Apparatuses and methods for registering sheet articles
Apparatuses and methods are provided for improving handling of sheet articles during processing within sheet processing machines, particularly for apparatuses and methods for registering sheet articles within a sheet or mail processing machine. A registration apparatus can be provided that aligns sheet articles, such as envelopes, by using negative pressure to register the sheet articles. The registration apparatus can have an elongated housing defining a slit therein for receiving a sheet article. At least a portion of a sheet article may be advanced within the slit of the registration apparatus. A negative pressure may be applied within the housing to pull the sheet article into alignment within the registration apparatus.
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This application relates to the U.S. patent application Ser. No. ______, entitled “INSERTER SYSTEMS AND METHODS” filed simultaneously, the disclosure of which is incorporated herein by reference in its entirety. Further, this application relates to the U.S. patent application Ser. No. ______, entitled “APPARATUSES AND METHODS FOR VARIABLY OPENING ENVELOPES” and to U.S. patent application Ser. No. ______, entitled “CREASE ROLLER APPARATUSES AND METHODS FOR USING SAME”, also filed simultaneously, the disclosures of which are also incorporated herein by reference in their entireties.
TECHNICAL FIELDThe subject matter disclosed herein relates generally to handling of sheet articles for processing. More particularly, the subject matter disclosed herein relates to apparatuses and methods for registering sheet articles within a sheet or mail processing machine.
BACKGROUNDIncreasingly, a widespread need exists in commercial and governmental institutions for sheet processing machines, particularly mail processing machines, capable of operating at higher operation speeds with high reliabilities and short down-times. Operating sheet processing machines at or near their maximum capability is critical for optimizing output and throughput. Delays or inefficiencies in any operation in the processing of sheet articles can undesirably affect further operations downstream. Since each operation is typically synchronized to the others, delays in feeding time, as well as in other operations, can be perpetuated throughout an entire sheet processing sequence or line.
Speeds and efficiencies of a sheet processing machine in high speed operations can be greatly affected by the handling of the sheet articles within the sheet processing machine. For example, demands on accuracy of sheet article positioning and alignment in the course of handling of sheet articles are greatly increased in high speed sheet or mail processing machines. False or inadequate alignment or registrations can result in misfeeds of sheet articles that can cause delays in processing.
A further example relates to processing of creased sheet articles. When processing creased sheet articles within a sheet processing machine, particular attention needs to be paid to the handling of the creased sheet articles. The crease of a sheet article can cause the sheet article to assume a non-planar position. Thus, the creased sheet article may become harder to process within a sheet processing machine. When filling an envelope within an inserter system, for example, the fold of the flap of the envelope along its hinge line often causes the envelope to assume a non-planar position, which makes handling within the inserter system more difficult. Also, the fold of the flap often causes the flap to block the mouth of the envelope. Thus, it is desirable to have the envelope assume a more planar position during processing within a sheet processing machine. Complicated mechanisms are currently used within sheet processing machines to force envelopes to assume a more planar position during processing. These mechanisms used to force envelopes to assume a more planar position during processing can slow down processing and also cause delays and inefficiencies.
Another example of where the handling of sheet articles within an inserter system can affect delays or inefficiencies relates to the filling of envelopes. The processes and apparatuses used for opening envelopes can create a bottle neck within an inserter system. Any delays or inefficiencies in such processes or apparatuses will likely affect production through the entire inserter system. Thus, any improvement in speeds or efficiencies can greatly affect production of the inserter system. For example, early steps for preparing the envelopes for insertion may be beneficial. Also, processing the envelope in a more effective manner can improve throughput of the inserter system. For instance, maximizing the amount that an envelope is held open is desirable to prevent unneeded contraction of the sides of the envelope that can result in misfeeds of insert material, while still holding the envelope opened wide enough to permit the filling of the envelope. Such an improvement could increase efficiencies in insertion of insert material into envelopes.
In light of the above, needs exist for improved handling of sheet articles within sheet processing systems, such as mail processing systems, particularly with regard to improving throughput and increasing efficiencies within a sheet processing machine.
SUMMARYIn accordance with this disclosure, novel apparatuses and methods are provided for improving handling of sheet articles during processing within sheet or mail processing machines, particularly for apparatuses and methods for registering sheet articles within a sheet or mail processing machine. A registration apparatus may be provided that aligns sheet articles, such as envelopes, by using negative pressure to register the sheet articles.
