Patent Description:
There is known a lamination technique of inserting an insertion sheet (paper, photo, etc.) between a two-ply lamination sheet or lamination film (e.g., a lamination pouch or lamination folder) and applying heat and pressure to the two-ply lamination sheet to bond the two-ply lamination sheet. The two-ply sheet is made of two sheets (plies) bonded (sealed) on one side as if one sheet is folded.

For example, <CIT> discloses a laminator that separates two sides of two-ply laminate film bonded at a front end, with separation and release means (upper and lower vacuum devices), and then inserts a protected paper sheet therein.

<CIT> discloses an image forming apparatus including a controller configured to control operations in a fixing device based on the thickness of a laminate sheet and perform desired lamination processing.

Depending on the sizes of the laminate sheet and the insertion sheets, one or more insertion sheets can be inserted into the laminate sheet. However, the above-described publications do not disclose a configuration that inserts a plurality of inner sheets into the laminate sheet. That is, the above-described lamination technology has a problem such as a limited use and does not fully satisfy a user's request.

In addition, the above-described publications do not disclose how to adjust a position of the insertion sheet inserted into the laminate sheet. In this point, the above-described lamination technology also has the problem such as the limited use and does not fully satisfy the user's request.

An object of the present disclosure is to provide a sheet processing apparatus configured to sandwich one or more sheet media in a two-ply sheet in which two sheets are overlaid and bonded together at a portion of the two-ply sheet and including a controller configured to control insertion processes for inserting a sheet medium (an insertion sheet) into a two-ply sheet (a laminate sheet) based on the size of the two-ply sheet that is a length in a conveyance direction, the size of the sheet medium, and a number of the sheet media to be sandwiched. In order to achieve this object, there is provided a sheet processing apparatus according to claim <NUM>. Advantageous embodiments are defined by the dependent claims.

Advantageously, the sheet processing apparatus includes circuitry configured to control insertion processing to insert the one or more sheet media into the two-ply sheet based on a length of the two-ply sheet in a conveyance direction, a length of one of the one or more sheet media in the conveyance direction, and a number of the one or more sheet media.

The sheet processing apparatus according to the present disclosure can automatically insert a plurality of insertion sheets into the two-ply sheet in addition to one insertion sheet. The sheet processing apparatus can satisfy the user's request.

Another object of the present disclosure is to provide a sheet processing apparatus that can insert at least one sheet medium (the insertion sheet) into the two-ply sheet (the laminate sheet) and includes circuitry configured to adjust a relative position of the sheet medium with respect to the two-ply sheet.

In order to achieve this object, there is provided a sheet processing apparatus, this specification further describes an improved sheet processing apparatus in which the sheet medium is sandwiched by the two-ply sheet made of two sheets overlaid and bonded together at one end. The sheet processing apparatus includes a first conveyer configured to convey the sheet medium and a second conveyer configured to convey the two-ply sheet. The sheet processing apparatus can insert at least one sheet medium into the two-ply sheet and includes circuitry configured to perform a single insertion mode in which one sheet medium is inserted into the two-ply sheet and a multiple insertion mode in which a plurality of sheet media are inserted into the two-ply sheet along the conveyance direction. The circuitry in the sheet processing apparatus is configured to be able to arbitrarily adjust the relative position of the sheet medium with respect to the two-ply sheet.

Accordingly, the sheet processing apparatus according to the present disclosure can automatically insert a plurality of insertion sheets into the two-ply sheet in addition to one insertion sheet, and the relative position of the sheet medium with respect to the two-ply sheet can be arbitrarily adjusted. The sheet processing apparatus can satisfy the user's request.

However, the disclosure of this patent specification is not intended to be limited to the specific terminology so selected and it is to be understood that each specific element includes all technical equivalents that operate in a similar manner and achieve similar results.

<FIG> is a schematic view illustrating a general arrangement of a sheet processing apparatus according to one embodiment of the present disclosure. A sheet processing apparatus <NUM> according to the present embodiment is to separate two sheets (plies) of a two-ply sheet (hereinafter referred to as a lamination sheet S) and to insert and sandwich an insertion sheet P (that is a sheet medium) between the separated sheets of the two-ply sheet.

The lamination sheet S is a two-ply sheet in which two sheets are overlaid and bonded together at a portion (or a side) of the two-ply sheet. For example, there is a two-ply sheet in which a first side is a transparent sheet such as a transparent polyester sheet and the opposite side is a transparent or opaque sheet and bonded to the other sheet on one side thereof. The two-ply sheet also includes a lamination film.

The insertion sheet P is an example of the sheet medium that is inserted into the two-ply sheet. The sheet medium may be thick paper, postcards, envelopes, plain paper, thin paper, coated paper, art paper, tracing paper, overhead projector (OHP) transparencies, and the like.

As illustrated in <FIG>, a sheet processing apparatus <NUM> includes a sheet tray <NUM> as a first tray on which the lamination sheets S are placed, a pickup roller <NUM> that feeds the lamination sheet S from the sheet tray <NUM>, and a conveyance roller pair <NUM>. The sheet processing apparatus <NUM> further includes a sheet feeding tray <NUM> as a second tray on which the insertion sheet P is placed, and a pickup roller <NUM> that feeds the insertion sheet P from the sheet feeding tray <NUM>.

In the sheet tray <NUM>, a sheet size sensor C6 is disposed. The sheet size sensor C6 serves as a size detector for the sheet to detect the size of the lamination sheet S that is a length of the lamination sheet S in a conveyance direction. In the sheet feeding tray <NUM>, a sheet size sensor C7 is disposed. The sheet size sensor C7 serves as a size detector for a medium to detect the size of the insertion sheet P that is a length of the insertion sheet P in the conveyance direction.

Each of the sheet size sensor C6 and the sheet size sensor C7 includes a plurality of sensors arranged side by side in the conveyance direction. Since the detection results of the sensors change depending on the size of the stacked lamination sheet S (or the insertion sheet P), the sheet size sensors C6 and C7 can detect the length of the lamination sheet S (or the insertion sheet P) in the conveyance direction.

A sheet sensor C1 to detect the position of the lamination sheet S being conveyed is disposed downstream from a conveyance roller pair <NUM> in the conveyance direction of the lamination sheet S. A sheet sensor C2 to detect the position of the insertion sheet P being conveyed is disposed downstream from a pickup roller <NUM> in the conveyance direction of the insertion sheet P.

The sheet sensors C1 and C2 may be used to detect the length of the lamination sheet S (or the insertion sheets P) in the conveyance direction.

Downstream from the conveyance roller pair <NUM> and the pickup roller <NUM> in the sheet conveyance direction, the sheet processing apparatus <NUM> further includes an entrance roller pair <NUM> as a first conveyor, a winding roller <NUM> as a rotator, an exit roller pair <NUM> as a second conveyor, and an output tray <NUM>. The sheet processing apparatus <NUM> further includes a separation claw <NUM> between the winding roller <NUM> and the exit roller pair <NUM>. The separation claw <NUM> is movable in the width direction of the sheet S.

A sheet sensor C3 to detect the position of the lamination sheet S and the insertion sheet P being conveyed is disposed downstream from the entrance roller pair <NUM> in the conveyance direction. An abnormality detector C4 to detect the state of the lamination sheet S is disposed downstream from the winding roller <NUM> in the conveyance direction. The abnormality detector C4 also functions as a sheet sensor C4. A sheet sensor C5 to detect the position of the lamination sheet S being conveyed is disposed downstream from the exit roller pair <NUM> in the conveyance direction.

The pickup roller <NUM>, the conveyance roller pair <NUM>, the entrance roller pair <NUM>, and the winding roller <NUM> are examples of a first feeder to feed a two-ply sheet. The pickup roller <NUM>, the entrance roller pair <NUM> and the winding roller <NUM> are examples of a second feeder.

