Abstract: A system and method for producing printed sheet material for use in a mailpiece inserter. The system comprises an input module for supplying the printed sheet material associated with a mailpiece fabrication job of the mailpiece inserter and a transfer module adapted to receive the printed sheet material from the input module and dispense the printed sheet material. An output module is adapted to receive the printed sheet material from the transfer module and convey the printed sheet material along the transport deck. A processor is operatively coupled to a mail run data file of the mailpiece fabrication job for controlling the input, transfer and output modules to stack the printed sheet material in accordance with the mail run data file. In the method, the output module includes at least two transport decks which may be repositioned such that one of the transport decks receives/stacks the printed sheet material in a manner which is best suited for subsequent use by the mailpiece inserter.

Abstract: A feed input assembly for accepting and conveying sheet material of variable length along a feed path including a processing station for performing an operation on the sheet material and an ingestion assembly adapted to capture the sheet material between the opposed friction drive surfaces and accept a leading edge of the sheet material from the processing station at a point of entry. The ingestion assembly includes transport elements having positionable opposed friction drive surfaces which are adapted to vary point of entry along the feed path. By varying the point of entry, sheet material of variable length can be accepted without varying the position of the processing station relative to the ingestion assembly. Also, a method for operating a feed input assembly having positionable friction drive surfaces.

Abstract: A method for maximizing the overall efficiency of an insertion system by running the system with the optimal balance between system throughput and potential for system stoppages. In other words, the system is capable of running at less than maximum throughput if running at such throughput is causing excessive amounts of system stoppages and thus, negatively impacting overall system efficiency. The foregoing is accomplished by an algorithm that controls the flow of material being processed by a particular section of the machine, or “module”. This algorithm is capable of reducing the flow rate of material to, or within, that module if a problem arises downstream that may lead to a paper jam.

Abstract: A method and system for performing monetary transactions across multiple source accounts. The method includes the steps of: determining whether a multi-source transaction is desired or required to complete a monetary transaction; selecting the specific source accounts to be accessed and debited to perform the monetary transaction; determining the amount of funds to be withdrawn from each of the source accounts; and communicating with the source accounts to (i) access the funds and (ii) determine whether adequate funds exist in each of the source accounts to perform the monetary transaction. When summed, the funds accessed from the multi-source accounts equal the total required to perform the monetary transaction. The final steps for completing the monetary transaction include approving the monetary transaction and transferring funds from the multiple source accounts to a single destination account.

Abstract: A method and system for drying printed ink on the face of a substrate material such as a mailpiece. The method comprising the steps of (i) providing a dryer having at least one variable output element for producing a plurality of dryer configurations, (ii) developing data correlating each of the dryer configurations with at least one print characteristic, (iii) storing the developed data in a memory storage device, (iv) obtaining the print characteristic associated with a particular print job and comparing the print characteristic with the developed data to define a desired dryer configuration, (v) adapting the dryer to assume the desired dryer configuration based upon the print characteristic, and (vi) drying the ink printed on the face of the substrate material. The system may include a taggant introduced into the ink and a means for identifying the taggant to determine the type of ink and the desired dryer configuration.

Abstract: A mailpiece inserter includes a feed conveyor adapted to feed a shingled stack of mailpiece envelopes along a feed path to an insert module and a chassis module adapted to produce content material for insertion into the mailpiece envelopes processed by the insert module. An envelope position detector is operative to sense a discontinuity in the shingled stack and issues a first position signal indicative thereof, and an input conveyor module is adapted to convey mailpiece envelopes into shingled engagement with an aft end of the shingled stack of mailpiece envelopes on the feed conveyor. The input conveyor module has an input end proximal to a single workstation of the chassis module which enables an operator to (i) feed mailpiece envelopes to the input module and (ii) supply content material to the chassis module.

