Abstract: In accordance with the present invention apparatus for stacking flat articles, such as envelopes, on edge, comprises structure for transporting the envelopes on edge along a transport path and a deck plate having an upper side adjacent the transport path. A vertical registration wall, which is mounted on the deck plate, defines a stacking bin in which the envelopes are stacked. A deflector, which is situated between the transporting structure and the stacking bin, pivots between a first and second position, wherein the first position allows the envelopes to be transported past the stacking bin and the second position deflects the envelopes into the stacking bin. There is an urge roller, located in the stacking bin between the deflector and the registration wall for urging the envelopes towards the registration wall. There is a spring loaded paddle slidably positioned in the stacking bin orthogonal to the registration wall and above the deck surface, for urging the stacked envelopes toward the urge roller.

Abstract: In accordance with the present invention apparatus for inserting enclosures into an envelope comprises an insertion section and an envelope staging section located upstream and below the insertion section. The envelope staging section includes structure for holding and forwarding an envelope fed from an envelope feeder. Envelope transport structure transports an envelope forwarded from the envelope staging section to the insertion section. The envelope transport structure includes a vacuum deck located at the insertion section and a vacuum drum located between the envelope staging section and the vacuum deck. The envelope transport structure further includes a plurality of envelope transport belts operating in cooperation with the vacuum drum and the vacuum deck. A plurality of backstops are located at the downstream end of the insertion section. A pivoting sucker bar assembly lifts open a top panel of the envelope when the envelope is against the backstops.

Abstract: The present invention provides an inserter based system that performs automated sorting of mailpieces in accordance with predetermined postal discount requirements. The system comprises an inserter for assembling the mailpieces and a sorter coupled to the inserter. The sorter includes a sorter controller and a plurality of on-edge sorting bins. The system also includes communicating mailpiece data and configuration data to the sorter controller. The sorter controller controls the sorting of mailpieces received from the inserter into sort groups according to postal discount requirements. A turn-up and alignment device and a vertical transport are located between the inserter and the sorter. The turn-up and alignment device turns the mailpieces from a horizontal alignment out of the inserter to a vertical alignment. The vertical transport transports the mailpieces on-edge to the sorter. The sorter further includes a scanner for scanning codes printed on the mailpieces.

Abstract: In accordance with the present invention a system for transporting, deskewing and stopping and envelope, comprises a plurality of laterally spaced, continuously moving, endless transport belts and a stationary vacuum deck having longitudinal grooves, each of which accommodates an upper reach of one of the continuously moving transport belts. The vacuum deck includes a plurality of vacuum ports arranged in longitudinal rows, each of which is adjacent at least one of the transport belts. A plurality of stop members are located at the downstream end of the vacuum deck. Vacuum at the vacuum ports urge an envelope against the continuously moving belts which transport the envelope to the stop members whereby the envelope is stopped and maintained in a deskewed position.

Abstract: The present invention provides an improvement in a stacking device having an urge roller, an input guide, a spring loaded backup paddle and a registration wall. The improvement comprises a series of ramp-shaped fingers located between the urge roller and the registration wall. The ramp fingers guide the lead edge of an envelope in such a manner as to create a pocket between the surface of the envelope and the ramp fingers. The lead edge of the next envelope follows the ramp fingers and thus is not forced against the surface of the previous envelope. As a result the lead edge of the second envelope will not catch on the external side seam of the first envelope.

Abstract: Apparatus and method for collating documents on edge. The apparatus includes: a document transport for conveying documents on edge along a path; at least two hoppers located adjacent the document path for supporting a plurality of documents on edge; a device for continuously conveying the documents through the document transport; and a device for intermittently feeding the documents from the hoppers to the document transport.

Abstract: The present invention provides an apparatus and method for receiving flat articles having a top edge alignment and horizontal orientation and transporting the articles along a transport path to a vertical orientation and a bottom edge alignment. The apparatus comprises a frame, a deck plate adjustably mounted to the frame, and structure for adjusting the position of the deck plate in a direction transverse to the paper path. A pair of entrance pulleys and exit pulleys are each mounted to the deck plate. The entrance pulleys rotate on a horizontal axis and the exit pulleys rotate on a vertical axis. First and second flexible, endless belts, are each wrapped around one of the entrance pulley and the exit pulleys wherein the belts complete a 90 degree twist from the respective entrance pulley to the respective exit pulley.

