Abstract: A continuous sheet folder apparatus is disclosed that can fold any size paper in half with nested inserts inside the paper. The apparatus can also function in an intermittent mode. The half folding apparatus is accomplished by a set of lifting fingers and stationary fingers which interact to curl the sheet leading edge upwards and over until it registers with the trailing edge, passing beneath it. The sheet is then creased in a presser unit. The lifting fingers are spring mounted and biased toward the oncoming sheet.

Abstract: A high-capacity collector apparatus and method are provided for collecting sheet articles and advancing collected sheet articles. The collector apparatus includes a stage for collecting a stack of sheet articles advanced thereto wherein the stage is adjustable to accommodate sheet articles of various dimensions or sizes. Pusher/stop members are provided and are operable to stop sheet articles collected in a stack in the stage and to subsequently push the stack of sheet articles from the stage. The pusher/stop members are preferably lug members fixedly attached to a plurality of belts with each belt having one lug member fixedly attached thereto.In a preferred embodiment, the collector apparatus comprises two pairs of independently controlled movable belts each having one lug member attached thereto.

Abstract: A method and apparatus for high speed merging of sheet material onto a transport from the side is disclosed. The apparatus includes a pocket formed from a series of bottom guides, a series of top guides, a side restrain, a front and rear backstop, all mounted to a framework and being mounted slightly above a transport via a provision. A source feeds insert material into the pocket at which time the insert material is held therein until advancing transport picks engage the insert as the picks pass through slots in the pocket and propel the insert out of the pocket and on to the transport or an existing sheet already on the transport. Paper control devices are positioned within the pocket to dampen bounce and help keep the insert contained in the pocket.

Abstract: The present invention provides a novel extension apparatus and method for providing a selectively adjustable conveying path for sheet articles between sheet processing apparatuses. The extension apparatus includes a base bracket with a pair of rotatably movable spring-loaded bracket arms attached to a shaft extending therethrough. A pair of bracket arm rollers are attached to each of the bracket arms. An extension plate is positioned above and slidably movable on the base bracket, and a pair of rotatable extension rollers are rotatably attached to a shaft extending through the extension plate such that slidable movement of the extension plate simultaneously and identically moves the extension rollers. A pair of rear rollers are utilized and are operatively aligned with an extension roller and a pair of the bracket arm rollers.

Abstract: An in-feed magazine apparatus for loading documents includes a magazine feed ramp having one or more document conveyor belts disposed along a bottom surface, the belts being arranged to engage the bottom boundary of the documents. The conveyer belts are configured to effect forward movement of the stack of documents toward a document shingler mechanism along a linear axis defined by forward movement of the conveyer belts. Also included is a backing plate having a lower portion disposed proximal to the conveyor belt, an upper portion disposed vertically upward from the lower portion, and a generally planar face parallel to the plane defined by the face of the documents. An upper and lower sensor sense contact with the front end of the stack of documents while a controller operatively coupled to the upper and the lower sensors determines when the front end of the stack of documents lies in a plane substantially parallel to the face of the backing plate.

Abstract: A document processing machine includes a sheet supplying apparatus for supplying a seriatim stream of sheets; an accumulator for accumulating the stream of sheets into sets; a reader for reading a mark on a document and decoding the mark to obtain information regarding the set to which the document belongs; a buffer for storing accumulated sets; and a controller for controlling a speed at which the sheet supplying apparatus operates based upon the state of one or more variables affecting the speed at which downstream devices can process sheets. Such variable include, e.g., the number of accumulated sets in the buffer, the number of sheets in a set being processed, the form length of sheets within a set being processed, and the speed at which a downstream base insertion machine can receive sets.

Abstract: An apparatus and method for computerized control of a "Phillipsburg-type" mail insertion machine. The mechanical timing and drive mechanisms of the prior art inserter are replaced with a programmable computer, solenoid valves, and pneumatic cylinders, or other suitable drivers. The computer's software includes a plurality of programmed look-up tables. An operational delay look-up table includes electro-mechanical lag times for the pneumatically driven stations/sub-assemblies of the inserter. Also provided are look-up speed tables, which include start and stop angles for actuation of each of the pneumatic cylinders. A first look-up speed table includes actuation data appropriate for operation of the machine within a relatively slow range of speeds. Four additional look-up speed tables provide correct actuation data for successively higher speed groups, up to 10,000 insertion cycles per hour.

