Stapler

Abstract

A stapler (1A) comprising a staple ejection unit (2) that ejects a staple, a binding unit (3) that bends a pair of staple legs of the staple ejected by the staple ejection unit (2), a binding drive unit (7) that executes a binding operation of an object to be bound by the staple, a detection unit (5) that detects the object to be bound, and a control unit (8) that drives the binding drive unit (7) when the detection unit (5) detects the object to be bound, wherein the control unit (8) switches the response time from when the detection unit (5) detects the object to be bound until the binding drive unit (7) is driven.

Description

Stapler

[0001] The present disclosure relates to a stapler that staples an object to be stapled with a needle.

[0002] Conventionally, a stapler has been proposed that drives a needle into an object to be stapled, such as a stack of papers, to staple it. An electric stapler driven by a motor includes a guide for abutting the tip of the object to be stapled. When the object to be stapled is inserted into the insertion port of the main body by the user, the front end surface of the object to be stapled abuts against the guide, and the guide moves backward, turning on the detection unit, generating a drive signal for driving the motor, and executing the stapling operation (see, for example, Patent Document 1).

[0003] Japanese Patent No. 5055762

[0004] In a conventional stapler, when the detection unit detects the object to be stapled during the operation of inserting the object to be stapled deeper, the stapling operation is executed. In a conventional stapler, the response time from when the detection unit detects the object to be stapled until the stapling motor that executes the stapling operation starts is constant. However, if the response time is set short, there is a high possibility of malfunction when including unstable elements of signals such as vibration.

[0005] On the other hand, when the object to be stapled is in a form called a blister pack, uses such as stapling the vicinity of the convex peripheral edge of the product storage part of the blister pack with a needle, or stapling the end of a strip-shaped packaging material with a needle are conceivable. In such a stapling method, the operator performs an operation of successively inserting the vicinity of the peripheral edge to be stapled into the stapler and continuously stapling. However, if the response time is set long, the working efficiency when performing a continuous stapling operation decreases.

[0006] Therefore, a stapler is provided that can optimize the response time from when the detection unit detects the object to be stapled until the stapling drive unit is driven.

[0007] To solve the above-mentioned problems, the present disclosure provides a stapler comprising: a needle-punching unit that shoots out needles; a stapling unit that bends a pair of needle legs of the needles shot out by the needle-punching unit; a stapling drive unit that performs a stapling operation of an object to be stapled with needles; a detection unit that detects an object to be stapled; and a control unit that drives the stapling drive unit when the detection unit detects an object to be stapled, wherein the control unit switches the response time from when the detection unit detects an object to be stapled until the stapling drive unit is driven.

[0008] In this disclosure, the response time from when the detection unit detects the object to be bound until the binding drive unit is driven can be switched, thereby reducing the risk of malfunction even when unstable signal elements such as vibration are included. Furthermore, when performing continuous binding operations, the response time from when the detection unit detects the object to be bound until the binding drive unit is driven can be optimized according to the usage conditions.

[0009] This is a side view showing an example of the stapler of this embodiment. This is a functional block diagram showing an example of the stapler of this embodiment. This is a side view showing an example of the operation of the stapler of this embodiment. This is a flowchart showing an example of the operation of the stapler of this embodiment. This is a flowchart showing an example of the operation of the stapler of another embodiment. This is a flowchart showing an example of the operation of the stapler of another embodiment.

[0010] Embodiments of the stapler of this disclosure will be described below with reference to the drawings.

[0011] <Example of the configuration of the stapler of this embodiment> Figure 1 is a side view showing an example of the stapler of this embodiment, and Figure 2 is a functional block diagram showing an example of the stapler of this embodiment.

[0012] The stapler 1A of this embodiment includes a staple-feeding section 2 that ejects staples (not shown) and a stapling section 3 that bends a pair of staple legs ejected by the staple-feeding section 2. The stapler 1A also includes a mounting section 4 on which the object to be stapled is placed and a detection section 5 that activates the staple-feeding section 2 and the stapling section 3 upon detection of the object to be stapled.

[0013] The stapler 1A has an insertion section 20 formed between the staple-issuing section 2, the stapling section 3, and the mounting section 4, into which the object to be stapled is inserted. The stapler 1A opens and closes in directions in which the staple-issuing section 2 and the stapling section 3 move closer together and further apart. In the stapler 1A, for example, the staple-issuing section 2 and the stapling section 3 are connected so that they can rotate relative to each other with a connecting shaft (not shown) as the pivot point.