Abstract: A print module for printing mailpieces comprises a print head assembly operative to deposit ink on each mailpiece and a registration plate for registering a first surface of each of the mailpieces during print operations. The print module includes a conveyor belt opposing the registration plate and engaging a second surface of each of the mailpieces for conveyance along a feed path. Disposed beneath and supporting an underside surface of the conveyor belt, is a continuous compliant deck operative to urge the conveyor belt and mailpieces toward the registration plate during printing. The compliant deck is also operative to print consecutive mailpieces of variable thickness dimension. The print module also includes a pivotable support rack for mounting the print head assembly to a housing.

Abstract: A system for dispensing adhesive-backed labels includes a housing assembly defining a first dispensing outlet, a system for conveying a supply of label material along a feed path and a peeler bar, positionable from a first position to a second position, to effect an abrupt directional change in the feed path thereof, and cause the face material to separate from the liner material. A processor is employed to control the bi-directional displacement of the conveyance system and position the peeler bar within the housing such that the label material is: (i) conveyed downstream of the peeler bar when the peeler bar is in the first position, and (ii) drawn back across the peeler bar to cause a trailing edge of the face material to separate form the liner material when the peeler bar is in the second position.

Abstract: A method, system and article for producing an envelope having improved seal integrity. The method comprises the steps of disposing at least one material at the interface of the adhesive seal between the flap and the body portion of the envelope, which material exhibits a characteristic property when combined with an activating agent. The envelope is then sealed by closing the flap onto the body portion of the envelope such that the activating agent combines with the material along the sealing interface. The sealing interface is inspected to determine whether the material exhibits the characteristic property thereby confirming that a seal has been produced between the flap and body portion of the envelope. The system and article are directed to the various modules of a mailpiece fabrication system employed to produce the mailpiece including an inspection module for confirming that a seal has been formed.

Abstract: A cross-fold system for use in combination with a device for folding sheet material and includes a rigid guide structure having a stationary reaction surface for supporting and guiding folded sheet material along a feed path between a sheet feed mechanism and a tensioning mechanism. Furthermore, the cross-fold system includes a paper break assembly disposed between the sheet feed mechanism and the tensioning mechanism. The paper break assembly, furthermore, includes an abrasion bar disposed transversely of the feed path and in opposed relation to the rigid guide. Moreover, the paper break assembly is repositionable from an active position to an inactive position such that, in the active position, the abrasion bar pressingly engages the sheet material against the stationary reaction surface of the guide assembly, and, in the inactive position, the abrasion bar permits the sheet material to pass to the tensioning mechanism without engaging the sheet material.

Abstract: A compliant conveyance system including a diverter having at least one sidewall structure defining an internal chamber in fluid communication with a pressure source. The sidewall structure includes a compliant interface surface for conveying sheet material along the feed path and a plurality of orifices effecting fluid communication between the compliant interface surface and the internal chamber. A means is provided for developing a pressure differential across the sheet material through the orifices to urge an interface surface of the sheet material against the compliant interface surface of the diverter such that the compliant interface surface conforms to the sheet material interface surface.

Abstract: A compliant conveyance system for processing mailpieces along a feed path, e.g., printing on a first surface of a mailpiece, while being registered against a contact surface of a registration plate. The conveyance system comprises at least one conveyor belt opposing the contact surface of the registration plate, a continuous, uninterrupted, compliant deck disposed beneath and supporting an underside surface of the conveyor belt, and a spring biasing device operative to bias the compliant deck and the conveyor belt toward the contact surface of the registration plate. The conveyor belt includes a drive surface for engaging a second surface of each of the mailpieces for conveyance along the feed path. As each of the mailpieces pass the registration plate, the compliant deck and spring biasing device urge the second surface of each mailpiece into engagement with the contact surface during processing.

Abstract: A method and system for validating the completeness of a document collation includes obtaining information concerning a document having a first page and a last page, and processing the obtained information. The processed information is employed to apply a marking on the document that may be readable through an enclosure that visually obscures the marking. The marking may provide information regarding the completeness of the document collation within the enclosure. The processed information may be employed in a manner such that the applied marking includes a first page mark on the first page of the document collation and a last page mark in the last page of the document collation. The marks may be applied in respective predetermined zones on the first page and the last page. The first page zone and the last page zone may have a predetermined relationship for a document collation.