On the exterior of the sheet processing apparatus <NUM>, a control panel <NUM> is provided as a display and operation device that displays information on the sheet processing apparatus <NUM> and receives operation input. Further, the control panel <NUM> also serves as a notification device to output a perceptual signal to a user. As an alternative, a notification device other than the control panel <NUM> may be separately provided in the sheet processing apparatus <NUM>. Additionally, the sheet processing apparatus <NUM> includes a controller <NUM> that is circuitry. The controller <NUM> receives input signals from the control panel <NUM> and the above-described sensors and controls the control panel <NUM>, rotations of the above-described rollers, or the like. The controller <NUM> in the present embodiment is disposed in the main body of the sheet processing apparatus <NUM> but may be disposed outside the main body. The controller may be a controller of an image forming apparatus, a controller of an image forming system, or a personal computer outside the main body of the sheet processing apparatus <NUM>.

The sheet processing apparatus <NUM> according to the present embodiment stores the lamination sheet S and the insertion sheet P on separate trays. The sheet processing apparatus <NUM> opens the lamination sheet S and inserts the insertion sheet P therein while conveying the lamination sheet S. Then, the exit roller pair <NUM> ejects and stacks the lamination sheet S, in which the insertion sheet P is inserted, onto the output tray <NUM>.

<FIG> is a view of a main part of the sheet processing apparatus <NUM> illustrated in <FIG>. As illustrated in <FIG>, each of the entrance roller pair <NUM> and the exit roller pair <NUM> is, for example, two rollers paired with each other and driven by a driver such as a motor. The controller <NUM> controls the driver to control rotations of the entrance roller pair <NUM> and the exit roller pair <NUM>. The entrance roller pair <NUM> rotates in one direction, whereas the exit roller pair <NUM> rotates in forward and reverse directions, thereby nipping and conveying the lamination sheet S and the insertion sheet P.

The entrance roller pair <NUM> conveys the lamination sheet S and the insertion sheet P toward the exit roller pair <NUM>. The conveyance direction indicated by arrow A is also referred to as a forward conveyance direction or a direction A.

In contrast, the exit roller pair <NUM> can switch the direction of rotation between the forward direction and the reverse direction. The exit roller pair <NUM> can convey the nipped lamination sheet S in the forward conveyance direction that is a direction toward the output tray <NUM> (see <FIG>) and in a direction reverse to the forward direction that is a direction in which the lamination sheet S is drawn back toward the winding roller <NUM>. The conveyance direction toward the winding roller <NUM> (the direction indicated by arrow B and the direction reverse to the forward conveyance direction) is referred to as the reverse conveyance direction or a direction B.

Between the entrance roller pair <NUM> and the exit roller pair <NUM>, the sheet processing apparatus <NUM> further includes the winding roller <NUM> that is a rotator and the separation claw <NUM>. Driven by a driver (motor or the like), the winding roller <NUM> rotates in the forward and reverse directions, and the direction of rotation can be switched between the forward direction and the reverse direction (clockwise and counterclockwise). The controller <NUM> controls the driver to control rotations of the winding roller <NUM> and operations of the separation claw <NUM>.

The winding roller <NUM> includes a roller <NUM> and a movable sheet gripper <NUM> disposed on the roller <NUM> to grip the lamination sheet S. The movable sheet gripper <NUM> grips an end of the lamination sheet S together with the roller <NUM>. The sheet gripper <NUM> may be integral with the outer circumference of the roller <NUM> or may be a separate component. The controller <NUM> controls a driver to move the sheet gripper <NUM>.

With reference to <FIG>, a description is given of a series of processes of the sheet processing apparatus <NUM>, that is, operations from separation of the lamination sheet S to insertion of the insertion sheet P. The controller <NUM> controls the series of processes to perform the operations. In <FIG>, elements identical to those illustrated in <FIG> are given identical reference numerals, and the descriptions thereof are omitted.

In <FIG>, the lamination sheets S are stacked on the sheet tray <NUM> such that the bonded side is on the downstream side in the direction of feeding (that is, the conveyance direction) of the pickup roller <NUM>. In the sheet processing apparatus <NUM>, the pickup roller <NUM> picks up the lamination sheet S from the sheet tray <NUM>, and the conveyance roller pair <NUM> conveys the lamination sheet S toward the entrance roller pair <NUM>.

Next, as illustrated in <FIG>, the entrance roller pair <NUM> conveys the lamination sheet S toward the winding roller <NUM>. In the sheet processing apparatus <NUM>, the entrance roller pair <NUM> conveys the lamination sheet S with the bonded end (the bonded end is one of four sides) on the downstream side in the forward conveyance direction indicated by arrow A (direction A).

Subsequently, as illustrated in <FIG>, the controller <NUM> in the sheet processing apparatus <NUM> temporarily stops conveyance of the lamination sheet S after the rear end of the lamination sheet S in the forward conveyance direction passes the winding roller <NUM>. That is, the controller <NUM> receives a trigger signal from the sheet sensor C3 when the sheet sensor C3 detects the leading end of the lamination sheet S and controls the rotations of the entrance roller pair <NUM> and the exit roller pair <NUM> to convey the lamination sheet S by a designated amount from the sheet sensor C3.

Next, as illustrated in <FIG>, the controller <NUM> in the sheet processing apparatus <NUM> controls the driver to open the sheet gripper <NUM>, reverse the rotation direction of the exit roller pair <NUM>, and convey the lamination sheet S in the reverse conveyance direction (direction B) toward the opened sheet gripper <NUM>.

Subsequently, as illustrated in <FIG>, the controller <NUM> in the sheet processing apparatus <NUM> controls the rotations of the exit roller pair <NUM> to temporarily stop conveyance of the lamination sheet S when the end of the lamination sheet S is inserted in the sheet gripper <NUM> and controls the driver to close the sheet gripper <NUM> to grip the end of the lamination sheet S. After the exit roller pair <NUM> conveys the lamination sheet S by a designated amount, the controller <NUM> performs the above-described action.

Then, as illustrated in <FIG>, the controller <NUM> in the sheet processing apparatus <NUM> controls the driver to rotate the winding roller <NUM> counterclockwise in the drawings and wind the lamination sheet S around the winding roller <NUM>. The lamination sheet S is wound around the winding roller <NUM> from the side where the two overlapping sheets of the lamination sheet S are not bonded.

As illustrated in <FIG>, when the lamination sheet S that is the two-ply sheet is wound around the winding roller <NUM>, a winding circumferential length difference is created between the two sheets in the amount of winding of the lamination sheet S around circumference of the winding roller <NUM>. There is a surplus of the inner ply, which becomes loose toward the bonded end. As a result, a space is created between the two sheets constructing the two-ply sheet. As inserting the separation claws <NUM> are inserted into the generated space from both sides of the lamination sheet S, the space between the two sheets can be reliably maintained. The controller <NUM> receives a trigger signal from the sheet sensor C5 when the sheet sensor C5 detects the end of the lamination sheet S and controls the driver to perform the above-described operations when the exit roller pair <NUM> conveys the lamination sheet S by a designated amount from the sheet sensor C5.

The following describes the separation claws <NUM>.

<FIG> is a schematic view of the separation claw <NUM> of the sheet processing apparatus <NUM>. <FIG> are schematic views illustrating an example of a drive configuration of the separation claw <NUM>. Further, <FIG> is a perspective view illustrating a state in which the separation claw <NUM> is inserted in the lamination sheet S.

As illustrated in <FIG>, when viewed from the upstream side in the conveyance direction, the height of the separation claw <NUM> gradually increases from the center in the width direction to the right end in <FIG>. Further, when viewed in the height direction, the size of the separation claw <NUM> in the conveyance direction gradually increase from the tip to the center. When viewed in the width direction, the separation claw <NUM> is shaped like a cross.

Further, in the present embodiment, referring to <FIG>, the two separation claws <NUM> are disposed facing each other and moved in the approaching direction and the moving away direction by a belt drive mechanism as illustrated in <FIG>, a rack and pinion mechanism illustrated in <FIG>, or the like.

As described above, in the present embodiment, the pair of separation claws <NUM> having the above-mentioned shape is movable in the width direction of the lamination sheet S. Accordingly, the separation claws <NUM> can be smoothly inserted into the gap created in the lamination sheet S as illustrated in <FIG>.