Abstract: Apparatus and a method for inserting documents into an envelope. The apparatus includes: an envelope inserting station; a device for feeding documents toward an envelope situated at the envelope inserting station; a device for inserting the documents into the envelope; a device for sensing whether or not the envelope is properly aligned at the insert station to receive the documents; and a device for diverting an envelope not properly aligned at the insert station.

Abstract: In accordance with the present invention a vacuum and belt document handling system comprises first structure for transporting individual documents along a document path in a first direction, second structure downstream from the first structure for transporting the individual documents in a second direction along the document path, and a vacuum drum having a peripheral section located between the first and second structure. The vacuum drum includes a plurality of non-rotating sections having stationary vacuum ports at the peripheral section and further includes a plurality of pulleys, each of which support an upper reach of an endless belt at the peripheral section of the vacuum drum between the first and second structure. The system further comprises a plenum shaft to which the non-rotating section of the vacuum drum is fixedly secured and the pulleys are rotatably secured. The plenum shaft is connected to a vacuum source and the stationary vacuum ports are connected to holes in the plenum shaft.

Abstract: The present invention provides a device for turning flat articles, such as envelopes, from a horizontal orientation to a vertical orientation as the articles are transported along a path from an entrance location to an exit location. The device comprises a pair of entrance pulleys, each of the entrance pulleys having an offset crown and rotating on a stationary horizontal axis, and a pair of exit pulleys, each of the exit pulleys having a centerline crown. The entrance pulleys are located longitudinally and vertically apart from one another such that one of the entrance pulleys functions as lower entrance pulley and the other entrance pulley functions as an upper entrance pulley, with the upper entrance pulley being located downstream from the lower entrance pulley. The exit pulleys rotate on a stationary vertical axis. One of the exit pulleys is located downstream from an upstream one of the exit pulleys. The device further comprises first and second flexible, endless belts.

Abstract: Apparatus for separating sheets of material. The apparatus includes: a device for supporting adjacent sheets of material; a vacuum cup for acquiring one of the adjacent sheets of material, the vacuum cup having a circumferential inner wall with an opening adjacent the one sheet of material and a circumferential outer wall coaxial with and surrounding but spaced from the inner wall, wherein the inner wall closes the end of the outer wall adjacent the one sheet of material, and wherein the outer wall includes a flexible, corrugated section enabling the outer wall to collapse in the axial direction; and a device to create separate vacuums within the inner wall and the outer wall, wherein the vacuum within the inner wall causes the vacuum cup to acquire the one material sheet and the vacuum within the outer wall causes the cup to collapse and move away from the supporting device to thereby separate the one material sheet from its adjacent sheets.

Abstract: Improvement to an apparatus for singulating respective documents fed thereto, the apparatus comprising first document feeding structure including first and second document feeding structure adjacent one another. The improvement is to the second document feeding structure and comprises a first section including an upstream end and a downstream end, the upstream end being pivotally mounted to a frame member, and including at least two outboard endless belts therearound and second structure for moving the outboard belts upstream relative to a path of travel in vertically spaced second belt runs; and a second section having at least two inboard endless belts therearound. The second section is pivotably mounted at one end to the first section.

Abstract: An in-line inserter device comprises envelope and insert feeding assemblies, an envelope inserting station assembly, a sealing and stacking assembly, and various diverter stations. The envelope feeding assembly withdraws envelopes from a hopper-held envelope stack and conveys them to the inserting station. Each modular insert feeding assembly comprises a hopper-held insert stack disposed above, along, and in line with an insert conveyor. The conveyor, along its track, carries inserts dispensed from the hopper-held insert stacks to the inserting station. Diverter stations are disposed ahead of the envelope inserting station for diversion of envelopes and inserts and ahead of the inserted envelope stacking assembly to divert inserted envelopes, for normal operational purposes and for rectification of sensed faults by rejection and extraction of processed faulty items.

