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.

Abstract: A safety device for automated processing equipment which is disposed in combination with a linear actuator to prevent operator injury. The safety device includes a base plate and a spherical element engaging the base plate to effect relative displacement of structural elements having at least one spring element projecting downwardly from the base plate, the base plate defining an aperture therein having a peripheral edge, and the at least one of the spring element including a ramped surface defining a lead angle relative to a horizontal plane, and a spherical element coupled to the end of the actuation shaft and engaging the peripheral edge of the aperture in a coupled operating mode, and disengaging the peripheral edge of the aperture when transitioning from the coupled operating mode to a safe operating mode.

Abstract: A system and method for producing printed sheet material for use in a mailpiece inserter. The system comprises an input module for supplying the printed sheet material associated with a mailpiece fabrication job of the mailpiece inserter and a transfer module adapted to receive the printed sheet material from the input module and dispense the printed sheet material. An output module is adapted to receive the printed sheet material from the transfer module and convey the printed sheet material along the transport deck. A processor is operatively coupled to a mail run data file of the mailpiece fabrication job for controlling the input, transfer and output modules to stack the printed sheet material in accordance with the mail run data file. In the method, the output module includes at least two transport decks which may be repositioned such that one of the transport decks receives/stacks the printed sheet material in a manner which is best suited for subsequent use by the mailpiece inserter.

Abstract: A system for processing nested/unnested content material in a mailpiece inserter includes a first accumulator, a second accumulator and a folding module disposed therebetween. The first accumulator is operative to feed individual sheets of content material, in one operating mode, and accumulate multiple sheets of content material in another operating mode. The second accumulator is operative to accumulate unnested, folded sheets of content material in one operating mode, and feed sheets of nested, folded sheets of content material in another operating mode.

Abstract: A system and method for producing printed sheet material for use in a mailpiece inserter. The system comprises an input module for supplying the printed sheet material associated with a mailpiece fabrication job of the mailpiece inserter and a transfer module adapted to receive the printed sheet material from the input module and dispense the printed sheet material. An output module is adapted to receive the printed sheet material from the transfer module and convey the printed sheet material along the transport deck. A processor is operatively coupled to a mail run data file of the mailpiece fabrication job for controlling the input, transfer and output modules to stack the printed sheet material in accordance with the mail run data file. In the method, the output module includes at least two transport decks which may be repositioned such that one of the transport decks receives/stacks the printed sheet material in a manner which is best suited for subsequent use by the mailpiece inserter.

Abstract: A safety device for automated processing equipment which is disposed in combination with a linear actuator to prevent operator injury. The safety device includes a base plate and a spherical element engaging the base plate to effect relative displacement of structural elements having at least one spring element projecting downwardly from the base plate, the base plate defining an aperture therein having a peripheral edge, and the at least one of the spring element including a ramped surface defining a lead angle relative to a horizontal plane, and. a spherical element coupled to the end of the actuation shaft and engaging the peripheral edge of the aperture in a coupled operating mode, and disengaging the peripheral edge of the aperture when transitioning from the coupled operating mode to a safe operating mode.

Abstract: A Right Angle Turn (RAT) module for processing multi-sheet collations includes opposed belt segments defining a conveyance channel for capturing multi-sheet collations therebetween and for conveying multi-sheet collations from an input and to an output end of the conveyance channel. The opposed belt segments define a first re-directing bend, a second re-directing bend, and a twist section disposed therebetween. The first re-directing bend includes a rolling element for re-directing the opposed belt segments about a first axis of rotation while the second re-directing bend includes a rolling element for re-directing the opposed belt segments about a second axis of rotation. The first and second axes of rotation are orthogonal to each other so as to effect a twist section therebetween.

Abstract: A system for processing nested/unnested content material in a mailpiece inserter includes a first accumulator, a second accumulator and a folding module disposed therebetween. The first accumulator is operative to feed individual sheets of content material, in one operating mode, and accumulate multiple sheets of content material in another operating mode. The second accumulator is operative to accumulate unnested, folded sheets of content material in one operating mode, and feed sheets of nested, folded sheets of content material in another operating mode.

Abstract: A Right Angle Turn (RAT) module for processing multi-sheet collations includes opposed belt segments defining a conveyance channel for capturing multi-sheet collations therebetween and for conveying multi-sheet collations from an input and to an output end of the conveyance channel. The opposed belt segments define a first re-directing bend, a second re-directing bend, and a twist section disposed therebetween. The first re-directing bend includes a rolling element for re-directing the opposed belt segments about a first axis of rotation while the second re-directing bend includes a rolling element for re-directing the opposed belt segments about a second axis of rotation. The first and second axes of rotation are orthogonal to each other so as to effect a twist section therebetween.

Abstract: An separating and staging machine is disclosed which is used in conjunction with high speed document processing apparatus in which a succession of collations of insert material moving along an insert material feed path to an insert location are inserted into envelopes fed to the insert location. The machine of the present invention feeds envelopes from a storage hopper to a feed path which is long enough to accommodate a plurality of staging locations at which individual envelopes are maintained until one is fed to the insert location, after which the envelopes at each staging location are advanced to the next staging location, and a new envelope is fed from the storage hopper to the first of the staging locations. With this arrangement the distance between successive envelopes moving through the staging locations is approximately equal to the distance between successive collations moving along the insert material feed path, thereby increasing the rate at which envelopes can be fed to the insert location.

Abstract: Disclosed is an apparatus for aligning the leading and trailing edges in abutting relationship of two adjacent webs preparatory to splicing the abutting edges together with adhesive tape, and for perforating the tape subsequent to being applied to the adjacent web wedges along the seam formed by the web edges. The apparatus comprises a fixture adapted to lie on a flat surface for holding the trailing and leading edge portions of a pair of preceding and succeeding tapes securely in place with the end edges thereof abutting so that a piece of adhesive tape can be applied thereto. The apparatus also comprises a device which cooperates with a guide on the fixture for perforating the tape along the seam formed by the aforementioned edges so that the web sheets can be separated by feeding the web into a bursting machine or otherwise.

Abstract: An apparatus is disclosed for closing and sealing the flaps of envelopes that have passed through an inserting machine in which collations of insert material have been inserted into the envelopes, and for detecting whether or not certain envelopes cannot be properly closed and sealed and for separating such envelopes from those that are properly closed and sealed. The apparatus is constructed and arranged such that if insert material is improperly inserted into the envelope such that the flap cannot turn freely about the crease line that connectes the flap to the envelopem, the flap will remain substantially in the flat, extended position it occupies when the envelope enters the closing and sealing apparatus. That position of the flap is sensed and the envelope is then diverted from the normal path of properly closed and sealed envelopes into a collection bin for retreival by an operator.