Some of the objects having been stated hereinabove and are addressed in whole or in part by the present subject matter. Other objects will become evident as the description proceeds when taken in connection with the accompanying drawings as best described hereinbelow.
A full and enabling disclosure of the present subject matter including the best mode thereof to one of ordinary skill of the art is set forth more particularly in the remainder of the specification, including reference to the accompanying figures, in which:
Reference will now be made in detail to presently preferred embodiments of the present subject matter, one or more examples of which are shown in the various figures. Each example is provided to explain the subject matter and not as a limitation. In fact, features illustrated or described as part of one embodiment can be used in another embodiment to yield still yet another embodiment. It is intended that the present subject matter covers such modifications and variations.
The term “sheet article” is used herein to designate any sheet article, and can include, for example and without limitation, envelopes, sheet inserts folded or unfolded for insertion into an envelope or folder, and any other sheet materials.
The term “mail article” is used herein to designate any article for possible insert into a mailing package, and can include, for example and without limitation, computer disks, compact disks, promotional items, or the like, as wells any sheet articles.
The term “document set” is used herein to designate one or more sheet articles and/or mail articles grouped together for processing.
As defined herein, the term “insert material” can be any material to be inserted into an envelope, and can include, for example and without limitation, one or more document sets, sheet articles, mail articles or combinations thereof.
The present subject matter relates to sheet processing, such as, for example, mail inserting systems, mail sorting systems, and any other sheet processing systems. For example,
Inserter system IS can include, for example, an envelope feeder module, generally designated as 100, which feeds envelopes in a direction A into an inserting station module, generally designated as 300. An assembly station module 800 can be used to collect one or more sheet articles and/or one or more mail articles from upstream into a first document set that can be sent to a staging station 900 before being conveyed in a direction B toward inserting station module 300. In front of or behind each first document set on a conveying path of the inserter system IS, one or more sheet articles and/or mail articles can be fed on the conveying path to form second document sets as the first document sets move in direction B so that each first document set and corresponding second document sets can be combined together into insert material for insertion into an envelope.
The second document sets are fed into the conveying path to be combined with the first document sets by one or more modules 1000 of enclosure feeders EF1, EF2. Each enclosure feeder module EF1, EF2 can include one or more station feeders for providing second document sets to be included in insert material to fill the envelope. Enclosure feeders EF1, EF2 can feed second document sets in front of the first document set or behind the first document set. Further, enclosure feeders EF1, EF2 can feed sheet articles and/or mail articles on top of the first document set.
In the examples shown, a collating apparatus module 2000, as shown and described in U.S. patent application Ser. No. 11/240,604, filed Sep. 30, 2005, the disclosure of which is incorporated herein by reference in its entirety, can be provided to collate the first and second document sets together before being feed to the inserting station module 300 where the material can then be placed into an envelope. Each filled envelope can then be directed in direction C1 into a sealer module 700 after insertion has occurred. The envelopes can be sealed in the sealer module 700 before they are sent out for metering and mailing. Further, the inserting station module can include an apparatus for diverting defects in a direction C2 out of the inserter system IS.
Other modules can be included in the inserter system IS. For example, a sheet feeder SF for feeding in sheet articles to be collected in the assembly station 800 is normally positioned upstream of the assembly station 800. Assembly station 800 can be followed by staging station 900. Further, other modules can be placed inside the inserter system IS such as a folder module FM, reader module R and an accumulator module AM as are commonly used within the art. These modules can be placed anywhere within inserter system IS where they may be needed for a desired use.
Reader R can be used to read and collect information from sheets passing under it, for example, from bar codes. Reader R can be in direct communication with controller 600. Reader R can read information from sheet articles and/or mail articles to be used by controller 600 to control insertion system IS. The information read by reader R can help determine how a grouping of sheet articles and/or mail articles in a document set will be processed within inserter system IS. Further, the information can be used to determine what other document sets may be needed in the insert material for any particular envelope. Accordingly, the information can also be used to determine the amount of insert material to be received in each envelope.
According to certain aspects of the present subject matter, a registration apparatus for aligning a sheet article is provided. The registration apparatus includes an elongated housing defining a slit along at least a portion of a length of the housing for receiving at least a portion of a sheet article. The housing further defines an interior in communication with the slit. A vacuum connection can be attached to the housing and can be in communication with the interior of the housing. The vacuum connection can be configured for pulling a portion of a sheet article within the slit to align the sheet article.
