Abstract:
Sheets can be manipulated for punching, perforating and/or folding. The systems and methods according to this invention allow sheets to be punched and/or perforated in various configurations. The systems and methods according to this invention allow sheets to be folded in various forms and/or configurations. Sheets can be inverted to ensure proper orientation. The systems and methods according to this invention allow the number and/and or locations of punches and/or perforations and the type and/or length of folds to be controlled on a sheet-by-sheet basis. The systems and methods according to this invention allow the sheet preparation module to be optionally configured within the photocopying system depending on the needs and flexibility of the finishing requirements of the operator. The modularity of the sheet preparation module design as a “plug and play” unit enables greater functionality for the manipulation of sheets.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    1. Field of Invention  
           [0002]    This invention is directed to systems and methods for punching, perforating and folding of sheets in a printing system.  
           [0003]    2. Description of Related Art  
           [0004]    Photocopiers have become standard equipment in today&#39;s offices, enabling businesses to increase productivity and efficiency. Today&#39;s photocopying systems provide high-speed reproduction with ease of use. Additionally, current photocopying systems offer end-to-end capability from feeding to finishing that includes features such as sorting, collating and binding. Many systems combine several features to further increase productivity and ease of use by the operator.  
           [0005]    Sheet folding systems are in use in many photocopying systems using various folding techniques, such as folding rollers and knife-edge folding assistance devices. Further, hole punchers, sheet perforators, and sheet inverters are used to enhance photocopying and document publication.  
           [0006]    An important element of a photocopying system is the ability to handle large complicated print jobs with minimal user input. Systems exist that automate document handling, copying and finishing, such as hole punching, sheet perforation, and/or folding, with minimal user input. This reliability and ease of use further enables increases in user productivity. Such systems are needed that provide capabilities to photocopying systems.  
         SUMMARY OF THE INVENTION  
         [0007]    However, few systems currently package the functional elements that handle the end-to-end copying requirements in a unique architecture.  
           [0008]    This invention provides systems and methods for punching, perforating, and/or folding sheets for a printing system.  
           [0009]    This invention separately provides systems and methods for punching sheets with various hole configurations.  
           [0010]    This invention separately provides systems and methods for perforating sheets.  
           [0011]    This invention further provides systems and methods for selectively folding sheets into different fold configurations.  
           [0012]    In various exemplary embodiments of the systems and methods according to this invention, sheets can be manipulated for punching, perforating and/or folding. For example, sheets to be manipulated may be punched, or perforated or folded only. In other various exemplary embodiments, sheets can be punched and perforated only, punched and folded only, perforated and folded only, or punched, perforated, and folded.  
           [0013]    In various exemplary embodiments of the systems and methods according to this invention, sheets can be punched in various punching configurations. For example, sheets can be punched with one hole, two holes, or three or more holes, based upon the punch and die units used in the system.  
           [0014]    In various exemplary embodiments of the systems and methods according to this invention, sheets can be folded in various forms. For example, sheets can be z-folded for inserting larger sheets into small size sets, half-folded, c-folded, or z-folded for mailings, brochures, or for manually inserting ink envelopes. In various exemplary embodiments, sheets that are z-folded for insertion into a set can be inverted to ensure proper orientation.  
           [0015]    In various exemplary embodiments of the systems and methods according to this invention, sheets can be stacked based on the type of manipulations performed. For example, z-folded and c-folded sheets not used in sets and/or half-folded sheets can be stacked in a top tray.  
           [0016]    In various exemplary embodiments of the systems and methods according to this invention, the type and length of the fold can be controlled on a sheet-by-sheet basis. For example, the first copy of a photocopied sheet can be z-folded for mailing in an envelope and the second copy of the photocopied sheet can be half-folded for flyer manual distribution.  