[0014] In stapler 1A, the side where the space between the staple-issuing section 2 and the stapling section 3 opens and closes is referred to as the front side, and the side where the staple-issuing section 2 and the stapling section 3 are connected is referred to as the rear side.

[0015] The detection unit 5 is activated when it is pressed by the object to be bound, which is placed on the mounting unit 4 and inserted into the insertion unit 20. The detection unit 5 may also be a non-contact type sensor, such as an optical sensor.

[0016] The stapler 1A includes a staple drive unit 7 that performs the staple operation of the object to be stapled with staples. The staple drive unit 7 includes a staple motor 70. Driven by the staple motor 70, the staple drive unit 7 moves the staple dispensing unit 2 and the staple unit 3 in directions toward and toward relative proximity. As the staple dispensing unit 2 and the staple unit 3 move toward relative proximity, the object to be stapled is held between the staple dispensing unit 2 and the staple unit 3.

[0017] Furthermore, the binding drive unit 7 moves a forming plate (not shown) provided in the staple ejection unit 2 by the drive of the binding motor 70, thereby forming the staples. In addition, the binding drive unit 7 moves a driver plate (not shown) provided in the staple ejection unit 2 by the drive of the binding motor 70, thereby ejecting the formed staples. Note that if staples that have been pre-formed into a predetermined shape are used, the staple forming process using the forming plate can be omitted.

[0018] During the operation of the staple-feeding unit 2 to eject the staple, the leg of the staple is pressed against a clincher (not shown) provided in the binding unit 3, and the leg of the staple is bent.

[0019] The stapler 1A includes a control unit 8. The control unit 8 is configured to set the response time t from the time the object to be stapled is detected by the detection unit 5 and a detection signal S is input from the detection unit 5 until the stapler motor 70 is started. The stapler 1A also includes a storage unit 80. The storage unit 80 stores multiple response times t, etc. As a specific example, the storage unit 80 is a storage medium (for example, a non-temporary computer-readable medium) that stores multiple response times t, etc., and the control unit 8 is a processor that reads and executes the information stored in this storage medium.

[0020] The control unit 8 switches the response time t according to the number of times the detection unit 5 detects the object to be bound. The number of times the detection unit 5 detects the object to be bound refers to the number of times the detection signal S is input from the detection unit 5.

[0021] The control unit 8 sets the response time t1 when the detection unit 5 detects the object to be bound for the first time to be longer than the response time t2 when the detection unit 5 detects the object to be bound for the second time or later. The response time t1 is the initial value of the response time.

[0022] The detection unit 5 detecting the object to be bound for the first time means, for example, that the detection unit 5 detects the object to be bound for the first time after the power is turned on. It also means that the detection unit 5 detects the object to be bound for the first time after a predetermined waiting time has elapsed since the last time the object to be bound was detected by the detection unit 5. When the control unit 8 determines that the detection unit 5 has detected the object to be bound for the first time, it resets the response time t to its initial value.

[0023] Furthermore, the control unit 8 switches the response time t according to the interval at which the detection unit 5 detects the objects to be bound. The interval at which the detection unit 5 detects the objects to be bound is the time interval at which the detection signal S is input when the detection unit 5 detects an object to be bound and then detects the next object to be bound.

[0024] For example, when the detection unit 5 detects the object to be bound for the second time or later, the control unit 8 sets the response time t shorter if the interval between detections is less than a threshold, compared to when the interval is greater than or equal to the threshold. Also, when the detection unit 5 detects the object to be bound for the second time or later, the control unit 8 sets the response time t longer if the interval is greater than or equal to the threshold, compared to when the interval is less than the threshold. The control unit 8 may also stepwise switch the response time t depending on the number of times and the interval between detections of the object to be bound by the detection unit 5. For example, the interval thresholds can be set in multiple stages, with the first threshold Ta > second threshold Tb in descending order, and the response times corresponding to the thresholds can be set to ta > tb > tc respectively. If the detected interval is greater than or equal to Ta, the response time is set to ta. If Ta > detected interval > Tb, the response time is set to Tb. If the detection interval is less than or equal to Tb, the response time may be set to tc. Also, for example, if the detection unit 5 detects that the number of detections per unit time is increasing, the response time t may be made shorter than the previous time, and if it detects that the number of detections per unit time is decreasing, the response time t may be made longer than the previous time.