Abstract: An envelope packing apparatus for packing a plurality of envelopes with a packing material comprising a buffer stack for holding an accumulated stack of the envelopes and a packing assembly for accepting the envelopes from the buffer stack and inserting the packing material into the envelopes.

Abstract: A guide apparatus and method are provided for selectively guiding sheet articles into a first, second or third conveying path. In a preferred embodiment, the first and second conveying paths are the upper and lower conveying paths, respectively, of a dual-deck accumulator and the third conveying path is a divert path. The guide apparatus includes a guide member having a pair of spaced-apart divert plates which are elongated and parallel so as to define a slot therebetween for passage of sheet articles therethrough. The divert plates are fixedly positioned with respect to one another and selectively pivotal in a first position for guiding sheet articles into a first conveying path, a second position for guiding sheet articles into a second conveying path and a third position for guiding sheet articles into a third conveying path.

Abstract: A linerless label applicator for forming and applying a discrete, pressure sensitive adhesive linerless label to a document is adapted to receive and advance a plurality of documents, one at a time, along a document path through the applicator. The applicator includes a label storage and feed section, a label cutting section and a label application section. The storage and feed section stores the label material in roll form thereon and feeds the material through a feed assembly into the cutting section. The label cutting section includes a label drive assembly, a label guide assembly and a cutting assembly. The drive assembly includes a feed roller and a plasma coated idler roller which contacts the label adhesive and prevents adhesion thereto. The guide assembly includes a fan/vacuum manifold which retains the non-adhesive side of the label material in contact with the cutting assembly surfaces.

Abstract: An accumulator apparatus and method are provided for accumulating sheet articles. The accumulator apparatus includes an upper belt system and lower belt system operative for advancing sheet articles in seriatim manner therebetween. Guide rollers are provided at the entrance of the sheet articles between the upper and lower belt systems for guiding the sheet articles therebetween without pinching. Nip rollers are provided downstream from the entry guide rollers for pulling sheet articles into the accumulator apparatus between the guide rollers and the nip rollers. A ramp system operative for deflecting advancing sheet articles is provided downstream from the nip rollers. Sheet articles deflected by the ramp assembly can then be accumulated in an accumulation location where the lower belt system is maintained in a spaced-apart position below the accumulation location such that the lower belt system cannot contact or mark sheet articles accumulated therein.

Abstract: A pivotal mail tray unloader for unloading a tray having mail pieces horizontally stacked therein includes a frame having an elongated, inclined support surface, a carriage slidably mounted to the frame, and a retaining member slidably mounted to the frame. The carriage includes first, second and third pivotal support members. The first support member pivots upwardly and forwardly from said support surface and carries the tray thereon. The second support member is also pivotal upwardly and forwardly and is positioned adjacent to and forward of the first support member. The second member receives the tray from the first support member. The third support member is mounted to the second support member forward thereof and is adapted to receive the mail pieces thereon. The third support member pivots forwardly to receive the mail pieces and subsequently, pivots rearwardly to reorient the mail in a generally vertical orientation.

Abstract: A multi-stage, serpentine-shaped buffer has an entry area for receiving documents, a first level comprising a first plurality of document stages, a first turn-around for substantially reversing the direction of document travel following said first plurality of stages, a second level vertically adjacent to said first level, said second level comprising a second plurality of document stages, a second turn-around for substantially reversing the direction of document travel, and a third level vertically adjacent to said second level, said third level comprising a third plurality of document stages.