           [0017]    In various exemplary embodiments of the systems and methods according to this invention, the sheet preparation module can be optionally configured within the photocopying system depending on the need and flexibility of the finishing requirements of the operator. The modularity of the sheet preparation module design as a “plug and play” unit enables greater functionality for the manipulation of sheets. For example, the sheet preparation module can be situated to accept output sheets from an image output terminal or from a sheet feed module. Sheets from the sheet preparation module can be sent to a finisher to be incorporated into sets or stacks or sheets can be redirected to a top tray of the sheet preparation module.  
           [0018]    These and other features and advantages of this invention are described in, or are apparent from, the following detailed descriptions of various exemplary embodiments of the systems and methods according to this invention. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0019]    Various exemplary embodiments of the invention will be described in detail with reference to the following figures, wherein:  
         [0020]    [0020]FIG. 1 is a block diagram of one exemplary embodiment of a photocopying system usable with various exemplary embodiments of the systems and methods according to this invention;  
         [0021]    [0021]FIG. 2 is a block diagram of one exemplary embodiment of the sheet preparation module for the photocopier system of FIG. 1;  
         [0022]    [0022]FIG. 3 is a block diagram of one exemplary embodiment of a the sheet preparation module;  
         [0023]    [0023]FIG. 4 shows in greater detail one exemplary embodiment of the folder unit of the sheet preparation module of FIGS. 2 and 3;  
         [0024]    [0024]FIG. 5 shows in greater detail an exemplary embodiment of the inverter unit of the sheet preparation module of FIGS. 2 and 3; and  
         [0025]    [0025]FIG. 6 is a flowchart outlining an exemplary embodiment of a method for manipulating a sheet using the sheet preparation module. 
     
    
     DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS  
       [0026]    Various exemplary embodiments of the systems and methods according to this invention enable the manipulation of sheets in a photocopying system to be advanced by using a sheet preparation module. The mechanisms and techniques used in sheet preparation modules according to this invention provide a combination of punching, perforating, and/or folding.  
         [0027]    In various exemplary embodiments of the systems and methods of this invention, a sheet fed into the sheet preparation module can be effectively manipulated based upon the requirements of a particular job submitted by an operator of the printing or photocopying system. It should be appreciated that sheets requiring no manipulation can be bypassed through the sheet preparation module to a downstream module, such as, for example, a finisher module.  
         [0028]    In various exemplary embodiments, sheets may be punched with varying configures of holes using replaceable punch/die configurations. It should be appreciated that punched sheets can also be folded and/or perforated.  
         [0029]    In various exemplary embodiments, sheets may be perforated in various locations. The locations of the perforation on the sheet are fully controllable on a sheet-to-sheet basis.  
         [0030]    In various exemplary embodiments, sheets may be folded in various configurations based on the operator requirements. Sheets may be z-folded, c-folded, and half-folded for letters, brochures, cards and the like. In various exemplary embodiments, the type of folding and the position of the one or more folds on the sheet relative to the edges of the sheet and/or other folds are fully controllable on a sheet-to-sheet basis.  
         [0031]    In various exemplary embodiments, sheets diverted to the sheet preparation module for manipulation are registered to ensure proper alignment of the sheet prior to manipulation using a tamping system. The sheet, after registration, may be punched. The sheet may then be transported out of the registration and punch area and transported to a perforator unit. In various exemplary embodiments, a rotary perforation wheel with a backer roll is used to perforate the sheet. In various exemplary embodiments, the perforation wheel and backer may be moved, for a given sheet, to the appropriate cross-process location before the sheet arrives. In various exemplary embodiments, the perforation wheel and backer engage the sheet only when required. After being perforated, the sheet may then pass to a folding area. The type of fold performed on the sheet, such as z-folds, c-folds, and half-folds, and the like, may be predicated on the requirements of the system operator. After folding, sheets may be sent to a finisher module or exit to a top tray of the sheet preparation module.  
         [0032]    It should be appreciated that the type of punching, perforating, and folding may vary and/or differ on a job-to-job basis or even on a sheet-to-sheet basis, depending on the requirements of the system operator.  