A description of the operation of the sheet processing apparatus <NUM> is continued below. With the separation claws <NUM> inserted in the space in the lamination sheet S, the controller <NUM> in the sheet processing apparatus <NUM> controls the driver to rotate the winding roller <NUM> clockwise in the drawings (see <FIG>). After the winding roller <NUM> is rotated by a predetermined amount, the controller <NUM> controls the driver to open the sheet gripper <NUM>. The space in the lamination sheet S moves to the rear end of the lamination sheet S in the forward conveyance direction (direction A) as illustrated in <FIG>. As a result, the end portion of the lamination sheet S is separated into the upper and lower sheets.

In this state, the controller <NUM> in the sheet processing apparatus <NUM> controls the driver to temporarily stop the conveyance of the lamination sheet S and further move the separation claws <NUM> in the sheet width direction to separate the rear end of the lamination sheet S in the entire range. The controller <NUM> uses the trigger signal from the sheet sensor C5 when the sheet sensor C5 detects the end of the lamination sheet S and controls the driver to perform the above-described operations when the exit roller pair <NUM> conveys the lamination sheet S by a designated amount from the sheet sensor C5.

<FIG> is a perspective view illustrating a state of the separation claws <NUM> and the lamination sheet S in <FIG>. Since the separation claw <NUM> also has the function of the bifurcating claw that guides the separated sheets of the lamination sheet S in different directions due to the above-described shape (see <FIG>), the two separated sheets of the lamination sheet S can be kept in postures to be conveyed to different paths.

Further, since the separation claws <NUM> are movable in the width direction (see <FIG>), the separation claws <NUM> can be positioned suitably to support the postures of the sheets of the lamination sheet S as illustrated in <FIG>. Therefore, even when the size of the lamination sheet S and the rigidity (or retentivity meaning the propensity to retain a particular shape once applied, such as curvature of paper) change, the separated sheets of the lamination sheet S can be guided in desired branching directions. This eliminates the need for a bifurcating member (e.g., a bifurcating claw) over the entire width of the conveyance passage and a driver to drive the bifurcating member, and the cost can be reduced.

Next, after the separation claws <NUM> separate the rear end of the lamination sheet S in the entire range, as illustrated in <FIG>, the controller <NUM> in the sheet processing apparatus <NUM> controls the driver to rotate the exit roller pair <NUM> counterclockwise in <FIG> and convey the lamination sheet S in the reverse conveyance direction (direction B). Then, the separation claws <NUM> guide the two separated sheets of the lamination sheet S in the upper and lower directions, respectively, and the sheets are fully separated.

Then, the controller <NUM> in the sheet processing apparatus <NUM> controls the driver to temporarily stop the conveyance of the lamination sheet S, with the bonded portion of the lamination sheet S held (nipped) in the exit roller pair <NUM>. Accordingly, the lamination sheet S has the bonded side as one end and widely opens the other end.

The controller <NUM> uses the trigger signal from the sheet sensor C5 when the sheet sensor C5 detects the end of the lamination sheet S and controls the driver to perform the above-described operations when the exit roller pair <NUM> conveys the lamination sheet S by a designated amount from the sheet sensor C5.

Referring to <FIG>, and <FIG>, a description is given of modifications of the guide routes of the two separated piles (the upper and lower sheets) of the lamination sheet S.

<FIG> illustrates the above-described routes (see <FIG>) for guiding the upper and lower sheets in the same direction from the bonded portion of the lamination sheet S. Alternatively, the upper and lower sheets may be guided in opposite directions. For example, as illustrated in <FIG>, the routes may be in an inverted S-shape. Alternatively, as illustrated in <FIG>, the routes may be in an S-shape.

A description is provided of an advantageous configuration of the present disclosure.

The sheet processing apparatus <NUM> of the present embodiment inserts one to a plurality of insertion sheets P into the sheet S depending on the size of the sheet S (that is the length of the sheet S in the conveyance direction) and the size of the insertion sheet P (that is the length of the insertion sheet P in the conveyance direction). Firstly, a single insertion mode is described, and next, a multiple insertion mode is described. In the single insertion mode, the sheet processing apparatus <NUM> inserts the one insertion sheet P into the lamination sheet S. In the multiple insertion mode, the sheet processing apparatus <NUM> inserts a plurality of insertion sheets P into the lamination sheet S along the conveyance direction.

In the single insertion mode, as illustrated in <FIG>, the controller <NUM> in the sheet processing apparatus <NUM> controls rotations of the entrance roller pair <NUM> to convey the insertion sheet P conveyed from the sheet feeding tray <NUM> (see <FIG>) toward the exit roller pair <NUM> in the forward conveyance direction in the direction A.

Subsequently, as illustrated in <FIG>, the controller <NUM> in the sheet processing apparatus <NUM> controls rotations of the exit roller pair <NUM> so that the lamination sheet S and the insertion sheet P converge to insert the insertion sheet P into the opened lamination sheet S.

As illustrated in <FIG>, the exit roller pair <NUM> in the sheet processing apparatus <NUM> conveys the lamination sheet S, with the insertion sheet P inserted therein, in the forward conveyance direction (direction A), thereby overlaying the two sheets one on another again and closing the opening. A roller disposed downstream from the exit roller pair <NUM> ejects and stacks the lamination sheet S sandwiching the insertion sheet P onto the output tray <NUM> (<FIG>).

Next, the multiple insertion mode is described. In the multiple insertion mode, a plurality of insertion sheets P (two sheets in the following embodiment) are arranged and inserted in the conveyance direction.

As illustrated in <FIG>, the controller <NUM> in the sheet processing apparatus <NUM> controls the rotations of the entrance roller pair <NUM> to convey a first insertion sheet (hereinafter referred to as a first insertion sheet P1) conveyed from the sheet feeding tray <NUM> (see <FIG>) toward the exit roller pair <NUM> in the forward conveyance direction in the direction A.

Subsequently, as illustrated in <FIG>, the controller <NUM> in the sheet processing apparatus <NUM> controls the rotations of the exit roller pair <NUM> so that the lamination sheet S and the first insertion sheet P1 converge to insert the first insertion sheet P1 into the opened lamination sheet S. At this time, the controller <NUM> controls the driver to rotate the pickup roller <NUM> and convey the second insertion sheet (hereinafter referred to as a second insertion sheet P2) from the sheet feeding tray <NUM> (see <FIG>) toward the exit roller pair <NUM> in the forward conveyance direction (the direction A).

Subsequently, as illustrated in <FIG>, the controller <NUM> in the sheet processing apparatus <NUM> controls the rotations of the entrance roller pair <NUM> so that the lamination sheet S and the second insertion sheet P2 converge to insert the second insertion sheet P2 into the opened lamination sheet S.

As illustrated in <FIG>, the exit roller pair <NUM> in the sheet processing apparatus <NUM> conveys the lamination sheet S, with the first and second insertion sheets P1 and P2 inserted therein, in the forward conveyance direction (direction A), thereby overlaying the two sheets one on another again and closing the opening.

Even if there are three or more insertion sheets, the insertions sheets can be sandwiched by substantially the same operations.

As an alternative example, in the case of a sheet processing apparatus including a heat and pressure device capable of heating and pressurizing the lamination sheet S, as illustrated in <FIG>, the route is switched with a bifurcating claw <NUM> to forward the lamination sheet S to the heat and pressure device. Not only in the multiple insertion mode but also in the single insertion mode, the route may be switched with the bifurcating claw <NUM> similarly.

As described above, the controller <NUM> in the sheet processing apparatus <NUM> according to the present embodiment can control the driver and other parts to perform insertion processing to insert the insertion sheet P into the lamination sheet S.

The following describes a configuration in which the controller <NUM> in the sheet processing apparatus <NUM> acquires the size of the lamination sheet S, the size of the insertion sheet P, which are lengths in the conveyance direction of the sheet S and the insertion sheets P, and the number of the insertion sheets P to be sandwiched.

