.