         [0033]    [0033]FIG. 1 is a block diagram of one exemplary embodiment of a photocopying system  100  usable to process and manipulate a sheet. As shown in FIG. 1, the photocopying system  100  includes a sheet feed module  200 , an image output terminal  300 , a sheet preparation module  400 , and a finisher module  500 .  
         [0034]    It should be appreciated that in various exemplary embodiments, these elements, while shown in FIG. 1 as separate elements, are not necessarily separate and distinct components. Thus, the functions and/or operations of any one or more of these elements may be carried out by a single device, structure and/or subsystem. Furthermore, it should be appreciated that the sheet preparation module  400  in FIG. 1 may be located or positioned within the photocopying system  100  to accept sheets from the image output terminal  300  or from the sheet feed module  200 , for example.  
         [0035]    [0035]FIG. 2 is a block diagram of one exemplary embodiment of a sheet preparation module  400  according to this invention for the photocopying system  100 . As shown in FIG. 2, the sheet preparation module  400  includes one or more of a controller  470 , a memory  480 , an input/output interface  490 , a punch unit  420 , a perforator unit  424 , and a folder unit  430  connected together by one or more control and/or data busses and/or one or more application programming interfaces  475 .  
         [0036]    The memory  480  shown in FIG. 2 can be implemented using any appropriate combination alterable, volatile or non-volatile memory, or non-alterable, or fixed memory. The alterable memory, whether volatile or non-volatile can be implemented using any one or more ecstatic or dynamic brand, a floppy disc or disc drive, a writeable or rewriteable optical disc and disc drive, a hard drive, a flash memory or the like. Likewise, the non-alterable or fixed memory can be implemented using any one or more ROM, PROM, EPROM, EEPROM and optical disc, ROM, disc such as CD-ROM or DVD-ROM, and disc drive or the like.  
         [0037]    As shown in FIG. 2, one or more input device  492  and display devices  494  are connected to the input/output interface  490 . In general, the one or more input devices  492  will include any one or more of a keyboard, a keypad, a touch screen, or any other known or later developed system for providing control and/or data signals to the sheet preparation module  400 . The one or more input devices  492  can further include any manual or automated device usable by a user or other system to present data or other stimuli to the sheet preparation module  400 .  
         [0038]    The punch unit  420  can be any hardware system, device or apparatus that enables the sheet preparation module  400  to punch holes in sheets. In various embodiments, the punch unit  420  can include any combination of any combination of hardware elements, such as punch and die units, servos and/or solenoids that provide any combination of punch holes.  
         [0039]    The perforator unit  424  can be any combination of hardware elements that enables sheets in the sheet preparation module  400  to be perforated. In various embodiments, the perforation unit  424  can include a combination of hardware, including a rotary perforation wheel with a backer roll.  
         [0040]    The folder unit  430  can be any combination of hardware elements that enables the sheet in the sheet preparation module  400  to be folded. In various exemplary embodiments, the folder unit  430  can include any hardware elements, such as one or more simple buckle folders, one or more sets of drive rollers, one or more sets of servo control nip rollers and/or and one or more sets of folder fold rollers that enable various types of folds to be controllably applied to each sheet on a sheet-to-sheet basis. The type of folds performed by the folder unit  430  may include, but is not limited to, c-folds, z-folds, and half-folds.  
         [0041]    [0041]FIG. 3 is a diagram of one exemplary embodiment of the sheet preparation module  400 . As shown in FIG. 3, the sheet preparation module  400  includes a sheet-receiving inlet  412 , a bypass path  459 , and a sheet-discharging outlet  468 . One or more sets of transport nip rollers  418  and/or  469  move the sheets along the bypass path  459 .  
         [0042]    A sheet to be manipulated is diverted from the bypass path  459  to a primary manipulation path  416  by a gate  414 . As shown in FIG. 3, the primary manipulation path  416  includes one or more sets of transport nip rollers  418 , one or more sets of nip rollers  408 , the punch unit  420 , a leading edge registration gate  422 , the perforator unit  424 , and the folder unit  430 .  