As illustrated in <FIG>, the sheet processing apparatus <NUM> according to the present embodiment includes the sheet size sensor C6 serving as a size detector for the sheet and the sheet size sensor C7 serving as the size detector for the medium. Based on the detection results of the sheet size sensors C6 and C7, the controller <NUM> in the sheet processing apparatus <NUM> determines whether the length of the insertion sheet P in the conveyance direction is equal to or smaller than a threshold value. When the length of the insertion sheet P in the conveyance direction is equal to or smaller than the threshold value, the controller <NUM> automatically switches to the multiple insertion mode and performs the insertion processing. In contrast, when the length of the insertion sheet P in the conveyance direction is larger than the threshold value, the controller <NUM> automatically switches to the single sheet insertion mode and performs the insertion processing.

In particular, when the length of the insertion sheet P in the conveyance direction is equal to or less than half the length of the lamination sheet S in the conveyance direction, the controller <NUM> may automatically switch to the multiple insertion mode and perform the insertion processing. In the multiple insertion mode, the controller <NUM> determines the number of insertion sheets P sandwiched in the lamination sheet S from the quotient of the size of the lamination sheet S divided by the size of insertion sheet P.

Instead of or in addition to the detection results of the sheet size sensors C6 and C7, the controller <NUM> may use the detection results of the sheet sensors C1 and C2.

As described above, the controller <NUM> in the sheet processing apparatus <NUM> according to the present embodiment can automatically control the insertion processing according to the sizes of the lamination sheet S and the insertion sheet P.

The following describes a configuration for the user to input data and select the insertion modes. <FIG> are views illustrating examples of an operation screen to set a lamination sheet size, an insertion sheet size, and a number of the lamination sheets that are displayed on a control panel of the sheet processing apparatus illustrated in <FIG>.

As illustrated in <FIG>, the sheet processing apparatus <NUM> according to the present embodiment accepts selecting and inputting the size of the lamination sheet S (lamination film), the size of the insertion sheet P, and the number of the insertion sheets P sandwiched, which are performed by the user by touching the screen on the control panel <NUM>.

However, when the sum of the lengths of the insertion sheets P in the conveyance direction is equal to or larger than the length of the lamination sheet S in the conveyance direction, the controller <NUM> in the sheet processing apparatus <NUM> determines that the input data are wrong. As illustrated in <FIG>, the controller <NUM> controls the control panel <NUM> to display an error message and prompt the user to select and input the sizes or the number described above again.

Specifically, the controller <NUM> controls the control panel <NUM> to accept the data input by the user when the following size condition is satisfied, that is, L1 ≥ L2 × n where L1 is the length of the lamination sheet S in the conveyance direction, L2 is the length of the insertion sheet P in the conveyance direction, and n is the number of the insertion sheets sandwiched by the lamination sheet S.

After the controller <NUM> in the sheet processing apparatus <NUM> accept the data, the controller <NUM> performs the insertion processing to insert the insertion sheet P into the sheet S.

On the other hand, if L1 < L2 × n, the controller <NUM> controls the control panel <NUM> to notify the user a message, that is, display the error message and prompt the user to select and input the sizes or the number again.

In this way, the user can select either the single insertion mode to insert the one insertion sheet P into the lamination sheet S or the multiple insertion mode to insert the multiple insertion sheets into the lamination sheet S on the control panel <NUM>.

Alternatively, the controller <NUM> in the sheet processing apparatus <NUM> may automatically perform the insertion processing based on the above size condition.

As described above, the controller <NUM> in the sheet processing apparatus <NUM> according to the present embodiment controls the driver and other parts to perform the insertion processing to insert the insertion sheet P into the lamination sheet S based on the length of the lamination sheet S in the conveyance direction, the length of the insertion sheet P in the conveyance direction, and the number of the insertion sheets P. As a result, the sheet processing apparatus <NUM> can automatically and suitably insert one or a plurality of insertion sheets P into the lamination sheet S.

In addition, since the configuration of the sheet processing apparatus <NUM> is simpler than a laminator using a vacuum device, the entire sheet processing apparatus can be simple and compact.

Additionally, as illustrated in <FIG>, the sheet processing apparatus <NUM> according to the present embodiment can store the lamination sheets S and insertion sheets P on separate trays to be conveyed separately. Accordingly, it is not necessary to stack the lamination sheets S and the insertion sheets P in a predetermined order, for added convenience. In the present embodiment, the lamination sheets S are stacked on the sheet tray <NUM>, and the insertion sheets P are stacked on the sheet feeding tray <NUM>. However, where to stack the lamination sheets S and the insertion sheets P are not limited thereto. Alternatively, the insertion sheet P can be stacked on the sheet tray <NUM> and the lamination sheet S can be stacked on the sheet feeding tray <NUM>.

Next, descriptions are given of a laminator, an image forming apparatus, and an image forming system including the sheet processing apparatus according to any of embodiments of the present disclosure.

<FIG> is a view illustrating an example of general arrangement of the laminator including the sheet processing apparatus according to one embodiment of the present disclosure. As illustrated in <FIG>, a laminator <NUM> includes the sheet processing apparatus <NUM> described above, the bifurcating claw <NUM> to switch the conveyance route of the lamination sheet S, heat and pressure rollers <NUM> as a heat and pressure rotator to heat and press the lamination sheet S, and an ejection roller <NUM> disposed downstream from the heat and pressure rollers <NUM>.

The laminator <NUM> can perform a series of operations from feeding and separation of the lamination sheet S, insertion of the insertion sheet P, and lamination with heat and pressure on a stand-alone basis. This series of operations can be carried out automatically without human intervention, and convenience can be improved.

<FIG> is a view illustrating an example of an image forming system including an image forming apparatus and the laminator according to one embodiment of the present disclosure. An image forming system <NUM> includes an image forming apparatus <NUM> including a laminator 200a to perform a laminating process.

The laminator 200a includes the sheet tray <NUM> on which lamination sheets S or insertion sheets P are stacked. Additionally, the laminator 200a can receive at least one of the lamination sheets S and the insertion sheets P fed from the image forming apparatus <NUM>. Therefore, an image can be added in-line on the lamination sheet S or the insertion sheet P by the image forming apparatus <NUM> (for example, a printer or a copier).

The configuration of the image forming apparatus <NUM> is described in detail. As illustrated in <FIG>, an intermediate transfer device <NUM> is disposed in the main body of the image forming apparatus <NUM>. The intermediate transfer device <NUM> includes an endless intermediate transfer belt <NUM> entrained around a plurality of rollers and stretched almost horizontally. The intermediate transfer belt <NUM> rotates counterclockwise in the drawing.

Below the intermediate transfer device <NUM>, image forming devices 154c, <NUM>, 154y, and <NUM> for yellow (Y), magenta (M), cyan (C), and black (K) are arranged in a quadruple tandem manner along an extended direction of the intermediate transfer belt <NUM>. Each of the image forming devices 154c, <NUM>, 154y, and <NUM> includes a drum-shaped image bearer that rotates clockwise in the drawing. Around the image bearer, a charging device, a developing device, a transfer device, and a cleaning device are disposed. Below each image forming device <NUM>, an exposure device <NUM> is disposed.

Below the exposure device <NUM>, a sheet feeder <NUM> is disposed. The sheet feeder <NUM> includes a first sheet feeding tray <NUM> that stores lamination sheets S and a second sheet feeding tray <NUM> that stores insertion sheets P. The first sheet feeding tray <NUM> is an example of a third tray on which two-ply sheets are stacked, and the second sheet feeding tray <NUM> is an example of a fourth tray on which sheet media (insertion sheets) are stacked.

A first sheet feeding roller <NUM> is disposed at the upper right of the first sheet feeding tray <NUM> and feeds the lamination sheets S from the first sheet feeding tray <NUM> one by one to a sheet feeding passage <NUM>. A second sheet feeding roller <NUM> is disposed at the upper right of the second sheet feeding tray <NUM> and feeds the insertion sheets P from the second sheet feeding tray <NUM> one by one to the sheet feeding passage <NUM>.

