Abstract: A vacuum release assist system for a document insertion station is described. The vacuum suction cup system is used for opening an envelope. The vacuum release assist system ensures that the suction cup is timely released during the removal of the envelope from the insertion station. In one configuration, a solenoid actuator is used to push away the envelope from the suction cup. In another configuration, a blow-off valve is used to introduce positive air pressure to timely release the suction cup.

Abstract: In a mailing machine where an envelope feeder is used to feed envelopes one at a time into a mail inserter and an insert feeder is used to move insert material into the envelope in the mail inserter for mail insertion, a suction cup assembly having two suction cups is used to keep the throat of the envelope in the mail inserter open. Each suction cup is movably mounted on an air actuated holder so as to allow the suction cup to move up and down to open the envelope throat. The suction cup assembly is movably mounted on a mounting stand in the mail feeder at a pivot so that the suction assembly can be rotated at the pivot so as to deflect the suction cups further away from the insert feeder if a jam involving the insert material or the envelope occurs.

Abstract: An envelope feeder for removing envelopes from an envelope stack. The envelope feeder comprises a shuttle plate and a suction cup assembly. The shuttle plate translates between a position under the envelope stack and another position partially remote from the envelope stack. The shuttle plate includes an orifice passing through its surface and an envelope gripping mechanism in connection with a vacuum valve. The suction cup assembly has a suction cup connected to a hollow rod that is in connection with another vacuum valve. An actuator engages the suction cup and moves the suction cup between an extended position and a retracted position. The suction cup attaches to an envelope at the bottom of the envelope stack when it is in the extended position, and pulls the envelope toward the shuttle plate as it moves to the retracted position. Then the envelope gripping mechanism retains the envelope, allowing the shuttle plate to remove the envelope from the envelope stack.

Abstract: A method for creating mailpieces from a single web of printed material. The web of printed material includes printed matter to be used on envelopes, and other printed matter to be used on mail content to be included in the envelopes. The content pages are rectangular in shape and may be oriented relative to the envelope sheets in a number of different configurations. In some configurations, two sets of content pages and/or envelope sheets can be printed across the width of the web. The method starts with cutting consecutive sections of the web into separated sheets. Some of the separated sheets are envelope sheets including envelope printed matter, and some of the sheets are mail content sheets including mail content printed matter. The method includes cutting variable sized sheets depending on whether a sheet is a mail content sheet, or an envelope sheet. The method further includes cutting variable sized envelope sheets depending on the size of the mailpieces.

Abstract: A vacuum release assist system for a document insertion station is described. The vacuum suction cup system is used for opening an envelope. The vacuum release assist system ensures that the suction cup is timely released during the removal of the envelope from the insertion station. In one configuration, a solenoid actuator is used to push away the envelope from the suction cup. In another configuration, a blow-off valve is used to introduce positive air pressure to timely release the suction cup.

Abstract: An inserter input system including a web feeder providing a web of printed material to be split by a web slitting knife along the web's direction of travel. The split web is then cut transverse to the direction of travel by a rotary cutter operating at a first velocity, resulting in side-by-side individual sheets. Downstream of the rotary cutter, a right angle turn mechanism receives each of the side-by-side sheets and reorients them by ninety degrees. Further the right angle turn reorients the sheets into a serial shingled arrangement. A high speed separation nip pulls individual shingled sheets out from the shingled arrangement. The speed of the separation nip is such that a predetermined gap between the previously shingled sheets is formed.

Abstract: An inserter input system including a web feeder providing a web of printed material to be split by a web slitting knife along the web's direction of travel. The split web is then cut transverse to the direction of travel by a rotary cutter operating at a first velocity, resulting in side-by-side individual sheets. Downstream of the rotary cutter, a right angle turn mechanism receives each of the side-by-side sheets and reorients them by ninety degrees. Further the right angle turn reorients the sheets into a serial shingled arrangement. A high speed separation nip pulls individual shingled sheets out from the shingled arrangement. The speed of the separation nip is such that a predetermined gap between the previously shingled sheets is formed.

