Abstract: Methods and tools for opening polyfilm-wrapped packages. A tool includes a rubbing surface and a motor configured to move the rubbing surface. The tool includes a power source connected to supply power to the rubbing surface. The rubbing surface is applied to the polyfilm wrapping while being moved to create an opening in the polyfilm wrapping caused at least in part by friction heat. The opening is created without damaging contents of the package.

Abstract: A mail cart for use in manual sorting of mail pieces according to the inventions includes a generally rectangular frame and wheels mounted on the frame for rolling support of the cart on a floor. A bottom, substantially horizontal shelf is secured to the frame along with a first inclined shelf secured to the frame above the bottom shelf and spaced from the bottom shelf in a vertical direction, which first inclined shelf extends forwardly and upwardly at an acute angle relative to a horizontal plane. A second inclined shelf is secured to the frame above the first inclined shelf and spaced from the first inclined shelf in a vertical direction. The second inclined shelf extends forwardly and upwardly at an acute angle relative to a horizontal plane, which angle is preferably the same as the angle of first shelf.

Abstract: The invention provides a method for preparing mail for delivery by first sorting mail to carrier delivery order to create a series of batches of mail for delivery to respective recipients, then packaging the batches of mail in mail holders. Application of computer-implemented alert trigger criteria are used to determine whether a condition exists indicating an enhanced probability that one or more mail pieces in each batch is not correctly addressed such that it should not be delivered to that recipient. An alert mark is then printed on the mail holder for a batch containing one or more mail pieces having an enhanced probability of not being correctly addressed.

Abstract: A system, method and apparatus for sorting items for delivery. A smart case module includes a plurality of bins. Each bin includes a display for a sort criteria for the bin and a first indicator to indicate that the bin is active. The bin also includes an input device for an operator to use to indicate that an item has been placed in the bin. The bin further includes a second indicator to indicate that the bin contains a sufficient number of items for a shipping container.

Abstract: A holder for flat objects according the invention includes an endless belt made of a flexible sheet material, wherein an end portion of the belt is folded into itself forming an inner bend and an outer bend with the inner bend disposed inside of the outer bend. A set of first and second support rods are disposed side by side in parallel to each other, the first rod at the bottom of the inner bend and the second rod at the bottom of the outer bend. A pair of third and fourth rods extend through parallel endwise openings in the belt between the inner and outer bends, which third and fourth rods are disposed side by side in parallel to each other with the belt is wound over the third and fourth rods so that the belt can slide over the third and fourth rods, whereby movement of the first rod away from the second rod causes sliding movement of the belt over the third and fourth rods. In a preferred embodiment an inside surface of the belt is attached to one or both of the first and second rods.

Abstract: An address label rework station according to the invention includes a conveyor which can simultaneously transport a series of spaced parcels along a conveyor path in a substantially horizontal stream. The station includes a camera, A work space, a microphone is usable by an operator in the work space, a targeting device directing a human operator in the work space. Station also includes a sensor system, a labeler and a printer to print shipping information. The station also includes a computer configured to receive and recognize image and voice data, generate a label with a recognized shipping address, and control the conveyer to apply a new label to the parcel by the labeler at the position selected using the targeting device.

Abstract: The invention provides a method for preparing mail for delivery by first sorting mail to carrier delivery order to create a series of batches of mail for delivery to respective recipients, then packaging the batches of mail in mail holders. Application of computer-implemented alert trigger criteria are used to determine whether a condition exists indicating an enhanced probability that one or more mail pieces in each batch is not correctly addressed such that it should not be delivered to that recipient. An alert mark is then printed on the mail holder for a batch containing one or more mail pieces having an enhanced probability of not being correctly addressed.

Abstract: A method and apparatus are provided for automatic bundle transport, positioning, wrapper entry, wrapper opening, wrapper loosening, wrapper removal and wrapper dunnage takeaway. The wrapper is made from pliable material, thin film or similar material and which can comprise a variety of package types and sizes of mail, media or other items. Additionally the method and apparatus of the invention performs the tasks of wrapper removal and discharge without damaging the item contents within. A bundle unwrapping machine according to the invention includes a conveyor by which bundles are presented to the unwrapping machine for opening. An opening mechanism includes a pair of openers positioned to engage a bundle on opposite sites. The bundle is transported into an opening zone in which it is supported for engagement with the openers.

Abstract: A mail cart for use in manual sorting of mail pieces according to the inventions includes a generally rectangular frame and wheels mounted on the frame for rolling support of the cart on a floor. A bottom, substantially horizontal shelf is secured to the frame along with a first inclined shelf secured to the frame above the bottom shelf and spaced from the bottom shelf in a vertical direction, which first inclined shelf extends forwardly and upwardly at an acute angle relative to a horizontal plane. A second inclined shelf is secured to the frame above the first inclined shelf and spaced from the first inclined shelf in a vertical direction. The second inclined shelf extends forwardly and upwardly at an acute angle relative to a horizontal plane, which angle is preferably the same as the angle of first shelf.