Abstract: A system for binding variable thickness multi-sheet collations includes first and second processing stations including a stitcher and stapler, respectively and a means for determining the thickness of a multi-sheet collation. A processor is responsive to a thickness value signal and selects one of the first and second processing stations to bind the multi-sheet collation. A conveyance system then transports the multi-sheet collation to the selected one of the first and second processing stations. A method includes the steps of: stacking sheet material to produce a multi-sheet collation, determining the thickness of the multi-sheet collation, and selecting an apparatus to bind the multi-sheet collation from one of at least two binding apparatus based upon the thickness of the multi-sheet collation. The multi-sheet collation is then conveyed along a feed path to a selected one of the binding apparatus.

Abstract: An envelope sealing apparatus for sealing an envelope having a main body and a sealable flap foldable about a hinge between the flap and main body, and sealable thereto. The apparatus comprises a feed path along which an envelope can be fed; a driving means associated with the feed path for feeding an envelope along the feed path; a flap securing means cooperative with the driving means to secure an open envelope flap in contact with the driving means; and a flap sealing means cooperative with the driving means to seal the flap to the main body when the driving means drives the envelope in a flap sealing direction along the feed path. A mail piece creation device incorporating such an envelope sealer is further provided, along with corresponding methods.

Abstract: A system for processing nested/unnested content material in a mailpiece inserter includes a first accumulator, a second accumulator and a folding module disposed therebetween. The first accumulator is operative to feed individual sheets of content material, in one operating mode, and accumulate multiple sheets of content material in another operating mode. The second accumulator is operative to accumulate unnested, folded sheets of content material in one operating mode, and feed sheets of nested, folded sheets of content material in another operating mode.

Abstract: An adjustable item transport includes a deck for supporting items, a transport element for transporting the items along the deck on a transport path, a plurality of support elements rotatably supporting the transport element, and an adjustment member. Each support element may include a plurality of recesses configured to receive the transport element. Each recess corresponds to an operating position of the transport element. The adjustment member may include a handle portion, a first guide portion adjacent to a first edge of the transport element, and a second guide portion adjacent to a second edge of the transport element. Movement of the handle portion substantially perpendicular to the transport path engages one of the first guide portion and the second guide portion with a respective edge of the transport element to move the transport element between recesses in the support element to change the operating position of the transport element.

Abstract: A method for introducing instructions/commands within or acting on the content material of a mail run data file. The method comprises the steps producing an object-oriented data file of the mailpiece content material and displaying a visual image thereof to the user. The visual image displayed spatially corresponds to the object oriented data file. Through the use of a graphical user input device, such as a point-and-click input device, the user defines a region of the visual image. Further, the user creates or selects a rule or expression indicative of a desired instruction/command in connection with the defined region. The rule or expression is represented in computer program code and operates a signal processor to perform the selected instructions/commands.

Abstract: An apparatus including a belt support system having a first belt support roller and a system for automatically moving the first belt support roller. The belt support system partially wraps a continuous belt on a belt drive roller. The belt support system includes the first belt support roller at an upstream side of the belt drive roller and a second belt support roller at a downstream side. The system for moving the first belt support roller moves the first roller from a first location relative to the belt drive roller to a second different location, based upon a predetermined load of the belt on the first belt support roller to thereby reduce an amount of wrap of the belt on the belt drive roller and reduce a length of the belt located proximate to the belt drive roller between the first and second belt support rollers.

Abstract: An inserter system includes a pre-fold accumulator subsystem in which plural sheets are collected before folding and insertion into an envelope. A divert gate is at the upstream side of the pre-fold accumulator to selectively downwardly divert sheets fed in a reverse direction from the pre-fold accumulator. Positioning of the divert gate is controlled by a mechanism that couples the divert gate and a drive shaft that drives a sheet drive belt component of the pre-fold accumulator.