Abstract: A print module for printing mailpieces comprises a print head assembly operative to deposit ink on each mailpiece and a registration plate for registering a first surface of each of the mailpieces during print operations. The print module includes a conveyor belt opposing the registration plate and engaging a second surface of each of the mailpieces for conveyance along a feed path. Disposed beneath and supporting an underside surface of the conveyor belt, is a continuous compliant deck operative to urge the conveyor belt and mailpieces toward the registration plate during printing. The compliant deck is also operative to print consecutive mailpieces of variable thickness dimension. The print module also includes a pivotable support rack for mounting the print head assembly to a housing.

Abstract: A vacuum conveyance/manifold system is provided for processing mailpieces. The vacuum conveyance/manifold system includes at least one conveyor belt and a compliant deck disposed beneath and supporting an underside surface of the conveyor belt. The conveyor belt has rows of aligned apertures disposed therein and a drive surface for engaging a face surface of each of the mailpieces. The compliant deck defines a neutral axis in bending and has a high elongation, low modulus material in a portion of the deck which is distal from the bending neutral axis, and a high yield strength, high modulus material in a portion of the deck which lies coincident with the bending neutral axis. Furthermore, the compliant deck has a plurality of elongate slots formed in the high elongation, low modulus material, which elongate slots are aligned, and in fluid communication, with the rows of apertures in the conveyor belt.

Abstract: An apparatus is provided for altering the spatial orientation and/or direction of sheet material. The apparatus includes an input deck for receiving sheet material along an input feed path, an output deck for forwarding sheet material along an output feed path, and an orbit nip roller assembly disposed adjacent to and aligned with the input and output decks. The orbit nip roller assembly includes a primary and secondary roller defining a roller nip which lies substantially parallel to the input and output feed paths. The secondary roller is adapted to be bi-directionally displaced in an arc about the periphery of the primary roller such that the roller nip orbits the primary roller from a first radial position to a second radial position.

Abstract: A vacuum conveyance/manifold system is provided for processing mailpieces. The vacuum conveyance/manifold system includes at least one conveyor belt and a compliant deck disposed beneath and supporting an underside surface of the conveyor belt. The conveyor belt has rows of aligned apertures disposed therein and a drive surface for engaging a face surface of each of the mailpieces. The compliant deck defines a neutral axis in bending and has a high elongation, low modulus material in a portion of the deck which is distal from the bending neutral axis, and a high yield strength, high modulus material in a portion of the deck which lies coincident with the bending neutral axis. Furthermore, the compliant deck has a plurality of elongate slots formed in the high elongation, low modulus material, which elongate slots are aligned, and in fluid communication, with the rows of apertures in the conveyor belt.

Abstract: A registration plate assembly for a compliant conveyance system and is adapted for use in combination with an array of print heads each having a print head nozzle. The registration plate assembly includes a mounting plate, a registration plate affixed to the mounting plate and at least one runner fastened to the mounting plate and disposed within an opening defined by the registration plate. The mounting plate has at least one aperture therein for accepting a print head nozzle associated with each of the print head and the registration plate includes and an opening for permitting the deposition of ink from each of the print head nozzles. The runner is aligned with the feed path of the conveyance system and has a blade portion disposed at a location between adjacent print head nozzles which is operative to maintain a stand-off distance from the face surface of each mailpiece to one of the print head nozzles.

Abstract: A compliant conveyance system for processing mailpieces along a feed path, e.g., printing on a first surface of a mailpiece, while being registered against a contact surface of a registration plate. The conveyance system comprises at least one conveyor belt opposing the contact surface of the registration plate, a continuous, uninterrupted, compliant deck disposed beneath and supporting an underside surface of the conveyor belt, and a spring biasing device operative to bias the compliant deck and the conveyor belt toward the contact surface of the registration plate. The conveyor belt includes a drive surface for engaging a second surface of each of the mailpieces for conveyance along the feed path. As each of the mailpieces pass the registration plate, the compliant deck and spring biasing device urge the second surface of each mailpiece into engagement with the contact surface during processing.

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: An apparatus includes a frame, a rotatable first shaft, wherein the first shaft includes a first cam, a rotatable second shaft, an item gripper connected to the second shaft by a connection including a link and an offset shaft rotatably connected to the link, and a linkage. The link is adapted to rotate with the second shaft for pivoting the offset shaft about the second shaft. The item gripper includes jaws adapted to open and close when the offset shaft is axially rotated relative to the link. The linkage connects the first cam on the first shaft to a rider on the offset shaft. The linkage includes a second having a stepped surface for a stepped movement of the rider along the stepped surface to open the jaws during a predetermined angular movement of the offset shaft about the center axis of the second shaft.

Abstract: An apparatus for registering sheet material while being conveyed along a feed path including: (i) a conveyance deck for conveying sheet material along a support surface, (ii) a registration member defining an abutment surface operative to align an edge of the sheet material as the sheet material is conveyed along the support surface of the conveyance deck, and (iii) a drive mechanism disposed adjacent to the registration member and along the conveyance deck. The drive mechanism includes a flexible belt disposed about and supported by at least two rolling elements, and a means for driving the flexible belt about the rolling elements. The flexible belt includes a twisted section defining a plurality of spiral edge segments operative to (i) frictionally engage a surface of the sheet material to urge the sheet material against the abutment surface and (ii) convey the sheet material along the conveyance deck.

