Abstract: An envelope sealing and flipping system can be incorporated into a mail inserter system to seal an envelope with a complete unbroken glue line and simultaneously flip the envelope face-up for downstream processing. The system includes a flip cage that receives an envelope and a moveable wetting brush that contacts the flap. The flip cage rotates, causing the flap to drag underneath the wetting brush, and realigning the envelope with a sealer nip which seals the envelope. The flip cage rotates continuously to receive, flip, and seal many envelopes.

Abstract: Folder systems and related methods are provided for accurately and efficiently folding a paper carrier that has a card attached without bending or dislodging the card from the carrier. A movable fold chute receives a portion of the carrier with the card attached and allows the carrier to fold while protecting the card portion of the carrier. The fold chute moves between different positions which allow the carrier to enter and exit through folding rollers along a generally straight paper path without forcing the cards around small radii, thereby preventing damage to the cards or causing them to separate from the carrier sheet.

Abstract: Folder systems and related methods are provided for accurately and efficiently folding a paper carrier that has a card attached without bending or dislodging the card from the carrier. A movable fold chute receives a portion of the carrier with the card attached and allows the carrier to fold while protecting the card portion of the carrier. The fold chute moves between different positions which allow the carrier to enter and exit through folding rollers along a generally straight paper path without forcing the cards around small radii, thereby preventing damage to the cards or causing them to separate from the carrier sheet.

Abstract: An envelope sealing and flipping system can be incorporated into a mail inserter system to seal an envelope with a complete unbroken glue line and simultaneously flip the envelope face-up for downstream processing. The system includes a flip cage that receives an envelope and a moveable wetting brush that contacts the flap. The flip cage rotates, causing the flap to drag underneath the wetting brush, and realigning the envelope with a sealer nip which seals the envelope. The flip cage rotates continuously to receive, flip, and seal many envelopes.

Abstract: According to some embodiments, a double detection apparatus for a mail-piece inserter includes a detectable flag affixed to a rotating mail-piece gripper of a mail-piece rotary feeder. A stationary proximity sensor may generate a voltage output based on a presence of the detectable flag in a direction along a first axis normal to the rotation of the mail-piece gripper. A decision unit may then generate a double detect alert signal when a phase shift above a pre-determined threshold value is detected in the voltage output generated by the stationary proximity sensor. According to some embodiments, the decision unit may also generate a thin detect alert signal when a phase shift past another pre-determined threshold value is detected in the voltage output generated by the stationary proximity sensor.

Abstract: According to some embodiments, a stacking assembly accepts mail-pieces traveling from a re-direct mechanism in a first direction and urges a leading edge portion of a mail-piece toward a registration wall of a sortation bin. The stacking assembly may include a plurality of neighboring cam shafts, each with at least one cam, arranged along the first direction, such that rotation of the cam shafts results in synchronized rotation of the cams to guide an incoming mail-piece. Rotation of the cam shafts may also urge a previously stacked mail-piece away from the cams, and into the sortation bin, in a second direction perpendicular to the first direction.

Abstract: A method is provided for using a rotatable insertion horn to open an envelope prior to insertion of documents. A pair of insertion horns is positioned at the sides of an envelope inserting station. An envelope is fed into the envelope inserting station with its flap open. The collation of documents is pushed into the open end of the envelope. The insertion horns are positioned in an initial position that is fully outside the envelope, prior to arrival of the collation. The insertion horns are controlled to simultaneously rotate into the envelope as the collation passes between the insertion horns. Preferably, rotation of the insertion horns into the envelope does not begin until a lead edge of the collation is in a region between the insertion horns. This facilitates insertion of the collation without catching on an upstream edge of the insertion horns.

Abstract: A method for opening an envelope for insertion of a collation in an envelope inserting machine. The envelope is fed into an inserting station with its flap in an open position. The insertion station has vacuum belts to hold the envelope in position, and to move the envelope in an upstream or downstream direction. A suction cup is positioned above the envelope in the insertion station. The suction cup is moved downward to engage a top surface of the envelope near an upstream edge of the top surface. The suction cup then lifts the top surface of the envelope to open a throat of the envelope to facilitate insertion of a collation. The envelope on the vacuum belt is then moved in the upstream direction by a small amount so that the top surface of the envelope forms a more open angle for receiving the collation.

Abstract: An apparatus and method for opening an envelope for insertion of a collation. The apparatus includes a plurality of actuated suction cups that are positioned above an envelope in an insertion station. The actuated suction cups move downward to engage a top surface of the envelope and to lift the top surface away from the bottom surface in order to facilitate insertion of the collation. The suction cups include a first group that is actuated for opening all envelopes, and a second group, independently actuatable from the first group, and that is actuated only for opening envelopes having characteristics that require the additional suction cups.

Abstract: An optimized system and method for application of liquid for moistening adhesive on envelope flaps as part of an automated mail production process. Envelopes with open envelope flaps are transported beneath a moistening brush so that an interior side of the flaps, having adhesive thereon, come into contact with a lower end of the moistening brush. A flow of liquid is provided from a liquid supply coupled to the moistening brush to keep the moistening brush wet as moisture is transferred to the envelope flaps. The rate at which liquid is regulated such that moisture is maintained on the brush and a selected quantity of liquid (a dose) is provided for each envelope flap that it moistened. The dose is automatically determined as a function of physical dimensions of the envelope flap, and to optimize sealing of the envelope without excess dripping.

Abstract: A collation folding device comprising one or more fold rollers mounted in fixed positions. Below and adjacent to the fold rollers are adjustable nip rollers to form nip spacing between the rollers. The adjustable nip roller is mounted on a nip axis shaft. An adjustment mechanism is used for moving the nip axis shaft to adjust the nip spacing. The nip adjustment mechanism includes a bearing block cam follower on which the nip axis shaft is fixedly mounted and supported. An eccentric cam in operative contact with the bearing block cam follower. Rotation of the eccentric cam on the eccentric cam axis drives the bearing block cam follower in its linear motion to adjust the nip spacing.