According to other certain aspects of the present subject matter, a method of registering a sheet article within a sheet processing machine is provided. The method includes providing a registration apparatus having a slit therein for receiving a sheet article. A sheet article can be advanced at least partially within the slit of the registration apparatus. A negative pressure can be applied within the registration apparatus to pull the sheet article into alignment within the registration apparatus.
Inserting station module 300 is shown in more detail in
As shown in the illustrated embodiment, a pair of elongated slots 420 can be aligned down the conveying path 418 or deck 410. In such an embodiment, a pair of insertion pusher members 422, such as pusher pins or picks, can be conveyed down the parallel slot 420 such that the insertion pusher members 422 are conveyed parallel to one another to register the insert material and push the insert material into an envelope. Insertion pusher members 422 can then convey the envelope onto the right-angle-turn apparatus 310 to be conveyed to sealing module 700 or be diverted out of the inserter system if there is a defect therein. The deck 410 can also include elongated slots 424 in which collecting pusher members (not shown) from downstream in the inserter system IS can be conveyed. In such an embodiment, collecting pusher members can convey the insert material along conveying path 418 from upstream until such point that insertion pusher members 422 pick up the insert material to be conveyed toward the envelope. At such point, the collecting pusher members descend below conveying path 418 and deck 410.
The deck 410 can include a first platform 427 which overlays a second platform 428 and a third platform 429 to form the top surface 416 of the deck 410. Top side 416 can have insert guides 430 on either side of the conveying path 418 to help guide the insert material toward the envelope. Insert guides 430 can be adjustable to accommodate different sized insert material thereby helping to funnel the insert material toward the envelope. Flexible tabs 432 can be positioned above top side 416 of deck 410 such that the insert material can pass between the tabs 432 and top side 416 for the deck 410. Tabs 432 can be attached to the insert guide such that tabs 432 moves with insert guides 430. Tabs 432 can extend under the flap of the envelope but not into the mouth of the envelope in which the insert material is to be received.
Envelopes fed in direction A can be fed under crease roller apparatus 200 by sets of feed rollers 202, 206. The crease roller apparatus can score envelopes entering the variable envelope opener apparatus 400 along the fold of flaps of the envelope to bend the flaps of the envelopes against the fold. This scoring helps to keep the envelopes open for insertion of material as described in more detail below.
The sets of feed rollers 202, 206 feed the envelopes into a registration apparatus, generally designated as 440, that includes a housing 442 and a vacuum connection 444. Registration apparatus 440 registers the envelopes fed therein by the feed rollers to align the envelopes. The registration apparatus 440 and a flat plate 446 hold the envelopes fed into the registration apparatus 444 in a staging position. Flat plate 446 can be moved back and forth by an actuator 448 between an extended position and a retracted position. When flat plate 446 is extended, flat plate 446 is in a holding location. When flat plate 446 is retracted, flat plate is in an entry location. A first drop bar 450 is positioned above flat plate 446 and a second drop bar 452 is placed above the staging position between flat plate 446 and registration apparatus 440. As flat plate 446 is moved from the holding location to the entry location, first drop bar 450 and second drop bar 452 push each envelope into an insertion position where a holding system holds that envelope. A feeding guide, generally designated as 454, which can include a rotary actuator 456 can rotate fingers into the mouth of each envelope in the inserter position to hold it open while insertion pusher members 422 push the insert material into the envelope and then carry the envelope to right-angle-turn apparatus 310 shown in
Although the registration apparatus 440 is described relative to operation with an envelope, other sheet articles, for example, folded sheet articles, will operate in a similar manner.
Envelope E can be fed from the envelope feeder apparatus 100 (see
After the envelope has been scored by crease roll apparatus 200, the envelope can be fed into registration apparatus 440 for registering within variable envelope opener apparatus 400. As can be seen in
First end 464 of housing 442 can define an entrance 468 for slit 462 for receiving an envelope fed by the set of feed rollers 206. Vacuum connection 444 can provide a negative pressure from a vacuum source within housing 442 that aligns the envelope within the slit 462. A sensor 470 can detect the presence of an envelope within staging position 460 when the envelope resides in registration apparatus 440 and on top of flap plate 446. Once the envelope is received within staging position 460, first drop bar 450 and second drop bar 452 can be readied to push the envelope out of staging position 460 and into the insertion position within variable envelope opener apparatus 400. The vacuum source can be left on during the extraction of the envelope from the registration device. Alternatively, the vacuum source can be turned off when the drop bar 452 is actuated to extract the envelope and put it into the insertion position.
