Sheet Folding via Reverse Rotary Rollers
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Solution Overview
Problem
Conventional folding processing apparatuses require dedicated conveyance paths and stoppers, increasing their size, complexity, and costs, making them less efficient and more expensive.
Innovation Solution
An image forming system with a folding processing unit that uses a pair of conveyance rollers and a pair of forward-reverse rotary rollers to bend and fold sheets without the need for a dedicated conveyance path or stopper, allowing for a compact and cost-effective design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a dedicated conveyance path and stopper are used for folding operations, then the folding operation can be performed reliably, but the apparatus size increases and the configuration becomes complicated
Solution Approach 1:
The patent combines the conveyance function and folding function into a single conveyance path. The same conveyance path used for transporting sheets is also used to perform the folding operation by controlling the rotation of conveyance rollers, eliminating the need for a separate dedicated conveyance path and stopper mechanism.
Solution Approach 2:
The conveyance rollers serve multiple functions: they convey sheets during normal operation and also perform the folding operation by rotating in reverse. This multi-functional design eliminates the need for dedicated folding mechanisms, reducing apparatus complexity while maintaining folding reliability.
2Manufacturing precision
If a dedicated conveyance path and stopper are installed, then the folding operation can be performed with proper sheet positioning, but the initial costs and running costs increase
Solution Approach 1:
The patent merges the positioning and folding functions into the existing conveyance system. By controlling the rotation angle and direction of the conveyance rollers, the system achieves accurate folding positioning without requiring additional positioning mechanisms or stoppers, thereby reducing manufacturing costs.
Solution Approach 2:
The conveyance rollers utilize their own rotational capability to perform both conveyance and folding functions. The system uses the existing mechanical components to achieve precise positioning and folding, eliminating the need for additional expensive components while maintaining manufacturing precision.
3Adaptability or versatility
If the apparatus includes a dedicated conveyance path for folding, then the folding operation can be performed, but the apparatus size increases
Solution Approach 1:
The patent combines the folding function into the existing compact conveyance path, allowing the apparatus to perform folding operations without requiring additional space for a dedicated conveyance path. The same physical space is utilized for both conveyance and folding operations.
Solution Approach 2:
The system uses dynamic control of the conveyance rollers' rotation to perform folding operations. By reversing the rotation direction and controlling the rotation angle, the apparatus achieves folding capability within the existing spatial constraints, maintaining compact apparatus size while providing versatile functionality.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables a folding operation on sheets with a small-sized and simple configuration at low costs, improving the efficiency and reducing the complexity of the apparatus.
Implementation Method 1
a pair of conveyance rollers 320...convey the sheet 6 in a main-scanning direction
Implementation Method 2
a pair of forward-reverse rotary rollers 340...bend the sheet 6 toward a folding processing roller 350
Implementation Method 3
the folding processing roller 350...forms a folding line on the sheet 6
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
A sheet (6) is nipped and held by first and second bend forming rollers (341 and 342)) of which rotation axes are in a direction perpendicular to a sheet conveying direction, the conveying speed of the held portion is made lower than a sheet conveying speed on the upstream side so that a bend is formed on the sheet (6), the sheet (6) is conveyed toward the bend forming rollers (341, 342) such that the sheet conveying direction to the bend forming roller (341, 342)s passes through a line segment from the rotation axis of the first bend forming roller (341) to a predetermined position on a surface of the first bend forming roller (341), and the bend formed on the conveyed sheet (6) is pressed from the surface of the sheet (6) in a position on the opposite side of the second bend forming roller (342) with respect to the position where the sheet (6) is in contact with the first bend forming roller (341).