Abstract: A vacuum release assist system for a document insertion station is described. The vacuum suction cup system is used for opening an envelope. The vacuum release assist system ensures that the suction cup is timely released during the removal of the envelope from the insertion station. In one configuration, a solenoid actuator is used to push away the envelope from the suction cup. In another configuration, a blow-off valve is used to introduce positive air pressure to timely release the suction cup.

Abstract: An inserter input system including a web feeder providing a web of printed material to be split by a web slitting knife along the web's direction of travel. The split web is then cut transverse to the direction of travel by a rotary cutter operating at a first velocity, resulting in side-by-side individual sheets. Downstream of the rotary cutter, a right angle turn mechanism receives each of the side-by-side sheets and reorients them by ninety degrees. Further the right angle turn reorients the sheets into a serial shingled arrangement. A high speed separation nip pulls individual shingled sheets out from the shingled arrangement. The speed of the separation nip is such that a predetermined gap between the previously shingled sheets is formed.

Abstract: An inserter input system including a web feeder providing a web of printed material to be split by a web slitting knife along the web's direction of travel. The split web is then cut transverse to the direction of travel by a web cutter, resulting in side-by-side individual sheets. Downstream of the rotary cutter, a right angle turn mechanism receives each of the side-by-side sheets and reorients them by ninety degrees. Further the right angle turn reorients the sheets into a serial shingled arrangement. The right angle turn transport operates at a velocity that is a function of the product of the web cutting rate and the width of the documents. A high speed separation nip pulls individual shingled sheets out from the shingled arrangement. The speed of the separation nip is such that a predetermined gap between the previously shingled sheets is formed. The separation nip speed is further controlled as a function of the product of the cutting rate and the sum of the document length plus the predetermined gap.

Abstract: A rotatable pneumatic feeding head having a vacuum shoe with apertures for picking up an envelope from an envelope stack by negative air pressure. The feeding head has an outer cylinder with holes communicating with the apertures, and an inner cylinder with cutout regions operatively connected to a vacuum pump. The inner cylinder and the outer cylinder are rotated independently of each other such that when they are aligned, a negative pressure is created at the apertures through the cutout regions and the holes. When the inner cylinder and the outer cylinder are out of alignment, the negative pressure is cut off from the apertures. The vacuum shoe is removable so that it can be repaired or replaced when it is damaged or worn.

Abstract: A vacuum release assist system for a document insertion station is described. The vacuum suction cup system is used for opening an envelope. The vacuum release assist system ensures that the suction cup is timely released during the removal of the envelope from the insertion station. In one configuration, a solenoid actuator is used to push away the envelope from the suction cup. In another configuration, a blow-off valve is used to introduce positive air pressure to timely release the suction cup.

Abstract: A module in an envelope insertion station for transporting an envelope to an enclosure material insertion location, which uses endless belts to move the envelope until it is stopped by rotatable stops. A fixedly-mounted vacuum module having vacuum ports provides a suction force to the envelope urging the trailing edge of the envelope to press against the belts and provides the normal force required to move an envelope downstream as it enters the insertion deck without slippage against the translating endless belts. Additionally, a second vacuum module having vacuum ports provides suction force urging the leading edge of the envelope to press against the belts and provides the normal force required to prohibit the leading edge of the envelope from buckling during impact with the rotatable stops. The second vacuum module is removably mounted and mechanically linked to the rotatable stops so they can be repositioned together to accommodate different-sized envelopes.

Abstract: A module in an envelope insertion station for transporting an envelope to an enclosure material insertion location, which uses endless belts to move the envelope until it is stopped by rotatable stops. A fixedly-mounted vacuum module having vacuum ports provides a suction force to the envelope urging the trailing edge of the envelope to press against the belts and provides the normal force required to move an envelope downstream as it enters the insertion deck without slippage against the translating endless belts. Additionally, a second vacuum module having vacuum ports provides suction force urging the leading edge of the envelope to press against the belts and provides the normal force required to prohibit the leading edge of the envelope from buckling during impact with the rotatable stops. The second vacuum module is removably mounted and mechanically linked to the rotatable stops so they can be repositioned together to accommodate different-sized envelopes.

