Multiple edge media stapling system

A media stapling system for use with an image forming device having a user interface and a controller, the user interface providing a menu of one or more predetermined user selectable stapling patterns and a default stapling pattern;

• each stapling pattern having at least one predetermined stapling position, the media stapling system comprising:
• a media feeding system having an input for receiving printed media from the image forming device and providing a media path to a media stapling device and a media output location;
• a media stapling device, comprising:
• a planar media support for holding the printed media received from the media feeding system in a media stack for stapling;
• a track assembly having a planar support plate and a track mounted thereon, the support plate and media support having parallel planar orientations, the track having a curved track portion and a first and a second track portions contiguous with respective ends of the curved portion, each track portion having a rack thereon forming a continuous rack length therealong, the first and second track portions being positioned proximate to the media support and parallel to a first edge and a second edge of the media stack that are contiguous with one another with the curved track portion positioned adjacent a first corner of the media stack formed between the first and second edges;
• a carriage moveably coupled to the rack of the track;
• a position sensor disposed on the carriage for sensing the position of the carriage along the track and providing position data of the carriage;
• a stapler mounted on the carriage;
• and
• a drive mechanism coupled to the track and the carriage for moving the carriage along the track;
• and,
• the controller being in operable communication with the user interface, the media feeding system, the drive mechanism, the position sensor and the stapler,
• wherein the controller is configured to:
• actuate the media feeding system to feed the received printed media to the media support,
• actuate, based on one of the default stapling pattern and a selected stapling pattern, the drive mechanism to move the carriage and stapler along the track from an initial position track to the at least one predetermined stapling position of one of the default stapling pattern and the selected stapling pattern using position data,
• actuate, upon the carriage and stapler arriving at the at least one or more predetermined stapling positions, the stapler to staple the media stack, and
• actuate the media feeding system to move the stapled media stack to the media output location.

A media stapling system, comprising:

• a planar media support for holding a media stack having at least two media sheets for stapling, the media support having an orientation that is at an acute angle with respect to horizontal;
• a media feeding system for receiving at least two media sheets from an image forming device and feeding the received at least two media sheet onto the media support;
• a track assembly having:
• a planar support plate positioned substantially parallel with the media support;
• a track mounted on a top surface of the support, the track having at least two contiguous track portions, the at least two contiguous track portions each having a rack extending therefrom forming a continuous rack length, the rack being adjacent an edge of a correspondingly shaped slot in the support plate, the track positioned proximate to the media support with the at least two contiguous track portions being parallel to at least two contiguous edges of the media stack when present,
• the track further having a wheel guide channel formed in a top surface thereof, the wheel guide channel having at least two contiguous channel portions forming a continuous channel having a shape corresponding to the shape of the rack;
• a wheeled carriage moveable along the top surface of the support, the carriage having a guide wheel mounted thereon, the guide wheel positioned transverse to the track and closely received in the wheel guide channel;
• an encoder mounted on the wheeled carriage for providing a position data of the wheeled carriage along the track;
• a stapler mounted on the wheeled carriage;
• a drive mechanism for the wheeled carriage and stapler, drive mechanism having:
• a frame having an arm extending through the opening in the support and attached to an underside of the carriage;
• a motor mounted on the frame, the motor having an output shaft having a first gear mounted thereon;
• a drive shaft rotatably mounted to the frame, the driver shaft having a worm gear and a second gear thereon, the second gear aligned with the first gear;
• a trans-axle rotatably mounted to the frame and transverse to the drive shaft, the trans-axle having a transfer gear operably coupled to the worm gear and a pinion gear operably coupled to the rack;
• a drive belt operably coupled to the first and second gears;
• and
• and,
• a controller in operable communication with the motor, the encoder, the stapler and the media feeding system, the controller configured to:
• actuate the media feeding system to feed the at least two media sheets to be stapled onto the media support,
• actuate the drive mechanism to move the carriage and stapler the along the track to one or more predetermined stapling positions located along any of the at least two contiguous edges of the media stack, and,
• when at the one or more predetermined stapling positions, actuating the stapler to staple the media stack.