The sheet feeding passage <NUM> extends from the lower side to the upper side on the right side in the main body of the image forming apparatus <NUM> and communicates with the laminator 200a inside the image forming apparatus <NUM>. The sheet feeding passage <NUM> is provided with a conveyance roller <NUM>, a secondary transfer device <NUM> disposed opposite the intermediate transfer belt <NUM>, a fixing device <NUM>, a sheet ejection device <NUM> including an ejection roller pair, and the like in order.

The first sheet feeding roller <NUM>, the conveyance roller <NUM>, and the sheet feeding passage <NUM> are examples of a third feeder to feed the two-ply sheet from the first sheet feeding tray <NUM> (the third tray). The second sheet feeding roller <NUM>, the conveyance roller <NUM>, and the sheet feeding passage <NUM> are examples of a fourth feeder to feed a sheet medium from the second sheet feeding tray <NUM> (the fourth tray). The intermediate transfer device <NUM>, the fixing device <NUM>, and the like are examples of an image forming device that forms an image on a two-ply sheet or a sheet medium.

Next, a description is given of operations of the image forming system <NUM> to form an image on the lamination sheet S and then perform lamination according to the present embodiment.

To form an image on the lamination sheet S, first, an image reading device <NUM> reads a document image, and the exposure device <NUM> performs image writing. Next, the image forming devices 154c, <NUM>, 154y, and <NUM> form respective color toner images on the image bearers thereof. Then, primary transfer devices 180c, <NUM>, 180y, and <NUM> sequentially transfer the toner images onto the intermediate transfer belt <NUM>, thereby forming a color image formed thereon.

By contrast, the image forming apparatus <NUM> rotates the first sheet feeding roller <NUM> to feed the lamination sheet S to the sheet feeding passage <NUM>. Then, the lamination sheet S is conveyed by the conveyance roller <NUM> through the sheet feeding passage <NUM> and sent to a secondary transfer position, timed to coincide with the color image on the intermediate transfer belt <NUM>. Then, the secondary transfer device <NUM> transfers the color image formed on the intermediate transfer belt <NUM> as described above onto the lamination sheet S.

After the image transfer, the fixing device <NUM> fixes the image on the lamination sheet S, and the sheet ejection device <NUM> sends the lamination sheet S to the laminator 200a.

Further, the image forming apparatus <NUM> rotates the second sheet feeding roller <NUM> to feed the insertion sheet P to the sheet feeding passage <NUM>, and the sheet ejection device <NUM> sends the insertion sheet P to the laminator 200a.

In this way, the lamination sheet S on which the image has been formed and the insertion sheet P are sent to the laminator 200a, and the laminating process is performed. The details of the laminating process have been described above and redundant descriptions are omitted.

With the above-described configuration, the image forming system <NUM> according to the present embodiment can perform the laminating process with the laminator 200a after image formation on the insertion sheet P. In addition, the image forming system <NUM> can perform the laminating process after image formation on both the insertion sheet P and the lamination sheet S.

Next, descriptions are given of an image forming apparatus and an image forming system including the sheet processing apparatus, according to a modification of the above-described embodiment.

<FIG> is a view illustrating a modified configuration of the image forming system including the image forming apparatus and the laminator according to the above-described embodiment. Differently from the image forming system <NUM> illustrated in <FIG>, an image forming system <NUM> includes an image forming apparatus <NUM> including an ejection roller pair <NUM> and an output tray <NUM>.

When the laminating process is not performed, the image forming apparatus <NUM> can eject the recording medium on which the image is formed using the ejection roller pair <NUM> of the main body to the output tray <NUM> of the main body. Therefore, the image forming apparatus <NUM> does not slow the image output speed when the laminating process is not performed.

The laminator 200a can be removably installed in the image forming apparatus <NUM>. That is, when the laminating process is unnecessary, the laminator 200a can be removed from the image forming apparatus <NUM>.

In addition, in the laminator 200a thus removed, the sheet feeding tray <NUM> on which the insertion sheets P are stacked and the pickup roller <NUM> to feed the insertion sheets P from the sheet feeding tray <NUM> can be mounted, so that the laminator 200a is used as a stand-alone machine similar to that illustrated in <FIG>.

The image forming apparatus <NUM> illustrated in <FIG> and the image forming apparatus <NUM> illustrated in <FIG> may include a sheet processing apparatus instead of the laminator. The image forming apparatus <NUM> illustrated in <FIG> may include a sheet processing apparatus that is removably attached thereto.

Further, aspects of this disclosure can be embodied as an image forming system that includes an image forming apparatus and the sheet processing apparatus <NUM> or the laminator <NUM> detachably coupled to the image forming apparatus. Furthermore, aspects of this disclosure can be embodied as a system including at least one of a sheet feeder (a stacker) and a case binding device or the like. Note that, in the case where the lamination sheet S is passed through the fixing device <NUM>, the lamination sheet S is not bonded at the fixing temperature but is bonded by application of heat higher than the fixing temperature.

Although the image forming apparatuses <NUM> and <NUM> employ electrophotography for image formation on the lamination sheet S and the insertion sheet in the description above, the image formation method is not limited thereto, and inkjet, stencil printing, or other printing method can be used.

<FIG> configured by <FIG>, <FIG>, and <FIG> is a flowchart illustrating a series of processes from sheet feeding to insertion of the insertion sheet and completion of the laminating process. The description below proceeds while indicating the reference numerals indicated in the flowchart.

First, in step S01, the controller <NUM> in the sheet processing apparatus <NUM> determines whether the user has selected the multiple insertion mode. When the user selects the multiple insertion mode, the controller <NUM> requests the user inputting the number of insertion sheets in step S02.

That is, the controller <NUM> controls the control panel <NUM> to display the operation screen as illustrated in <FIG> and request the user setting a lamination film size, the insertion sheet size, and the number of the insertion sheets to be sandwiched.

On the other hand, when the controller <NUM> determines that the user does not select the multiple insertion mode, the controller <NUM> in the sheet processing apparatus <NUM> performs step S03, that is, determines that the user select the single insertion mode.

Next, in step S11, the controller <NUM> in the sheet processing apparatus <NUM> controls the driver to start feeding the lamination sheet S (see <FIG>). In step S12, the controller <NUM> determines whether the end of the lamination sheet S has arrived at the sheet sensor C3 based on outputs from the sheet sensor C3 (see <FIG>). In step S13, the controller <NUM> determines whether the lamination sheet S has been conveyed by the designated amount from the sheet sensor C3, that is, whether a designated time has passed since the sheet sensor C3 detects the end of the lamination sheet S. In response to a determination that the lamination sheet S has been conveyed by the designated amount from the sheet sensor C3 (Yes in step S13), the controller <NUM> in the sheet processing apparatus <NUM> controls the driver to temporarily stop the sheet conveyance (see <FIG>). For example, the "designated amount" used here and those in subsequent processes are stored in a memory by a manufacturer based on empirical data. Subsequently, the controller <NUM> controls the driver to open the sheet gripper <NUM> in step S14 and convey the lamination sheet S in the reverse conveyance direction in step S15 (see <FIG>).

In step S16, the controller <NUM> in the sheet processing apparatus <NUM> determines whether the lamination sheet S has been conveyed by a designated amount. In response to a determination that the lamination sheet S has been conveyed by the designated amount (Yes in step S16), the controller <NUM> controls the driver to temporarily stop the sheet conveyance in step S17. In step S18, the controller <NUM> controls the driver to close the sheet gripper <NUM> to grip the end of the lamination sheet S (see <FIG>).

In step S19, the controller <NUM> in the sheet processing apparatus <NUM> controls the driver to rotate the winding roller <NUM> counterclockwise (in reverse) and wind the lamination sheet S around the winding roller <NUM> (see <FIG>). In step S20, the controller <NUM> determines whether the leading end of the lamination sheet S has arrived at the sheet sensor C5. In step S21, the controller <NUM> in the sheet processing apparatus <NUM> determines whether the lamination sheet S is conveyed by the designated amount from the sheet sensor C5. In response to a determination that the lamination sheet S has been conveyed by the designated amount from the sheet sensor C5 (Yes in step S21), the controller <NUM> determines whether the state of the lamination sheet S is normal using detection results of the abnormality detector C4 in step S22.