As can be seen in the exploded view of
Chamber 480 can extend the full length L of housing 442 or it can extend for a partial distance within length L. Similarly, the slit 462 can extend the full length L of housing 442 or it can extend only a partial distance along the length L. Slit 462 can also extend only along a portion of the length of chamber 480. As previously mentioned, housing 442 can define a convex slit 499A or a concave slit 499B as shown in
As in the embodiment shown in
One or more holding pins 488 can be inserted above slit 462 through at least one of front wall 472 or back wall 474. Holding pins 488 can help to prevent the envelope from sliding up chamber 480 when a vacuum is applied within housing 442. Holding pins 488 can be screws, shoulder bolts, pins, or the like. Holding pins 488 can be inserted through apertures 490 defined either in front wall 472, back wall 474, or both. A plurality of holding pins 480 can ensure that the envelope within registration apparatus 440 is properly registered before the envelope is removed from the staging position into the insertion position for insertion of the insert material into the envelope.
As can be seen in
Vacuum connection 444 of registration apparatus 440 can take on many different forms. The only requirement of vacuum connection 444 is that it provides enough negative pressure within housing 442 to properly align, or register, the envelopes that enter housing 442. An example of an embodiment of the vacuum connection is shown in the figures. Vacuum connection 444 of registration apparatus 440 can include a housing fitting 492 having a housing opening 494 disposed therein to engage housing 442 about second end 466. Housing opening 494 within housing fitting 492 can securely fit around second end 466 of housing 442 such that, when a negative pressure is pulled through housing fitting 492, it is also pulled through chamber 480 of housing 442. Housing fitting 492 can further include a connector opening 496 which is in communication with housing opening 494.
Vacuum connection 444 can further include a connector fitting 498, which can be received in connector opening 496 of housing fitting 492. Vacuum connection 444 can further include a vacuum tube 500, which can be secured to a vacuum source 502 that provides the negative pressure to housing 442. Vacuum tube 500 can be securely fitted to connector fitting 498 and also to vacuum source 502. Vacuum source 502 can be any structure that can create a negative pressure within a range that will properly align the envelope within registration apparatus 440. For example, vacuum source 502 can be a Gast blower, Model R 3105-1, manufactured by Gast Manufacturing, Inc., of Bent Harbor, Mich. Such a blower can create a negative pressure of up to about 0.5 pounds per square inch for use within registration apparatus 440. However, a lesser or greater negative pressure may be used to register envelopes or other sheet articles.
Vacuum connection 444 can include just a vacuum tube connected to the housing 442 and a vacuum source 502 or it can take on other forms. Further, the opening within the housing around which the vacuum connection is secured can be at other locations provided that the opening can provide the negative pressure into the chamber of the housing for registration of the envelope. The chamber can also be any desired shape that facilitates registration of envelope within the housing. For example, the chamber can be just a rear portion of slit 462.
For example, as shown in
Once an envelope E is registered within housing 442 of registration apparatus 440, envelope E can reside in staging position 460 as shown in
While described in conjunction with a variable envelope opener apparatus, registration apparatus 440, described herein, can be used in any sheet or envelope handling apparatus. The registration apparatus only needs a housing into which sheets or envelopes can enter and a vacuum connection that provides a negative pressure to the housing to register the sheets or envelopes. For example, the registration apparatus can be in another location within a sheet processing machine, wherein folded sheets pass through a slit in the registration housing. As the folded sheets are passing through the slit, a negative pressure can pull the folded sheets against the housing to register the folded sheets. The utility of registration apparatus is not limited to the processes described here in the context of examples used.
The embodiments of the present disclosure shown in the drawings and described above are exemplary of numerous embodiments that can be made within the scope of the appending claims. It is contemplated that the configurations for apparatuses for registering sheet articles within a sheet processing machine can comprise numerous configurations other than those specifically disclosed. The scope of a patent issuing from this disclosure will be defined by the appended claims.
Claims
1. A registration apparatus for aligning a sheet article, the registration apparatus comprising:
- (a) an elongated housing defining a slit along at least a portion of a length of the housing for receiving at least a portion of a sheet article, the housing further defining an interior in communication with the slit; and
- (b) a vacuum connection attached to the housing and in communication with the interior of the housing, the vacuum connection configured for pulling a portion of a sheet article within the slit to align the sheet article.
2. The registration apparatus according to claim 1, wherein the slit in the housing extends in a straight plane.
3. The registration apparatus according to claim 1, wherein the slit in the housing extends in a concave or convex shape.