         [0043]    As discussed above, sheets to be manipulated are diverted from the bypass path  459  to the manipulation path  416  by the gate  414 . One or more sets of transport nip rollers  418  move the sheets along the manipulation path  416  to the registration gate  422 . The registration gate  422  registers the leading edge of the sheet. Cross-process registration, if implemented, is accomplished using a tamping system, for example. For cross-process registration, the one or more sets of nip rollers  408  are opened to allow the sheet movement in the cross-process direction. After a sheet has been registered to ensure proper alignment, the sheet may be punched by the punch unit  420 . The sheet is transported out of the registration gate and punch area to the perforation unit  424 . If the sheet is to be perforated, in various exemplary embodiments a fully controllable rotary perforation wheel  426  performs the perforation. The perforation wheel  426  can be moved to the appropriate cross-process location prior to the arrival of the sheet and the perforation wheel  426  being engaged.  
         [0044]    From the perforation area, the sheet continues along the manipulation path  416  to the folding unit  430 . The folding unit  430  includes an initial folding area and a second folding area, enabling a multiple of fully controllable folding options. In various exemplary embodiments, the sheet may be z-folded, half-folded and c-folded, for example.  
         [0045]    If a sheet does not require folding, the sheet continues along the manipulation path  416  and may exit the sheet preparation module  400  via the sheet-discharging outlet  468 . Alternatively, sheets can continue to a tray path  466  leading to a tray exit  464  and a top tray  462 .  
         [0046]    A sheet that requires folding enters the folding unit  430  along the primary manipulation path  416  and extends into the initial folding area. If only a single fold is required, the sheet continues along the initial folding path  434 , by-passing the second folding area, and exits the folding unit  430 . If additional folding is required, the sheet stops in the second folding area and is directed along the second folding path  449 . After folding, the sheet exits the folding unit  430 . In contrast, folded sheets not sent to the finisher module  500  can be directed to the top tray  462  of the sheet preparation module  400  via the exit path  466  to the tray outlet  464 .  
         [0047]    [0047]FIG. 4 shows in greater detail one exemplary embodiment of the folding unit  430 . As shown in FIG. 4, the folding unit  430  includes fold rollers  446  and  448 , one-or more sets of servo control nip rollers  440 , and a drive roller  442 . An additional set of fold rollers, one or more sets of servo control nip rollers and a drive roller are situated in the folding unit  430  to provide a second fold. Although the first set of fold rollers and one or more sets of control nip rollers are described here, it should be appreciated that both sets of fold rollers and control nip rollers operate in the same manner.  
         [0048]    As shown in FIG. 4, the fold rollers  446  and  448  can be simple buckle folders. The one or more sets of servo control nip rollers  440  can be any type of controllable rollers that can be, for example, stopped and reversed. It should be appreciated that a moveable gate can also be used in addition to, or even in place of, the nip rollers  440 . That is, in various exemplary embodiments, the moveable gate can be moved along the manipulation path to change where the sheet is stopped relative to the fold rollers  446  and  448  to change where the fold is formed along the length of the sheet along the manipulation path  416 .  
         [0049]    The sheet to be folded by the sheet preparation module  400  is driven along the manipulation path  416  by the one or more sets of servo control rollers  438  to the folding unit  430  and the fold rollers  446  and  448 . The sheet continues along  416  to the one or more sets of servo control nip rollers  440 . The sheet enters the one or more sets of servo control nip rollers  440 , which drive the leading edge of the sheet forward until the desired fold positions is at the fold roll location between the fold rollers  446  and  448 . The one or more sets of servo control nip rollers  440  are quickly reversed, driving the lead edge of the sheet backwards. The trailing edge of the sheet is driven forward by the drive roller  442 , causing the sheet to buckle into the fold rollers  446  and  448 . The fold rollers  446  and  448  acquire the sheet by the fold roller  446  rolling clockwise and the fold roller  448  rotating counter-clockwise. This motion of the fold rollers  446  and  448  causes a fold to be made into the sheet. The folded sheet continues along the fold path  434  to the second folding area of the folding unit  430 .  