[0025] <Example of operation of the stapler in this embodiment> Figure 3 is a side view showing an example of the operation of the stapler in this embodiment, and Figure 4 is a flowchart showing an example of the operation of the stapler in this embodiment.

[0026] The object to be bound 100 is, for example, a blister pack in which a resin cover with a convex portion 110 formed thereon, into which the article is stored, is placed over a paper backing.

[0027] In step SA1 of Figure 4, when the object to be bound 100 is detected by the detection unit 5 and a detection signal S is input from the detection unit 5, the control unit 8 starts timing the response time t in step SA2. Also, when the object to be bound 100 is detected by the detection unit 5 and a detection signal S is input from the detection unit 5, the control unit 8 determines in step SA3 whether or not this is the first time the object to be bound 100 has been detected by the detection unit 5.

[0028] In step SA3, the control unit 8 determines that the detection unit 5 has detected the object to be bound 100 for the first time, and in step SA4, it determines whether the measured response time has reached the response time t1.

[0029] In step SA4, when the control unit 8 determines that the measured response time has reached the response time t1, in step SA5, it drives the staple motor 70 to operate the staple-punching unit 2 and the staple-binding unit 3 via the staple-driving unit 7. As a result, the stapler 1A holds the object to be stapled 100 between the staple-punching unit 2 and the staple-binding unit 3.

[0030] Furthermore, in the stapler 1A, staples are ejected from the staple ejection section 2, the legs of the staples ejected from the staple ejection section 2 are bent in the stapling section 3, and the object to be stapled 100 is stapled together.

[0031] When the binding operation is completed, the control unit 8 stops driving the binding motor 70 in step SA6.

[0032] If the control unit 8 determines in step SA3 that the number of times the detection unit 5 has detected the object to be bound 100 is the second time or later, then in step SA7, it determines whether the interval between detections of the object to be bound 100 by the detection unit 5 is greater than or equal to a threshold.

[0033] If the control unit 8 determines in step SA7 that the interval at which the detection unit 5 detects the object to be bound 100 is greater than or equal to a threshold, then in step SA8, it determines whether the measured response time t2 has been reached, which is shorter than t1.

[0034] In step SA8, when the control unit 8 determines that the measured response time has reached response time t2, in step SA5 it drives the binding motor 70 to operate the staple issuing unit 2 and the binding unit 3 via the binding drive unit 7. When the binding operation is completed, in step SA6 the control unit 8 stops driving the binding motor 70.

[0035] If the control unit 8 determines in step SA7 that the interval at which the detection unit 5 detects the object to be bound 100 is less than a threshold, then in step SA9 it determines whether the response time t3, which is shorter than the measured response time t2, has been reached.

[0036] In step SA9, the control unit 8 determines that the measured response time has reached response time t3, and in step SA5, drives the binding motor 70 to operate the staple issuing unit 2 and the binding unit 3 via the binding drive unit 7. When the binding operation is completed, the control unit 8 stops driving the binding motor 70 in step SA6.

[0037] If the object to be stapled 100 is in the form of a blister pack, one possible application is to staple the vicinity of the periphery of the convex portion 110 with staples. In this type of stapling, the worker rotates the object to be stapled 100 and inserts the stapler 1A sequentially into the vicinity of the periphery to be stapled. Therefore, the stapling operation is performed continuously on one object to be stapled 100.

[0038] In this type of operation, if the detection unit 5 detects the object to be bound 100 for the first time, and the response time t is set to be short, there is a high possibility of malfunction where the binding operation starts when the detection unit 5 is activated due to vibration, dropping, etc., even though the detection unit 5 has not actually detected the object to be bound 100.

[0039] Therefore, when the detection unit 5 detects the object to be bound 100 for the first time, the response time t is set to be longer. This reduces the risk of malfunction even when the signal contains unstable elements such as vibration.

[0040] On the other hand, if the response time t is set to be long, when performing continuous binding operations, the time from when the detection unit 5 detects the object to be bound 100 until the binding motor 70 starts up becomes long, making it impossible to improve work efficiency.

[0041] Therefore, when the number of times the detection unit 5 detects the binding object 100 is after the second time, the response time t is set shorter compared to the case where the number of times the detection unit 5 detects the binding object 100 is the first time. As a result, the time from when the detection unit 5 detects the binding object 100 until the binding motor 70 starts is shortened, so that the work efficiency can be improved when continuously performing the binding operation. Also, for example, after the second time operates at the response time t3, if the detection interval for the third time is greater than or equal to the threshold value (the detection interval has become longer, that is, the binding operation has become slower), the response speed becomes t2 and the response time becomes longer. Thereby, it becomes possible to set the response time according to the working speed of the operator.