The abnormality detector C4 detects the size of the gap between the two sheets of the lamination sheet S for the sheet processing apparatus <NUM> to determine whether or not the size of the gap exceeds a threshold. In step S23, the controller <NUM> in the sheet processing apparatus <NUM> determines whether the state of the lamination sheet is normal, that is, whether the size of the gap is equal to or greater than the threshold based on the detection result of the abnormality detector C4. In response to a determination that the state of the lamination sheet S is normal, the controller <NUM> proceeds to step S24a.

On the other hand, in response to a determination in step S23 that the state of the lamination sheet S is abnormal (the size of the gap is smaller than the threshold), the controller <NUM> in the sheet processing apparatus <NUM> controls the control panel <NUM> to display the abnormality (e.g., displays an error message) and stops the sheet processing (a job) in step S24b.

In step S24a, the controller <NUM> in the sheet processing apparatus <NUM> controls the driver to insert, from both sides, the separation claws <NUM> into the gap between the sheets of the lamination sheet S (see <FIG>). In step S25, the controller <NUM> in the sheet processing apparatus <NUM> controls the driver to rotate the winding roller <NUM> clockwise (forward direction) with the separation claws <NUM> inserted from both sides of the lamination sheet S, and convey the lamination sheet S in the forward conveyance direction.

In step S26, the controller <NUM> determines whether the leading end of the lamination sheet S has arrived at the sheet sensor C5. In response to a determination that the lamination sheet S has been conveyed by the designated amount from the sheet sensor C5 (Yes in S27), the controller <NUM> in the sheet processing apparatus <NUM> controls the driver to open the sheet gripper <NUM> in step S28.

In step S29, the controller <NUM> in the sheet processing apparatus <NUM> controls the driver to temporarily stop the conveyance of the lamination sheet S and, in step S30, move the separation claws <NUM> further in the sheet width direction (see <FIG>). As a result, the rear end portion of the lamination sheet S in the forward conveyance direction is separated into the upper and lower sheets.

In step S31, the controller <NUM> in the sheet processing apparatus <NUM> controls the driver to convey the lamination sheet S in the reverse conveyance direction. In step S32, the controller <NUM> determines whether the leading end of the lamination sheet S in the forward conveyance direction has arrived at the sheet sensor C5. In step S33, the controller <NUM> in the sheet processing apparatus <NUM> determines whether the lamination sheet S is conveyed by the designated amount after the sheet sensor C5 detects the leading end of the lamination sheet S. In response to a determination that the lamination sheet S has been conveyed by the designated amount from the sheet sensor C5 (Yes in step S33), the controller <NUM> suspends the sheet conveyance in step S34 (see <FIG>). As a result, the separation of the lamination sheet S is completed.

Subsequently, in step S35, the controller <NUM> in the sheet processing apparatus <NUM> determines whether or not to perform image formation (with an in-line image forming apparatus) on the insertion sheet P to be inserted into the lamination sheet S. In the case of in-line image formation (Yes in step S35), the controller <NUM> in the sheet processing apparatus <NUM> sends a signal to the in-line image forming apparatus to start a print job to form an image on the insertion sheet P in step S36. Then, the controller <NUM> proceeds to step S37.

On the other hand, when in-line image formation is not performed (No in step S35), the controller <NUM> proceeds to step S37.

In step S37, the controller <NUM> in the sheet processing apparatus <NUM> controls the driver to convey the insertion sheet P in the forward conveyance direction to be inserted in the opening of the lamination sheet S. In step S37, when the controller <NUM> performs the single insertion mode, the sheet processing apparatus <NUM> performs operations as illustrated in <FIG>, and when the controller <NUM> performs the multiple insertion mode, the sheet processing apparatus <NUM> performs operations as illustrated in <FIG>.

In step S38, the controller <NUM> in the sheet processing apparatus <NUM> determines whether the selected number of insertion sheets P are inserted into the lamination sheet S. After the insertion sheets P are inserted, the controller <NUM> proceeds to step S39.

In step S39, the controller <NUM> controls the driver to rotate the bifurcating claw <NUM> to switch the route. In step S40, the lamination sheet S sandwiching the insertion sheet P is conveyed to the heat and pressure device and heated and pressed to complete the lamination process (see <FIG>).

In the case of in-line image formation (Yes in step S35), the controller <NUM> sends the image forming apparatus the signal to start the print job after the sheet processing apparatus <NUM> completes separating the lamination sheet S, and the image forming apparatus prints an image on the insertion sheet P and conveys the insertion sheet P to the sheet processing apparatus. In this case, the sheet processing apparatus waits until the printed insertion sheet P is conveyed and reaches the sheet sensor C1. The controller <NUM> may send the image forming apparatus the signal to start the print job in advance based on a time to convey the printed insertion sheet P, for example, after the separation claws <NUM> completes operations illustrated in <FIG>. This can improve productivity.

<FIG> configured by <FIG>, <FIG>, and <FIG> is another flowchart illustrating a series of processes from sheet feeding to insertion of the insertion sheet and completion of the laminating process. The description below proceeds while indicating the reference numerals indicated in the flowchart.

First, in step S01a, the controller <NUM> in the sheet processing apparatus <NUM> obtains the length of the lamination sheet S and the length of the insertion sheet P in the conveyance direction from the size detector for the sheet and the size detector for the medium. The controller <NUM> determines whether the length of the insertion sheet P in the conveyance direction is equal to or smaller than half the length of the lamination sheet S in the conveyance direction.

In response to a determination that the length of the insertion sheet P in the conveyance direction is equal to or smaller than half the length of the lamination sheet S in the conveyance direction (Yes in step S01a), the controller <NUM> in the sheet processing apparatus <NUM> starts the multiple insertion mode in step S02a. In step S03a, the controller <NUM> calculates the number of insertion sheets P from the quotient of the size of the lamination sheet S and the size of the insertion sheet P.

On the other hand, in response to a determination that the length of the insertion sheet P in the conveyance direction is larger than half the length of the lamination sheet S in the conveyance direction (No in step S01a), the controller <NUM> in the sheet processing apparatus <NUM> starts the single insertion mode.

Since subsequent steps from step S11 are the same as that in the flowchart of <FIG>, the description thereof is omitted.

The following describes another aspect of the present disclosure.

The sheet processing apparatus <NUM> of the present embodiment is characterized in that the relative position of the insertion sheet P with respect to the lamination sheet S can be adjusted.

Specifically, when the first insertion sheet is inserted into the lamination sheet S, the controller <NUM> may perform four types of positioning control. A first positioning control uses abutting the insertion sheet to the bonded portion of the lamination sheet S (<FIG>). A second positioning control uses adjusting a protruding amount of the lamination sheet S from the nip of the exit roller pair <NUM> (<FIG>). A third positioning control uses adjusting the linear velocity difference in conveyance of the insertion sheet and the lamination sheet (<FIG>). A fourth positioning control uses a control of the merging timing (<FIG>).

The following describes each positioning control in the above-described order.

In the first positioning control, the insertion sheet P1 is abutted to the bonded portion of the lamination sheet S. As illustrated in <FIG>, when the insertion sheet P1 and the lamination sheet S converge in the sheet processing apparatus <NUM>, the exit roller pair <NUM> nips the bonded portion of the lamination sheet S opening toward the conveyance direction of the insertion sheet P1. In the above-described state, abutting the insertion sheet P1 to the bonded portion of the lamination sheet S positions the insertion sheet P1.

In the second positioning control, the controller <NUM> adjusts the protruding amount of the lamination sheet S from the nip of the exit roller pair <NUM>. As illustrated in <FIG>, the controller <NUM> in the sheet processing apparatus <NUM> controls the driver to rotate the exit roller pair <NUM> and cause the leading end of the lamination sheet S in the conveyance direction to protrude from the nip of the exit roller pair <NUM> by the protruding amount L. The controller <NUM> can adjust the protruding amount L based on detection results of the sheet sensor C5. Abutting the insertion sheet P1 to the nip of the exit roller pair <NUM> positions the insertion sheet P1 with respect to the lamination sheet S.