Abstract: A method for sorting mail to a case having a plurality of slots is described, wherein each slot corresponds to a destination. The method includes steps of loading a mail piece to be sorted into a delivery robot, determining for the mail piece a destination slot the mail piece is to be delivered to, moving the delivery robot along a rail disposed at the front of the case near the slots into proximity with an open end of the destination slot, inserting the mail piece from the delivery robot into the associated slot, and returning the delivery robot to a loading station whereby the cycle may be repeated. Such a method, when using a large number of robots moving along a common rail system, can sort a large volume of mail in carrier delivery order.

Abstract: A postal cart according to the invention includes a base on wheels and a support frame mounted on the base. An upper shelf and a lower shelf are mounted at the top and bottom of the frame and accessible from a front side of the cart. A series of rectangular compartments are accessible from the front side of the cart, each compartment configured for storage of one postal tray filled with mail, but insufficiently wide to store more than one such postal tray side by side in the same compartment. A number of pull out sliding shelves are mounted along the bottom of no more than about half of the compartments, the remaining compartments being free of the sliding shelves. The compartments are configured to fit one tray in each. The vertical density of the compartments is greater than would be possible if a sliding shelf were disposed in all of the compartments.

Abstract: A drive system for a robot includes a track including opposed sidewalls, an electrified rail positioned between the sidewalls, a shoe mounted on the robot for contacting the electrified rail providing power to the robot, a drive motor mounted on the robot, a rotating drive member, the drive member engaging the track to drive the robot when the drive motor is actuated, means for coupling the drive member to the drive motor and means for increasing the friction between the drive system and the track at selected locations along the track.

Abstract: A system for manual delivery of mail to a series of recipients includes a stack of mail holders each comprising a front flap, a back flap and a central fold. One or more mail pieces are disposed in each holder, such that all of the mail pieces in each holder are to be delivered to the same recipient. The holders are stacked in a predetermined order for a carrier delivery route, and may be banded or otherwise secured together until the time of delivery.

Abstract: A method for sorting mail pieces includes the steps of loading mail pieces to be sorted into individual holders, sorting the holders using an automated system that stores and reorders the holders so that the holders are ordered according to a sort scheme for the mail pieces, storing the sorted holders in a storage area during sorting, and then unloading the mail pieces from the holders in order according to the sort scheme. The storage step occurs during sorting in the sense that a series of reordered holders is gradually created in one of a variety ways by the sorting process, and a storage area is provided for this purpose. Preferably the method further includes steps of unloading the sorted holders from the storage area and transporting the holders to an unloading station at which the unloading step is carried out.

Abstract: A method is provided for processing mail at a sorting facility, which mail includes automation mail that can be processed automatically by automated machines at the sorting facility and manual mail which, due to its physical characteristics, cannot be processed by the automated machines at the sorting facility. Such a method includes the steps of placing a piece of manual mail into a sleeve such that the combination of sleeve and mail piece can be processed by the automated machines at the sorting facility, and processing the sleeve containing the manual mail piece on the automation equipment along with automation mail. Following processing, the sleeve can either be removed from the mail piece, or left in place for delivery to the postal customer.

Abstract: A mail case system facilitates sequence-sorting various types of mail together into individual bags that each represent delivery points. The mail case uses multi-bag inserts so that bags for a number of stops can be set up for sorting. At the end of the sorting operation, the entire insert may be pulled down from the case as a single unit to maintain the established delivery point sequence.

Abstract: A method for sorting mail to a case having a plurality of slots is described, wherein each slot corresponds to a destination. The method includes steps of loading a mail piece to be sorted into a delivery robot, determining for the mail piece a destination slot the mail piece is to be delivered to, moving the delivery robot along a rail disposed at the front of the case near the slots into proximity with an open end of the destination slot, inserting the mail piece from the delivery robot into the associated slot, and returning the delivery robot to a loading station whereby the cycle may be repeated. Such a method, when using a large number of robots moving along a common rail system, can sort a large volume of mail in carrier delivery order.

Abstract: A mail case system includes facilitates sequence-sorting various types of mail together into individual bags that each represent unique delivery points. The mail case uses multi-bag inserts so that the bags for several stops can be set up quickly for sorting. At the end of the sorting operation, the entire insert may be pulled down from the case as a single unit to maintain the established delivery point sequence. This eliminates the carrier's need to find separation points or to combine selections from multiple sequenced stacks of mail during the delivery operation. This results in a dramatic improvement in delivery efficiency.

Abstract: A mail case system includes facilitates sequence-sorting various types of mail together into individual bags that each represent unique delivery points. The mail case uses multi-bag inserts so that the bags for several stops can be set up quickly for sorting. At the end of the sorting operation, the entire insert may be pulled down from the case as a single unit to maintain the established delivery point sequence. This eliminates the carrier's need to find separation points or to combine selections from multiple sequenced stacks of mail during the delivery operation. This results in a dramatic improvement in delivery efficiency.

Abstract: A method for sorting mail to a case having a plurality of slots is described, wherein each slot corresponds to a destination. The method includes steps of loading a mail piece to be sorted into a delivery robot, determining for the mail piece a destination slot the mail piece is to be delivered to, moving the delivery robot along a rail disposed at the front of the case near the slots into proximity with an open end of the destination slot, inserting the mail piece from the delivery robot into the associated slot, and returning the delivery robot to a loading station whereby the cycle may be repeated. Such a method, when using a large number of robots moving along a common rail system, can sort a large volume of mail in carrier delivery order.