[0042] Furthermore, when continuously performing a binding operation such as rotating the binding object 100 and sequentially inserting the vicinity of the peripheral edge to be bound into the stapler 1A for binding, the length of the interval varies depending on the operator. Therefore, when the number of times the detection unit 5 detects the binding object 100 is after the second time, and the interval at which the detection unit 5 detects the binding object 100 is less than a predetermined threshold value, that is, when the interval at which the detection unit 5 detects the binding object 100 becomes shorter, the response time t is set even shorter. As a result, the time from when the detection unit 5 detects the binding object 100 until the binding motor 70 starts becomes even shorter, so that when continuously performing the binding operation, an operator with a shorter interval can further improve the work efficiency.

[0043] <Other operation examples of staplers in other embodiments> Figure 5 is a flowchart showing an example of the operation of a stapler in other embodiments. Steps SA1 to SA6 are the same as those in the above-described embodiment, and thus the description thereof is omitted.

[0044] When the control unit 8 determines in step SA3 that the number of times the detection unit 5 detects the binding object 100 is after the second time, in step SA7a, it determines whether or not the number of binding times within a predetermined unit time when the detection unit 5 detects the binding object 100 is greater than or equal to the threshold value.

[0045] When the control unit 8 determines in step SA7a that the number of stitching operations within a predetermined unit time during which the stitching object 100 is detected by the detection unit 5 is equal to or greater than the threshold value, the control unit 8 determines in step SA8a whether the measured response time has reached a response time t2 that is shorter than t1.

[0046] When the control unit 8 determines in step SA8a that the measured response time has reached the response time t2, the control unit 8 drives the stitching motor 70 in step SA5 to operate the needle punching unit 2 and the stitching unit 3 by the stitching drive unit 7. When the stitching operation ends, the control unit 8 stops driving the stitching motor 70 in step SA6.

[0047] When the control unit 8 determines in step SA7a that the number of stitching operations within a predetermined unit time during which the stitching object 100 is detected by the detection unit 5 is less than the threshold value, the control unit 8 determines in step SA9a whether the measured response time has reached a response time t3 that is longer than t2.

[0048] When the control unit 8 determines in step SA9a that the measured response time has reached the response time t3, the control unit 8 drives the stitching motor 70 in step SA5 to operate the needle punching unit 2 and the stitching unit 3 by the stitching drive unit 7. When the stitching operation ends, the control unit 8 stops driving the stitching motor 70 in step SA6.

[0049] For example, if the detection count per predetermined time of what was operating at the response time t2 is less than the threshold value (that is, when the stitching work has become slow), the response speed becomes t3 and the response time becomes longer. Thereby, it becomes possible to set the response time according to the working speed of the operator.

[0050] <Another example of the stapler operation in other embodiments> Fig. 6 is a flowchart showing an example of the stapler operation in other embodiments. Steps SA1 to SA6 are the same as those in the foregoing embodiment and thus the description thereof is omitted. In the present embodiment, for example, a plurality of levels are set such that the threshold values of the intervals are in descending order as the first threshold value Ta > the second threshold value Tb, and the response times corresponding to the threshold values are set such that ta > tb > tc, respectively.

[0051] If the control unit 8 determines in step SA3 that the number of times the detection unit 5 has detected the object to be bound 100 is the second time or later, then in step SA7b, it determines whether the interval between detections of the object to be bound 100 by the detection unit 5 is greater than or equal to the threshold Ta.

[0052] In step SA7b, the control unit 8 determines that the interval at which the detection unit 5 detects the object to be bound 100 is greater than or equal to the threshold Ta, and in step SA8b, it determines whether the measured response time has reached the response time ta.

[0053] In step SA8b, when the control unit 8 determines that the measured response time has reached the response time ta, in step SA5, it drives the binding motor 70 to operate the staple ejection unit 2 and the binding unit 3 via the binding drive unit 7. When the binding operation is completed, the control unit 8 stops driving the binding motor 70 in step SA6.

[0054] If the control unit 8 determines in step SA7b that the interval at which the detection unit 5 detects the object to be bound 100 is less than the threshold Ta, then in step SA9b, it determines whether the interval at which the detection unit 5 detects the object to be bound 100 is threshold Ta > detection interval > threshold Tb.