The above-described control can arbitrarily adjust a distance between the leading end of the lamination sheet S in the conveyance direction and the leading end of the insertion sheet P1 in the conveyance direction and adjust the relative position between the lamination sheet S and the insertion sheet P1. In addition, abutting the insertion sheet P1 to the nip of the exit roller pair <NUM> can correct an inclination of the insertion sheet P1.

In the third positioning control, the controller <NUM> adjusts a linear velocity difference between the exit roller pair <NUM> and the entrance roller pair <NUM>. As illustrated in <FIG>, after the separation of the lamination sheet S is completed, the controller <NUM> in the sheet processing apparatus <NUM> controls the drivers to set the linear speed V1 of the exit roller pair <NUM> that holds and conveys the separated lamination sheet S smaller than the linear speed V2 of the entrance roller pair <NUM> that conveys the insertion sheet P1, that is, V1 < V2. Then, as illustrated in <FIG>, abutting the insertion sheet P1 to the nip of the exit roller pair <NUM> at a timing calculated so as to set a positional relation between the bonded portion of the lamination sheet S and the insertion sheet P1 positions the insertion sheet P1 with respect to the lamination sheet S.

The above control can adjust the relative position of the insertion sheet P1 with respect to the lamination sheet S and improve productivity because both the exit roller pair <NUM> and the entrance roller pair <NUM> do not stop.

In the fourth positioning control, the controller <NUM> controls a converge timing at which the insertion sheet P1 and the lamination sheet S converge. As illustrated in <FIG>, after the separation of the sheet S is completed, the controller <NUM> in the sheet processing apparatus <NUM> controls the converge timing at which the exit roller pair <NUM> holding the separated sheet S starts to convey the lamination sheet S so that the insertion sheet P1 and the lamination sheet S converge at a desired relative position.

That is, as illustrated in <FIG>, the controller <NUM> controls the rotations of the exit roller pair <NUM> to start conveying the lamination sheet S before the insertion sheet P1 reaches the nip of the exit roller pair <NUM>. Then, as illustrated in <FIG>, the controller <NUM> controls rotations of the exit roller pair <NUM> and the entrance roller pair <NUM> so that the insertion sheet P1 and the lamination sheet S converge at the converge timing at which the insertion sheet P1 is at a desired relative position with respect to the lamination sheet S.

The above-described control can adjust the relative position of the insertion sheet P1 with respect to the lamination sheet S without abutting the insertion sheet P1 to the nip of the exit roller pair <NUM> or the lamination sheet S.

Subsequently, when the second insertion sheet P2 is inserted into the lamination sheet S, the controller <NUM> may perform three types of positioning control. A first positioning control uses abutting the insertion sheet P2 to the nip of the exit roller pair (<FIG>). A second positioning control uses adjusting the linear velocity difference in conveyance of the insertion sheet P2 and the lamination sheet S (<FIG>). A third positioning control uses a control of the converge timing (<FIG>).

In the first positioning control, the controller <NUM> positions the insertion sheet P2 by abutting the insertion sheet P2 to the nip of the exit roller pair <NUM>. As illustrated in <FIG>, the controller <NUM> in the sheet processing apparatus <NUM> adjusts a distance L2 between the rear end of the first insertion sheet P1 and the leading end of the second insertion sheet P2 in the conveyance direction that is also referred to as the protruding amount L2 of the lamination sheet S from the nip of the exit roller pair <NUM> in the conveyance direction based on detection results of the sheet sensor C5. Abutting the insertion sheet P2 to the nip of the exit roller pair <NUM> positions the insertion sheet P2 with respect to the lamination sheet S.

In the second positioning control, the controller <NUM> adjusts the linear velocity difference between the exit roller pair <NUM> and the entrance roller pair <NUM>. As illustrated in <FIG>, after the separation of the lamination sheet S is completed, the controller <NUM> in the sheet processing apparatus <NUM> controls the drivers to set the linear velocity V1 of the exit roller pair <NUM> that holds and conveys the separated lamination sheet S smaller than the linear velocity V2 of the entrance roller pair <NUM> that conveys the insertion sheet P2, that is, V1 < V2. Then, as illustrated in <FIG>, abutting the insertion sheet P2 to the nip of the exit roller pair <NUM> at a timing calculated so as to set a positional relation between the rear end of the first insertion sheet S and the second insertion sheet P2 positions the insertion sheet P2 with respect to the lamination sheet S.

In the third positioning control, the controller <NUM> controls a converge timing at which the second insertion sheet P2 and the lamination sheet S converge. As illustrated in <FIG>, before the second insertion sheet P2 reaches the nip of the exit roller pair <NUM>, the controller <NUM> controls rotations of the exit roller pair <NUM> to convey the lamination sheet S sandwiching the first insertion sheet P1 toward the output tray <NUM>. Subsequently, as illustrated in <FIG>, the controller <NUM> controls rotations of the exit roller pair <NUM> and the entrance roller pair <NUM> so that the second insertion sheet P2 and the lamination sheet S converge at a converge timing at which the insertion sheet P2 is positioned with respect to the rear end of the first insertion sheet P1. The above-described control can adjust the relative position of the second insertion sheet P2 with respect to the lamination sheet S without abutting the second insertion sheet P2 to the nip of the exit roller pair <NUM> or the lamination sheet S.

After the second insertion sheet P2 is inserted into the lamination sheet S, the exit roller pair <NUM> nips and conveys the lamination sheet S sandwiching the second insertion sheet P2 as illustrated in <FIG>. Thus, the controller <NUM> completes the multiple insertion mode. The controller <NUM> is configured to be able to adjust setting of the relative positions of the insertion sheets within a range in which the rear end of the final insertion sheet P does not protrude from the rear end of the lamination sheet S.

<FIG> is an example of an operation screen for setting the relative positions of the insertion sheets displayed on the control panel of the sheet processing apparatus illustrated in <FIG>. As illustrated in <FIG>, the user can set a length a that is a distance between an end of the lamination sheet and a leading end of the insertion sheet and a length b that is a relative distance of the insertion sheets on the operation screen. The user can adjust the lengths when the total sum of the distance between the end of the lamination sheet and the leading end of the insertion sheet, the relative distance of the insertion sheets, and the sum of the lengths of the insertion sheets P in the conveyance direction is equal to or smaller than the length of the lamination sheet S in the conveyance direction.

However, when the above-described total sum is larger than the length of the lamination sheet S in the conveyance direction, the controller <NUM> in the sheet processing apparatus <NUM> determines that the input data are wrong, that is, abnormality. As illustrated in <FIG>, the controller <NUM> controls the control panel <NUM> to display an error message and prompt the user to select and input the lengths described above again.

As described above, the controller <NUM> in the sheet processing apparatus <NUM> according to the present embodiment controls the driver and other parts to perform the insertion processing to insert the insertion sheets P into the lamination sheet S based on the length of the lamination sheet S in the conveyance direction, the lengths of the insertion sheets P in the conveyance direction, and the number of the insertion sheets P. As a result, the relative position of the insertion sheet P2 with respect to the lamination sheet S is adjusted, and the sheet processing apparatus <NUM> can automatically insert one or a plurality of insertion sheets P into the lamination sheet S.

Next, with reference to a flowchart of <FIG>, a characteristic part of the present embodiment is described below. <FIG> corresponds to parts A and B in <FIG>. <FIG> omits control steps corresponding to a part other than the parts A and B in <FIG> because they are the same as the steps in <FIG>.

Firstly, a part in <FIG> corresponding to the part A in <FIG> is described. In step S01, the controller <NUM> in the sheet processing apparatus <NUM> determines whether the user has selected the multiple insertion mode. When the user selects the multiple insertion mode, the controller <NUM> requests the user inputting the number of insertion sheets in step S02.

Next, in step S04, the controller <NUM> controls the control panel <NUM> to display the operation screen as illustrated in <FIG> and requests the user inputting the length a that is the distance between the end of the lamination sheet and the leading end of the insertion sheet and the length b that is the relative distance of the insertion sheets.

