Flexible belt sheet compiler

Abstract: A high capacity, sheet compiler (80) for stacking, registering and attaching one or multiple sets of copy sheets (49) from an electrophotographic printing machine. The copy sheets are discharged from the machine through chute (68) and are moved into an inclined compiling tray (90) and are longitudinally registered by flexible, endless belts (84) contacting the top surface of each sheet. The belts are restrained from deforming and walking or moving along the top of the stack by a restraining member (86) allowing greater stack capacity in the tray. Each sheet is then laterally shifted by a tamping mechanism (95) to laterally register the sheet. Once a complete set of sheets has been discharged and fully registered the stack is then attached by stapling or other means and is discharged by ejector rolls (109,110) from the compiling tray.

Description: This invention relates generally to a finishing station of an electrophotographic printing machine, and more particularly concerns a sheet compiler used therein. In a commercial electrophotographic printing machine, it is often desirable to stack the discharged copy sheets, numbering from two sheets up to a large number of sheets, in sets with very close stack registration so as to avoid a ragged or uneven looking stack edge in finished, bound or stapled copy sets. It is further desirable when stapling or binding a set of sheets to locate or move the registered stack to a position at which the stapling or binding device can act upon the stack without disturbing the stack registration. It is also desirable to be able to stack and register copy sheet sets rapidly so as to not interrupt the output of the printing machine. It is also advantageous to be able to accommodate a wide range of stack heights and to be able to compile large sets or stacks of sheets. It is further advantageous to be able to compile and stack a wide range of paper sheet sizes and weights and/or stiffnesses without damage to the edges of the sheets or image smearing or other damage to the copies. US-A-5,288,062 describes an apparatus for stacking, registering and attaching one or multiple sets of electrophotographic printing machine output. The copy sheets are discharged from the machine and fall into an inclined compiling tray and are longitudinally registered by flexible, endless belts contacting the top surface of each sheet and then laterally shifted by a tamping mechanism which has upwardly flared baffle to corrugate the sheet as it is shifted in order to increase the sheet beam strength and facilitate easier and more complete registration. The discharge nip assembly which includes the flexible belts is vertically adjustable to maintain optimum contact by the endless registration belt and allow for high capacity compiling. The compiling tray can also be adjustable. EP-A-0 346 851 A1 describes a discharge sheet stack compiler and registration device which utilizes endless belts for both end registration and as a lateral registration device. The sheets are discharged and compiled in a fixed tray and after compiling and stapling, are further discharged to a catch tray. In accordance with one aspect of the present invention, there is provided an apparatus for registering sheets being compiled into a stack according to claim 1. The apparatus comprises a drive member, a belt partially entrained around said drive member forming a selected arcuate configuration with an outer surface of said belt being adapted to contact a topmost sheet of the stack to urge the sheet into a registered position and a restraining device operatively associated with said belt to maintain said belt in the selected arcuate configuration as the sheets in the stack increase. Pursuant to another aspect of the invention there is provided an electrophotographic printing machine having such a sheet finisher for registering sheets being compiled into a stack. The sheet finisher comprises a drive member, a belt partially entrained around said drive member forming a selected arcuate configuration with an outer surface of said belt being adapted to contact a topmost sheet of the stack to urge the sheet into a registered position and a restraining device operatively associated with said belt to maintain said belt in the selected arcuate configuration as the sheets in the stack increase. The present invention will now be described by way of example with reference to the accompanying drawings, in which: Figures 1 and 2 are elevational views of a known flexible belt sheet compiling device; Figures 3 and 4 are elevational views of the of the high capacity flexible belt compiler of the present invention; and Figure 5 is a cross-sectional end view taken along the line in the direction of arrows 5-5 in Figure 4. In Figures 1 and 2, there is illustrated a typical flexible belt compiling tray 90 for known electro photographic printers. Such known compiling trays do not have a restraining member of the present invention, which increases the sheet capacity of the compiling apparatus. The sheets are discharged from a printing machine through the nip 87 formed between the discharge rollers 82 and 88 and into the compiling tray 90. The registration belt 84 has a larger diameter D than the drive roller 88. The trailing edge of the sheet, as it falls towards the tray 90, travels around the outside of the longitudinal registration belt 84 and is registered against the back wall 91 of the tray 90 by the friction of the belt 84 on top of the stack. As the stack of sheets 49 builds in height, the longitudinal registration belt 84 is deformed into an elliptical shape (see Figure 2). This deformation of the longitudinal registration belt 84 increases the distance, represented by 89, that a sheet has to travel out of the nip 87 and then back toward the registration wall 91. The problem with this increased distance and resulting extra scuffing force is that it decreases the reliability of the compiler and also limits the number of sheets which may be accurately registered and compiled. Some other approaches to solve this problem have been to make the compiling tray movable in the vertical direction so as to maintain a relatively stable belt profile and/or to cause the discharge nip to move in a vertical direction relative to the tray for the same purpose. These approaches, while achieving a solution to the problem, add to the complexity and cost of the machine and are not practical for many applications. Turning next to Figures 3 and 4, the same type of belt compiler 80 is shown utilizing the restraining member 86 of the present invention. As in the previously described known compiler of Figures 1 and 2, a sheet 49 is discharged through a chute represented by arrow 68 and through the nip 87 formed between the discharge rolls 82 and 88 where, as it falls, its trailing edge travels along the outside of the flexible longitudinal registration belt 84 and is driven by the belt 84 back against the registration wall 91 of the tray 90. As the stack of sheets 49 builds, the restraining member 86 prevents the belt 84 from "walking" or moving away from the registration wall 91 along the top of the stack of sheets 49 into the severe elliptical shape as shown in Figure 2 by distance 89 and maintains a relatively stable belt profile. This restrained belt profile minimizes longitudinal distortion of the belt, as represented by the deformation distance 89' (which is less than the distance 89 in Figure 2), and allows the stack to build to a greater height while maintaining the accuracy of registration. Increased belt stability is also an added benefit of using the restraining member. The restraining member is easily mounted to the curl guard 85 which also assists in the registration of the sheets by preventing any curled up edges of the sheets from stubbing prior to registering against the registration wall 91. Once the compiled stack of sheets 49 is into the tray 90, it may be attached by means of a stapler, binder, stitcher, or other attaching device into a completed attached set. The completed and attached set can then be driven out of the tray 90 by set ejector driver rolls 109, 110 which come together to clamp the compiled set and move it onto the stacking tray 92. Of course, other set discharge devices such as clamps, pushers, grabbers etc. could also be utilized to eject the set from the compiling tray. Turning next to Figure 5, which is a partially shown, cross-sectional end view of the compiler tray of Figures 3 and 4, it can be seen that a pair of side tampers 95 can be utilized to maintain lateral registration within the tray. As illustrated, the pair of tampers 95 are utilized in a center registered type machine. As each sheet 49 is discharged into the tray 90 and registered by the belt 84 against the back wall 91 of tray 90, the tamper members 95 move toward each other as indicated by arrows 96 to the width of the sheets and align the sheets laterally. As each sheet is discharged, the tamper members 95 are actuated, thereby maintaining laterial registration in conjunction with the longitudinal registration performed by belts 84. Obviously, a single tamper member and a fixed side registration wall could be utilized for a side registered type device. Accordingly, there is provided an improved compiling apparatus for stacking, registering and attaching one or multiple sets of electrophotographic printing machine output having increased stack hight in the tray. The copy sheets are discharged from the machine into an inclined compiling tray and are longitudinally registered by flexible, endless belts contacting the top surface of each sheet, while restraining members restrict longitudinal distortion. Each sheet is then laterally shifted by a tamping mechanism to register the sheet. Once a complete set of sheets has been discharged and fully registered, the stack is then attached by stapling or other means and is discharged from the compiling tray.