Abstract: An impact pulley apparatus and method are provided for use with a high-speed media processing apparatus by driven attachment to the rotatable shaft of a motor associated therewith to absorb impact energy caused by the high-speed media processing apparatus encountering media to be conveyed. The impact pulley apparatus includes a base plate for mounting on the rotatable shaft such that rotation of the shaft causes identical and simultaneous rotation of the base plate. A pulley member is operatively connected to the base plate by biasing members which are springs in the preferred embodiment such that the pulley member is substantially identically rotatable with rotation of the base plate in one direction in a non-actuated position until an amount of impact energy is encountered by the pulley member sufficient for the pulley member to biasedly rotate in the same direction less than the base plate in an actuated position of the impact pulley apparatus in order to absorb the impact energy.

Abstract: A pivotal tray unloading apparatus is directed to unloading a plurality of generally rectangular documents onto a feed ramp where the documents are disposed in a generally rectangular container. The container has a bottom surface, upstanding sidewalls and forward and rear endwalls. The apparatus has a primary axis defined to be coaxial with the common edge of the bottom surface and the rear endwall of the container. The apparatus includes a first generally planar reference surface, a second generally planar reference surface fixedly attached to the first reference surface at a substantially right angle, where the second reference surface has a support paddle operatively coupled thereto. The first and second reference surfaces are configured to pivot forwardly and backwardly about the primary axis. The backward pivoting of the reference surfaces effects registration of the plurality of documents toward the first reference surface.

Abstract: A device for measuring the thickness of objects to be handled in mail processing machines, particularly collating machines, inserters and the like, has a relatively-stationary back-up part; a gripper jaw; a rotating axis for mounting the gripper jaw pivotably in relation to the back-up part, whereby an object to be handled is engagable between the gripper jaw and the back-up part; an actuator system operatively connected between the back-up part and the gripper jaw for generating pivotal movement of the gripper jaw between an engagement position and an open position in relation to the back-up part; a movement-transmission part fastened to the rotating axis; and, a measuring device provided operatively between the movement-transmission part and the back-up part, the measuring device providing position-detector signals corresponding to predetermined pivotal positions of the gripper jaw in relation to the back-up part.

Abstract: An envelope sealer includes a first horizontal plate for receiving an envelope, a vacuum manifold for drawing open the envelope's downward-facing flap as it departs from the first horizontal surface, and a plow for catching the flap and directing it such that the flap travels below a second horizontal plate while the body of the envelope travels above the second horizontal plate. A fiber-optic sensor system is provided for detecting the non-presence of a flap during the travel of the envelope over the second horizontal plate and for actuating a downstream diverter in response thereto. An unseal unseal ramp is provided for lifting the flap over the plow if it is determined that the envelope should not be sealed. During the flap 's travel below the second horizontal plate, it passes and engages a wetted brush, whereby water is applied to the flap's adhesive surface.

Abstract: A document accumulator capable of tool-less adjustment to accomodate a plurality of paper sizes includes a shaft laterally oriented across a paper path through the accumulator, a guide element mounted to the shaft for contacting and guiding documents transported through the accumulator, a connector for slidably connecting the guide element to the shaft, and a compressible O-ring inserted between the shaft and the connector for imparting friction therebetween, whereby the guide element can be translated along the shaft without the use of a tool.

Abstract: A document accumulator capable of tool-less adjustment to accommodate a plurality of paper sizes includes first and second shafts laterally oriented across a paper path through the accumulator, first and second multi-grooved pulleys affixed to the first and second shafts, respectively, and at least one endless belt extending between the shafts, the endless belt engaging a first groove of the first multi-grooved pulley and a first groove of the second multi-grooved pulley. The belt is translatable without the use of tools into a second groove of the first multi-grooved pulley and a second groove of the second multi-grooved pulley for making a paper-size adjustment.

Abstract: A document sorting section for sorting flat documents wherein a plurality of primary document conveying paths are interposed between rows of opposing document stacking elements and document diverters are positioned in the primary paths. Each of the primary conveying paths are in conveying communication with separate diverters and corresponding sorting paths, such as angularly disposed sorting paths, wherein each of the sorting paths is in conveying communication with either of the primary conveying paths, but not both. A primary pivotal diverter, located upstream from the first and second primary conveying paths, diverts documents from the main transport path to either of the primary conveying paths.