         [0050]    In the second folding area, a second fully controlled fold, if needed, is performed using the same technique used in the initial folding area. It should be appreciated that the folding controls in both the initial fold area and second fold area allow any number of fold positions to be performed on a sheet-by-sheet basis and enable the folding of different sized sheets.  
         [0051]    It should be appreciated that, if two folds are to be formed in the sheet, the type of fold, such as z-fold or c-fold, is controlled by selecting the location where the first fold is formed along the length of the sheet, where the length is the dimension of the sheet along the manipulation path  416 . That is, when the folded sheet exits the first set of fold rollers  446  and  448 , the fold becomes the leading edge of the sheet. If the first fold is formed closer to the original leading edge than to the trailing edge, a first flap portion of the sheet formed by the fold will be on the side of the sheet facing the fold roller  448 . In various exemplary embodiments, if the first and second fold areas are arranged as shown in FIG. 3, when the sheet is driven into the fold rollers of the second folding area, the first flap portion of the sheet formed by the first set of fold rollers  446  and  448  will be on the same side of the sheet from a second flap portion of the sheet formed by the fold rollers of the second fold area. As a result, a c-fold is formed in the sheet.  
         [0052]    If the first fold is formed closer to the trailing edge than to the original leading edge, the first flap portion of the sheet formed by the fold will be on the side of the sheet facing the fold roller  446 . In various exemplary embodiments, if the first and second fold areas are arranged as shown in FIG. 3, when the sheet is driven into the fold rollers of the second folding area, the first flap portion of the sheet formed by the first set of fold rollers  446  and  448  will be on the opposite side of the sheet from a second flap portion of the sheet formed by the fold rollers of the second fold area. As a result, a z-fold is formed in the sheet. It should be appreciated that, if the second folding area is arranged differently, the relative locations where the first fold is formed along the sheet to obtained a c-fold and a z-fold could be reversed.  
         [0053]    A sheet not requiring a second fold continues along the fold path  434  to the inverter area  450 . A sheet requiring a second fold exits the folding unit  430  via the second fold path  449  to the inverter area  450 .  
         [0054]    Sheets can be inverted prior to being sent to the finisher module  500 . FIG. 5 depicts an inverter  450  for the sheet preparation module  400 . The inverter  450  includes an inverter path  455  and an inverter gate  454 . One or more sets of transport nip rollers  456  and  458  are aligned with an exit path  460  and the inverter path  455  to control the sheet along both paths.  
         [0055]    A sheet to be output through a sheet discharging outlet  468  that will not be inverted continues from the manipulation path  452  through the exit path  460  to the bypass path  459 . In the bypass path  459 , the sheet is then ejected from the sheet preparation module  400  via the sheet-discharging outlet  468 . A sheet not inverted can also continue from the manipulation path  452  through the inverter path  45 . 5  and then be transported along the bypass path  459  to the tray path  466  by opening the gate  454 . The sheet is then ejected from the sheet preparation module  400  to the top tray  462  via the tray exit  464 .  
         [0056]    A sheet is inverted to change its orientation. In general, the orientation is changed to swap the leading edge for trailing edge, that is, so that the trailing edge before inversion becomes the leading edge after inversion. For a sheet that is to be sent to the sheet discharging outlet  468  to be inverted, the inverter gate  454  is opened to divert the sheet into the inverter path  455 . The sheet is transported along the inverter path  455  by the one or more sets of transport nip rollers  458  to the bypass path  459  and into one or more sets of servo controlled nip rollers  469 . When the sheet is fully on the bypass path  459 , the one or more sets of servo controlled nip rollers  469  reverse and send the sheet back along the bypass path  459  towards the exit  468 . The sheet can then be ejected from the sheet preparation module  400  by transporting it back along the bypass path  459  to the sheet-discharging outlet  468 .  