Claims: A high capacity sheet compiling apparatus (80) for registering sheets (49) being compiled into a stack, comprising: an endless flexible belt (84) entrained around a drive member (88), the belt being of larger diameter (D) than the drive member and forming a closed loop, and the belt having an outer surface which, at a position spaced from the drive member, contacts a topmost sheet of the stack, the belt sliding over the topmost sheet to urge the sheet into a registered position, and the endless belt being deformable to accommodate a varying number of sheets in the stack; characterised by: a restraining device (86) engaging the belt to maintain in a substantially constant position the point of contact between the belt and the topmost sheet as the number of sheets in the stack increases. The apparatus claimed in claim 1, wherein the drive member is a roller which is paired with a second roller (82) to form a nip (87) through which the sheets are driven into an inclined tray (90) for stacking therein; and wherein the tray has an end wall (91) for registration of the stack of sheets thereagainst by said endless belt. The apparatus claimed in claim 1 or 2, further characterised by means (109,110) for ejecting a compiled sheet stack from said tray. The apparatus as claimed in any of the preceding claims, further characterised by a lateral registration device (95) to align laterally each of the received sheets in said tray. The apparatus as claimed in any of the preceding claims, further characterised by means disposed adjacent to said tray, for attaching the sheets of the stack to one another. The apparatus as claimed in any of the preceding claims, further characterised by a guide (85) disposed parallel to said endless belt at a height not lower than that of the lower outer surface of said endless belt. The apparatus as claimed in claim 6, wherein said restraining device is a roller rotatably mounted on each of said guides. The apparatus as claimed in any of the preceding claims, wherein said restraining device comprises a rotatable member in contact with an inner surface of said endless belt, so that said belt is restrained from excessive deforming by limiting the amount of walking along the top of the stack. An electrophotographic printing machine having high capacity, sheet compiling apparatus according to any one of claims 1 to 8. The printing machine as claimed in claim 9, wherein said restraining device comprises a rotatable member in contact with an inner surface of of said endless belt to restrain said belt from deforming by walking along the top of the stack.

Inventors: FALVO JOHN R, RIZZOLO CHARLES D, FALVO, JOHN R., RIZZOLO, CHARLES D.
Applicants: XEROX CORP, XEROX CORPORATION
Application year: 1995
Main classification: G03G15
IPC codes: G03G15, B65H31, B65H29