4. The registration apparatus according to claim 1, wherein the interior of the housing comprises a hollow chamber running along the length of the housing, the chamber being in communication with the slit and the opening.
5. The registration apparatus according to claim 4, wherein the housing comprises a front wall, back wall, top wall and bottom wall that define the chamber.
6. The registration apparatus according to claim 5, wherein the slit is defined in the front wall of the housing.
7. The registration apparatus according to claim 6, wherein the housing and the vacuum connection are configured for creating negative pressure within the housing whereby the vacuum connection can pull a sheet article against an interior of the back wall of the housing.
8. The registration apparatus according to claim 4, wherein the housing comprises a first end and a second end with an opening leading into the chamber defined in both the first and second ends, the opening on the second end having the vacuum connection attached thereto.
9. The registration apparatus according to claim 8, wherein the slit extends through the first end of the housing defining an entrance in which the sheet article is received.
10. The registration apparatus according to claim 9, wherein the width of the entrance is greater than the width of the slit.
11. The registration apparatus according to claim 8, wherein the entrance converges to the slit.
12. The registration apparatus according to claim 9, wherein the slit extends across the length of the housing.
13. The registration apparatus according to claim 4, further comprising a plurality of holding pins disposed in the housing proximal to the slit.
14. The registration apparatus according to claim 1, further comprising a sensor disposed on the housing for determining the presence of a sheet article within the slit in the housing.
15. The registration apparatus according to claim 1, further comprising a stopper device positioned proximal to the slit within the housing configured to stop the envelope after entry of the sheet article into the slit.
16. The registration apparatus according to claim 1, further comprising a depth adjuster configured to move the registration apparatus between different positions to accommodate for different sized sheet articles.
17. The registration apparatus according to claim 1, wherein a length of the slit in the housing is greater than a length of a sheet article to be received therein.
18. A registration apparatus for aligning an envelope in an inserter system, the registration apparatus comprising:
- (a) an elongated housing having a front wall, back wall, top wall and bottom wall forming a chamber within the housing running along a length of the housing, the housing defining an opening at a first end and a second end of the housing and the housing defining a slit along at least a portion of the length that extends through the first end of the housing to define an entrance therein, the slit and the entrance being configured to receive an envelope;
- (b) a plurality of holding pins disposed in the housing proximal to the slit; and
- (c) a vacuum connection communicating with the chamber of the housing whereby the vacuum connection can cause a negative pressure within the housing for pulling an envelope into the slit to align the envelope within the housing by pulling the envelope against an interior of the back wall of the housing.
19. A method of registering a sheet article within a sheet processing machine, the method comprising the steps of:
- (a) providing a registration apparatus having a slit therein for receiving a sheet article;
- (b) advancing a sheet article at least partially within the slit of the registration apparatus; and
- (c) applying a negative pressure within the registration apparatus to pull the sheet article into alignment within the registration apparatus.
20. The method according to claim 19, wherein the negative pressure is continuously applied within an interior of the housing.
21. The method according to claim 19, wherein the negative pressure is removed when the sheet article is removed from the slit of the registration apparatus.
22. The method according to claim 19, further comprising stopping the sheet article once it is fed into the slit of the registration apparatus before the step (c) of applying a negative pressure.
23. The method according to claim 19, further comprising detecting the presence of a sheet article within the registration apparatus.
24. The method according to claim 23, wherein, if no sheet article is detected, step (b) of feeding a sheet article into the slit of registration apparatus occurs.
25. The method according to claim 19, further comprising adjusting the position of the registration apparatus to accommodate for different sized sheet articles.
26. A method of registering an envelope within an inserter system, the method comprising the steps of:
- (a) providing a registration apparatus having a slit therein for receiving envelopes;
- (b) advancing an envelope within the slit of the registration apparatus;
- (c) detecting the presence of an envelope within the registration apparatus;
- (d) stopping the envelope once it is fed into the slit of the registration apparatus; and
- (e) applying a negative pressure within the registration apparatus, whereby the envelope is pulled into alignment within the registration apparatus.
Type: Application
Filed: Oct 12, 2006
Publication Date: Apr 17, 2008
Applicant:
Inventors: Edward J. Kapturowski (Court Apex, NC), Robert T. Snyder (Raleigh, NC), Chris Peterson (Fuquay-Barina, NC)
Application Number: 11/546,553
International Classification: B65H 9/04 (20060101);