         [0057]    In various exemplary embodiments, it is also possible to invert as sheet that is to be output to the top tray  462 . To invert such a sheet, the inverter gate  454  remains closed to divert the sheet into the exit path  460  and onto the bypass path  459  towards the exit  468 . The sheet is transported along the bypass path  459  to one or more sets of transport nip rollers positioned along the bypass path  459 . When the sheet is fully on the bypass path  459 , these one or more sets of transport nip rollers then reverse to drive the sheet to the one or more sets of servo controlled nip rollers  469 . The one or more sets of servo controlled nip rollers  469  are then driven to send the sheet along the tray path  466  towards the exit  464  to eject the sheet from the sheet preparation module  400  into the top tray  462 .  
         [0058]    [0058]FIG. 6 is a flowchart outlining one exemplary embodiment of a method for manipulating a sheet using any of various exemplary embodiments of a sheet preparation module according to the invention. Beginning in steps S 200 , operation continues to step S 210 , where the sheet preparation module receives a sheet from an image output terminal. Then, in step S 220 , a determination is made whether the sheet is to be manipulated. If the sheet is to be manipulated, operation continues to step S 230 . Otherwise, operation jumps to step S 330 .  
         [0059]    In step S 230 , the sheet is registered to ensure the sheet is properly aligned prior to manipulation. Next, in step S 240 , a determination is made whether the sheet is to be punched. If the sheet is punched, operation continues to step S 250 . Otherwise, the sheet passes through a sheet punch unit without being punched and operation jumps to step S 260 . In step S 250 , the sheet is punched one or more times to form one or more sets of holes within the sheet. Then, in step S 260 , a determination is made whether the sheet is to be perforated. If the sheet is to be perforated, operation continues to step S 270 . Otherwise, the sheet passes through the sheet perforation unit without being perforated and operation jumps to step S 280 .  
         [0060]    In step S 270 , the sheet is perforated to form one or more lines of perforation in the sheet. Next, in step S 280  a determination is made whether the sheet is to be folded to form a first fold. If the sheet is to be folded, operation continues to step S 290 . Otherwise, the sheet passes through the sheet fold unit without being folded and operation jumps to step S 320 . In step S 290 , the sheet is folded to form a first fold. Then, in step S 300 , a determination is made whether a second fold is to be formed in the sheet. If so, operation continues to step S 310 . Otherwise, the sheet passes through the second fold portion of the sheet fold unit without being folded a second time and operation jumps to step S 320 . In step S 310 , the sheet is folded a second time. Operation then continues to step S 320 .  
         [0061]    In step S 320 , a determination is made whether the sheet is to be output to the finisher module. If the sheet is to be output to the finisher module, operation continues to step S 330 . Otherwise, operation jumps to step S 360 . In step S 330 , a determination is made whether the sheet is to be inverted. If the sheet is to be inverted, operation continues to step S 340 . Otherwise, operation jumps directly to step S 350 . In step S 340 , the sheet is inverted. Then in step S 350 , the sheet is output from the sheet preparation module to the finisher module. Operation then jumps to step S 390 .  
         [0062]    In contrast, in step S 360 , a determination is made whether the sheet is to be inverted. If the sheet is to be inverted, operation continues to step S 370 . Otherwise, operation jumps directly to step S 380 . In step S 370 , the sheet is inverted. Then in step S 380 , the sheet is output from the sheet preparation module into an output tray or the like. Operation then continues to step S 390 , where operation of the method ends. Of course, it should be appreciated that, if inverting the sheet that is to be output to the output tray is not implemented, steps S 360  and S 370  are omitted and, in step  5380 , the uninverted sheet is output to the output tray or the like.  
         [0063]    While this invention has been described in conjunction with various exemplary embodiments, it is to be understood that many alternatives, modifications and variations would be apparent to those skilled in the art. Accordingly, the preferred embodiments of this invention, as set forth above are intended to be illustrative, and not limiting. Various changes can be made without departing from the spirit and scope of this invention.