Abstract: A jam detector in an inserting station of an inserter comprises horizontal and vertical photosensors and therewith associated retroreflective targets; the horizontal sensors have a light beam directed across and above an envelope positioned in the inserting station, and the vertical sensors have a pair of vertical light beams directed toward opening fingers while the fingers are positioned in the inserting station for holding envelopes open. The jam detector detects jam malfunctions during the inserting cycle by sensing interruption of the horizontal beam and uninterrupted retroreflection of the vertical beams.

Abstract: In an inserter, a skew and misalignment detector for measuring skew misalignment of inserts that are conveyed on and along a conveyor comprises a plurality of photosensors disposed above the insert-conveying path in transverse relation thereto and a plurality of retroreflective targets disposed beneath the insert-conveying path in transverse relation thereto and directed toward the photosensors. Inserts obstruct the targets while being conveyed thereover. The photosensor signals are sampled in synchronism with the insert-conveying motion. The obtained signals are evaluated in relation to pre-established skew rejection threshold criteria in dependence on insert conveying speed. Inserts are diverted when the skew detector arrangement provides measures of skew and misalignment of inserts that exceed rejection threshold criteria.

Abstract: A turnover module for turning over envelopes comprises a plurality of pulleys and disposed thereabout a driven endless belt in the general shape of a flattened figure `8`. The belt includes a crossover region and a first and a second reach extending therethrough. The reaches contact one another resiliently along length portions thereof while crossing over and twisting about one another. Envelopes are received in a first orientation at an entry end of the reaches; nipped between the reaches; transported thereby through the crossover region while being turned over by virtue of the twist of the reaches about one another; and, delivered from the turnover module in a second orientation.

Abstract: An inserter with collation tracking comprises a programmable computer, means for tracking handled items including individual tracking and collation tracking, sensing means for sensing individual items in different locations, as well as for sensing defective, multiple or missing items, corrective action means, and, means for updating tracking information in correspondence with corrective action taken. The inserter performs corrective action in the form of the rejection and diversion of defective items. Further, the inserter provides for complementarily associating envelopes with particular inserts intended for insertion thereinto, for collation tracking of such complementarily-associated items, and for the diversion of such associated items if at least one of the associated items has been stigmatized as defective.

Abstract: An inserter station for inserting inserts into envelopes comprises an insert conveyor for conveying inserts to an inserting location, a gripper drum for delivering envelopes to the inserting location, vacuum means for holding bottom surfaces of envelopes, suction cups for lifting top sides and opening envelopes, and an insert pusher for pushing inserts into opened envelopes. The insert pusher moves along a noose-shaped path in a vertical plane. The path has a horizontal, forwardly-directed portion along which the pusher moves to engage and push inserts into evelopes. The path has a retracting portion that curves downwardly and backwardly out of the way of envelopes and inserts being provided to the inserting location. In operation, an envelope is delivered to the inserting location and has its bottom surface held by vacuum applied thereto. The top side of the envelope is lifted by suction cups so that the envelope is opened to receive inserts.

Abstract: A feeder module for feeding sheet inserts and having a thickness detector for measuring the thickness of inserts comprises: a gripper drum disc for transporting the inserts upon its periphery; a detector caliper assembly including a pivotable arm having a follower roller borne at one end and a magnet mounted at the other end, the arm being spring loaded with the follower roller against the periphery of the gripper drum disc; and, a stationary Hall sensor to measure relative displacement between the sensor and the magnet. As an insert is transported upon the periphery of the gripper drum disc, the insert is interposed between the periphery and the follower roller and the Hall sensor senses the consequent magnet displacement as a measure of the thickness of the insert. In one embodiment, an adjustable anvil having a peripheral surface is mounted on a face of the gripper drum disc. The anvil is pre-adjusted so that its peripheral surface is disposed at a constant radius from the axis of rotation of the disc.

Abstract: An envelope flap opener comprises a revolving gripper drum for conveying envelopes thereupon in flap-up orientation with flap edge trailing and a revolving rotor disposed vicinally to the gripper drum, the rotor having at least one sucker cup extending from its periphery. Vacuum is valved to the sucker cup at a time when an envelope is conveyed upon the gripper drum past the rotor, the sucker cup grabs and opens the envelope flap, and subsequently the flap is released. Prior to release of the flap, a plow device intercepts the flap and further unfolds it. The plow device includes a photo-sensor for checking of proper flap opening and for detecting missing envelopes.