Abstract: A method and system for aligning a moving stack of sheets. A pair of cams, positioned on opposite sides of the moving stack, rotate synchronously to each other but in opposite directions. When the stack approaches the cams, the distance between the outer surfaces of the cams is wider to the stack width to receive the stack. As the stack moves forward further, the distance between the cam surfaces is reduced so as to allow the cam surfaces push the sheets toward a center line until the distance between the cam surfaces is substantially equal to the width of the sheets. In a sheet collator where sheets are moved by a plurality of finger pairs which are linked to a moving chain, the cam can also be linked to the moving chain so that their rotation is synchronous to motion of the stacks.

Abstract: A flat article hopper having a plurality of bottom rods to form a supporting surface for supporting a stack of flat articles and a paddle to push the flat articles towards a flat article feeder at the downstream end. A scrub wheel is rotatably mounted on a fixed, rotation axis on the paddle and is in contact with one of the bottom rods. The rotation axis of the scrub wheel is oriented at an angle relative to the rotation axis of the contacting rod, so that when the contacting rod rotates, it causes the scrub wheel to rotate, thereby producing a force on the paddle urging the paddle to move towards the downstream end. Preferably, the flat article hopper has a side rod on one side of the envelope stack, and the supporting surface is tilted from the horizontal surface, so that the flat articles are moved towards the side rod by gravity in order to register against the side rod. Preferably, the side rod also rotates in order to reduce the friction between the flat article stack and the side rod.

Abstract: A method and system for aligning a moving stack of sheets. A pair of cams, positioned on opposite sides of the moving stack, rotate synchronously to each other but in opposite directions. When the stack approaches the cams, the distance between the outer surfaces of the cams is wider to the stack width to receive the stack. As the stack moves forward further, the distance between the cam surfaces is reduced so as to allow the cam surfaces push the sheets toward a center line until the distance between the cam surfaces is substantially equal to the width of the sheets. In a sheet collator where sheets are moved by a plurality of finger pairs which are linked to a moving chain, the cam can also be linked to the moving chain so that their rotation is synchronous to motion of the stacks.

Abstract: A rotatable pneumatic feeding head having a vacuum shoe with apertures for picking up an envelope from an envelope stack by negative air pressure. The feeding head has an outer cylinder with holes communicating with the apertures, and an inner cylinder with cutout regions operatively connected to a vacuum pump. The inner cylinder and the outer cylinder are rotated independently of each other such that when they are aligned, a negative pressure is created at the apertures through the cutout regions and the holes. When the inner cylinder and the outer cylinder are out of alignment, the negative pressure is cut off from the apertures. The vacuum shoe is removable so that it can be repaired or replaced when it is damaged or worn.

Abstract: A method and apparatus for feeding envelopes in an envelope insertion machine, wherein a rotatable pneumatic feeding head is used to pick up an envelope from an envelope stack by a negative air pressure. The pneumatic feeding head is also used to move the envelope to a pair of take away rollers so that the envelope picked up by the feeding head can be moved further away from the envelope stack. It is preferred that the feeding head includes an outer cylinder having a row of vacuum ports and an inner cylinder having a plurality of apertures for air passage operatively connected to a vacuum pump. The inner cylinder is independently rotatable relative to the outer cylinder so that the negative air pressure is provided to the vacuum ports when the apertures of the inner cylinder are aligned with the vacuum ports, and the negative air pressure is turned off from the vacuum parts when the apertures and the vacuum ports are out of alignment.

Abstract: An envelope hopper having a plurality of bottom rods to form a supporting surface for supporting a stack of envelopes and a paddle to push the envelopes towards an envelope feeder at the downstream end. A scrub wheel is rotatably mounted on a fixed, rotation axis on the paddle and is in contact with one of the bottom rods. The rotation axis of the scrub wheel is oriented at an angle relative to the rotation axis of the contacting rod, so that when the contacting rod rotates, it causes the scrub wheel to rotate, thereby producing a force on the paddle urging the paddle to move towards the downstream end. Preferably, the envelope hopper has a side rod on one side of the envelope stack, and the supporting surface is tilted from the horizontal surface, so that the envelopes are moved towards the side rod by gravity in order to register against the side rod. Preferably, the side rod also rotates in order to reduce the friction between the envelope stack and the side rod.