[0055] If the control unit 8 determines in step SA9b that threshold Ta > detection interval > threshold Tb, then in step SA10b it determines whether the measured response time has reached the response time tb.

[0056] In step SA10b, when the control unit 8 determines that the measured response time has reached the response time tb, in step SA5 it drives the binding motor 70 to operate the staple ejection unit 2 and the binding unit 3 via the binding drive unit 7. When the binding operation is completed, the control unit 8 stops driving the binding motor 70 in step SA6.

[0057] If the control unit 8 determines in step SA9b that threshold Ta > detection interval > threshold Tb is not true, then in step SA11b it determines whether the measured response time has reached the response time tc.

[0058] In step SA11b, when the control unit 8 determines that the measured response time has reached the response time tc, in step SA5 it drives the binding motor 70 to operate the staple ejection unit 2 and the binding unit 3 via the binding drive unit 7. When the binding operation is completed, the control unit 8 stops driving the binding motor 70 in step SA6.

[0059] This control mechanism ensures that, for example, if the second detection occurs with a response time tc, and the detection interval for the third detection is longer than or equal to Ta (i.e., the binding process slows down), the response speed becomes ta, and the response time increases. This makes it possible to set the response time according to the operator's work speed.

[0060] Furthermore, if a device malfunction occurs, a buzzer sound is used to notify the user. However, if the buzzer sound and the sound from the binding operation occur simultaneously, it becomes difficult to recognize the buzzer sound. To address this, the response time t is switched according to the number of times and intervals in which the detection unit 5 detects the object to be bound, thereby staggering the timing of the buzzer sound due to a device malfunction such as running out of staples and the sound from the binding operation.

[0061] Although various embodiments have been described above with reference to the drawings, it goes without saying that this disclosure is not limited to such examples. It is clear to those skilled in the art that various modifications or alterations can be conceived within the scope of the claims, and these will naturally also fall within the technical scope of this disclosure. Furthermore, the components of the above embodiments may be combined in any way without departing from the spirit of the invention.

[0062] This application is based on a Japanese patent application (Patent Application No. 2025-008106) filed on January 20, 2025, the contents of which are incorporated herein by reference.

[0063] This disclosure provides a stapler that optimizes the response time from when the detection unit detects the object to be stapled until the staple drive unit is driven.

[0064] 1A... Stapler, 2... Staple ejection unit, 20... Insertion unit, 3... Binding unit, 4... Placement unit, 5... Detection unit, 7... Binding drive unit, 70... Binding motor, 8... Control unit, 80... Memory unit, 100... Binding target, 110... Convex part

Claims

1. A stapler comprising: a needle-punching unit that ejects needles; a binding unit that bends a pair of needle legs of the needle ejected by the needle-punching unit; a binding drive unit that performs a binding operation on an object to be bound using the needles; a detection unit that detects the object to be bound; and a control unit that drives the binding drive unit when the detection unit detects the object to be bound, wherein the control unit switches the response time from when the detection unit detects the object to be bound until the binding drive unit is driven.

2. The stapler according to claim 1, wherein the control unit sets the response time according to the number of times the detection unit has detected the object to be stapled.

3. The stapler according to claim 1, wherein the control unit is set to have a longer initial response time when the detection unit has detected the object to be stapled for the first time compared to when the detection unit has detected the object to be stapled for the second time or later.

4. The stapler according to claim 2, wherein the control unit sets the response time according to the interval at which the detection unit detects the object to be stapled.

5. The stapler according to claim 4, wherein the control unit shortens the response time when the interval in which the detection unit detects the object to be stapled is less than a threshold, compared to when the interval is greater than or equal to the threshold.

6. The stapler according to claim 4, wherein the control unit extends the response time when the interval at which the detection unit detects the object to be stapled is greater than or equal to a threshold, compared to when the interval is less than the threshold.

7. The stapler according to claim 4, wherein the control unit shortens the response time when the number of detections per predetermined time in which the detection unit detects the object to be stapled is equal to or greater than a threshold, compared to when the number of detections per predetermined time is less than the threshold.

8. The stapler according to claim 4, wherein the control unit extends the response time when the number of detections per predetermined time in which the detection unit detects the object to be stapled is less than a threshold, compared to when the number of detections per predetermined time is equal to or greater than the threshold.

9. The stapler according to claim 3, wherein the control unit returns the response time to its initial value when the interval between detections of the object to be stapled by the detection unit has elapsed since the waiting time.

10. The stapler according to claim 1, wherein the control unit switches the response time in steps.

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