In step S05, the controller <NUM> in the sheet processing apparatus <NUM> determines whether the total sum of the distance between the end of the lamination sheet and the leading end of the insertion sheet, the relative distance of the insertion sheets, and the sum of the lengths of the insertion sheets P in the conveyance direction is equal to or smaller than the length of the lamination sheet S in the conveyance direction. That is, the controller <NUM> determines whether the lamination sheet S can cover all insertion sheets. In response to a determination that the total sum of the distance between the end of the lamination sheet and the leading end of the insertion sheet, the relative distance of the insertion sheets, and the sum of the lengths of the insertion sheets P in the conveyance direction is equal to or smaller than the length of the lamination sheet S in the conveyance direction (Yes in step S05), the controller <NUM> starts feeding the lamination sheet S in step S11. On the other hand, in response to a determination that the total sum of the distance between the end of the lamination sheet and the leading end of the insertion sheet, the relative distance of the insertion sheets, and the sum of the lengths of the insertion sheets P in the conveyance direction is larger than the length of the lamination sheet S in the conveyance direction (No in step S05), the controller <NUM> in the sheet processing apparatus <NUM> controls the control panel <NUM> to display the error message as illustrated in <FIG> and returns to step S04 to request the user selecting and inputting the lengths described above.

In step S01, when the controller <NUM> determines that the user does not select the multiple insertion mode, the controller <NUM> in the sheet processing apparatus <NUM> performs step S03, that is, determines that the user select the single insertion mode. Next, in step S06, the controller <NUM> requests the user setting the length a that is the distance between the end of the lamination sheet and the leading end of the insertion sheet on the control panel <NUM>. Thereafter, the controller <NUM> starts feeding the lamination sheet S in step S11.

Next, a part in <FIG> corresponding to the part B in <FIG> is described. In step S31, the controller <NUM> in the sheet processing apparatus <NUM> controls the driver to convey the lamination sheet S in the reverse conveyance direction. In step S31a, the controller <NUM> determines whether the front end of the lamination sheet S in the reverse conveyance direction has arrived at the sheet sensor C4. Next, in step S31b, the controller <NUM> in the sheet processing apparatus <NUM> determines whether to stop the conveyance after conveying the bonded end of the lamination sheet S to the nip of the exit roller pair <NUM>.

When the controller <NUM> determines not stopping the conveyance (No in step S31b), the controller <NUM> in the sheet processing apparatus <NUM> determines whether the leading end of the lamination sheet S in the forward conveyance direction has arrived at the sheet sensor C5 in step S32. In step S33, the controller <NUM> in the sheet processing apparatus <NUM> determines whether the lamination sheet S is conveyed by the designated amount after the sheet sensor C5 detects the leading end of the lamination sheet S. In response to a determination that the lamination sheet S has been conveyed by the designated amount from the sheet sensor C5 (Yes in step S33), the controller <NUM> temporarily stops the sheet conveyance in step S34.

On the other hand, when the controller <NUM> determines stopping the conveyance (Yes in step S31b), the controller <NUM> controls the driver to temporally stop the conveyance of the lamination sheet S and completes separating the lamination sheet S in step S34. The step S3lb is defined as a branch condition A.

In step S37, the controller <NUM> in the sheet processing apparatus <NUM> controls the driver to convey the insertion sheet P in the forward conveyance direction to be inserted in the opening of the lamination sheet S. In step S37a, the controller <NUM> determines whether the insertion sheet P is conveyed from the sheet sensor C3 by a designated amount. In response to a determination that the insertion sheet P has been conveyed by the predetermined amount from the sheet sensor C3 (Yes in S37a), the controller <NUM> in the sheet processing apparatus <NUM> determines whether the exit roller pair <NUM> starts the conveyance of the lamination sheet S in step S37b.

In response to a determination that the exit roller pair <NUM> starts the conveyance of the lamination sheet S (Yes in step S37b), the controller <NUM> in the sheet processing apparatus <NUM> determines whether the linear velocity (V1) of the exit roller pair <NUM> is set to be equal to the linear velocity (V2) of the entrance roller pair <NUM> in step S37c. In response to a determination that the linear velocity (V1) of the exit roller pair <NUM> is set to be equal to the linear velocity (V2) of the entrance roller pair <NUM> (Yes in step S37c), the controller <NUM> continues conveying the lamination sheet S and the insertion sheet P, the insertion sheet P reaches the exit roller pair <NUM> at the timing at which the lamination sheet is conveyed by a designated amount, and the lamination sheet S and the insertion sheet P converge as described in the positioning control using the converge timing with reference to <FIG>, or 36A and 36B in step S37d.

On the other hand, in response to a determination that the linear velocity (V1) of the exit roller pair <NUM> is not set to be equal to the linear velocity (V2) of the entrance roller pair <NUM> (No in step S37c), the controller <NUM> sets the linear velocity (V1) of the exit roller pair <NUM> to be smaller than the linear velocity (V2) of the entrance roller pair <NUM> in step S37e to position the insertion sheet P with respect to the lamination sheet S as described in the positioning control using the linear velocity difference with reference to <FIG> and <FIG> or <FIG> and <FIG>.

Returning to the previous step S37b, in response to a determination that the exit roller pair <NUM> does not start the conveyance of the lamination sheet S (No in step S37b), the controller <NUM> in the sheet processing apparatus <NUM> determines whether the bonded portion of the lamination sheet S is in the nip of the exit roller pair <NUM> in step S37f. This is determined by the branch condition A described above.

In response to a determination that the bonded portion of the lamination sheet S is in the nip (Yes in step S37f), the controller <NUM> in the sheet processing apparatus <NUM> controls rotations of the exit roller pair <NUM> and the entrance roller pair <NUM> to causes the insertion sheet P to abut against the bonded portion of the lamination sheet S and subsequently controls the rotations of the exit roller pair <NUM> to convey the lamination sheet S in step S37g, which is described in the positioning control using abutting the insertion sheet to the bonded portion of the lamination sheet S with reference to <FIG>.

On the other hand, In response to a determination that the bonded portion of the lamination sheet S is not in the nip (No in step S37f), the controller <NUM> in the sheet processing apparatus <NUM> controls rotations of the exit roller pair <NUM> to convey the lamination sheet S from the nip by a designated amount in step S37h. In step S37g, the controller <NUM> in the sheet processing apparatus <NUM> controls the rotations of the entrance roller pair <NUM> to cause the insertion sheet P to abut against the nip of the exit roller pair <NUM> and subsequently controls the rotations of the exit roller pair <NUM> to start the conveyance of the lamination sheet S, which is described in the positioning control using adjusting a protruding amount of the lamination sheet S from the nip of the exit roller pair <NUM> with reference to <FIG> and <FIG>.

Subsequently, in step S38, the controller <NUM> in the sheet processing apparatus <NUM> determines whether the selected number of insertion sheets P are inserted into the lamination sheet S. After the selected number of insertion sheets P are inserted (Yes in step S38), the controller <NUM> proceeds to step S39. On the other hand, when the insertion sheet P is subsequently inserted into the lamination sheet S (No in step S38), the controller <NUM> in the sheet processing apparatus <NUM> conveys the sheet S by a designated amount in step S38a and proceeds to step S37.

Since the subsequent steps are the same as those described in the flowchart of <FIG>, the description thereof is omitted.

The embodiments of the present disclosure have been described in detail above. The above-described embodiments are examples and can be modified within the scope of the present disclosure. For example, any embodiment and any modification may be combined.

Numerous additional modifications and variations are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the present disclosure may be practiced otherwise than as specifically described herein. The number, position, and shape of the components of the image forming apparatus described above are not limited to those described above.

Claim 1:
A sheet processing apparatus (<NUM>) configured to sandwich one or more sheet media in a two-ply sheet in which two sheets are overlaid and bonded together at a portion of the two-ply sheet, the sheet processing apparatus being characterized in that it comprises
a controller (<NUM>) configured to control insertion processing to insert the one or more sheet media into the two-ply sheet based on a length of the two-ply sheet in a conveyance direction, a length of one of the one or more sheet media in the conveyance direction, and a number of the one or more sheet media.