Abstract: An apparatus is provided for altering the spatial orientation and/or direction of sheet material. The apparatus includes an input deck for receiving sheet material along an input feed path, an output deck for forwarding sheet material along an output feed path, and an orbit nip roller assembly disposed adjacent to and aligned with the input and output decks. The orbit nip roller assembly includes a primary and secondary roller defining a roller nip which lies substantially parallel to the input and output feed paths. The secondary roller is adapted to be bi-directionally displaced in an arc about the periphery of the primary roller such that the roller nip orbits the primary roller from a first radial position to a second radial position.

Abstract: A reconfigurable transport system includes a transport device for receiving items in a first orientation in one of a first portion and a second portion and releasing the items from the other of the first portion and the second portion. The transport device includes rotating transport elements in opposing relation. Items received between the transport elements are conveyed along a transport axis. The transport system further includes a positioning device for selectively moving the second portion between a first position in which the transport device maintains the items in the first orientation, and a second position in which the transport device rotates the items substantially about the transport axis to a second orientation.

Abstract: An item transport system includes a first transport element rotating around a plurality of first transport rollers in a first direction, a second transport element in opposing relation to the first transport element, the second transport element rotating around a plurality of second transport rollers in a second direction opposite to the first direction, a guide plate proximate to the first transport element for engaging the items during processing by an item processing element, and an item registration device configured to maintain the items in registration with the guide plate. The item registration device includes a plurality of independently articulating pivot assemblies biased to engage the second transport element with the first transport element and a plate associated with each pivot assembly. Each plate is fixedly constrained with respect to the pivot assembly at one end and slidably constrained with respect to the pivot assembly at another end.

Abstract: A method for printing information on a print medium, such as a mailpiece, that includes determining a thickness of the medium while it is being transported toward a print head, such as an ink jet print head, causing the distance between the top surface of the medium the print head when the medium is located below the print head to be within a specified range based on the determined thickness, and printing the information on the print medium. Also, an apparatus includes a printing station having a print head, a transport mechanism for transporting the medium toward the printing station, and a thickness measuring mechanism. The apparatus is structured to cause the distance between the top surface of the medium and a portion of the print head when the medium is located below the print head to be within a specified distance range based on the thickness of the medium.

Abstract: An item transport system includes a first transport element rotating around a plurality of first transport rollers in a first direction, a second transport element in opposing relation to the first transport element, the second transport element rotating around a plurality of second transport rollers in a second direction opposite to the first direction, a guide plate proximate to the first transport element for engaging the items during processing by an item processing element, and an item registration device configured to maintain the items in registration with the guide plate. The item registration device includes a plurality of independently articulating pivot assemblies biased to engage the second transport element with the first transport element and a plate associated with each pivot assembly. Each plate is fixedly constrained with respect to the pivot assembly at one end and slidably constrained with respect to the pivot assembly at another end.

Abstract: A mailer primarily composed of three layers, or sheets, that are fastened on top of one-another. A back sheet forms the back of both the outgoing and return mail pieces. The back sheet includes the reclosable flap and further includes an opening to allow external viewing of an identification code marked on a media sleeve that is placed in the finished mailer. A second sheet is a middle sheet fastened on top of the back sheet. The middle sheet also has an opening, and is attached to the back sheet such that the middle sheets opening aligns with the back sheet opening. A disk receiving slot is formed between the back sheet and the middle sheet. The aligned openings in the back and middle sheets are located in a center of the disk receiving slot. A third top sheet is removably attached on top of the middle sheet. The top sheet includes delivery markings for original mailing portion of the mailer.

Abstract: A method and system for preparing mail pieces that include RFID enabled cards. The improvement provides enhanced tracking and control capabilities for such mail pieces. In an inserter control system, individual RFID signals of the RFID enabled cards are related to particular mail pieces in a mail piece production database. The corresponding RFID enabled cards are fed into the inserter system from a card feeder. An attaching device attaches the cards to a carrier sheet. The inserter system transports the cards and carrier sheets to different stations where other documents are joined with the carrier sheets. The assembled mail pieces are then inserted into envelopes to form finished mail pieces. Sensors are located within the system to detect the RFID signals of the individual cards. The sensed individual RFID numbers are compared with stored mail piece data. The system is programmed to process the mail piece based on instructions in the database corresponding to the sensed number.

Abstract: A stacking apparatus (10) for stacking flat articles (12) on edge is provided, including a belt turn-up apparatus (20) for receiving the articles at an entry nip (26a) in a flat position and providing them to a discharge magazine (40) in an on-edge position, the belt turn-up apparatus (20) including a housing (20b) contained within an exterior frame (20a) and rotatable about a shaft (20c) near the entry nip (26a) via a screw adjustment (20d) at the egress end of the housing (20b), i.e. adjacent the discharge magazine (40), and so allowing an adjustment of the stacking apparatus (10) to compensate for different sizes of envelopes (12).

Abstract: A stacking apparatus (10) for stacking flat articles (12) on edge is provided, including a belt turn-up apparatus (20) for receiving the articles at an entry nip (26a) in a flat position and providing them to a discharge magazine (40) in an on-edge position, the belt turn-up apparatus (20) including a housing (20b) contained within an exterior frame (20a) and rotatable about a shaft (20c) near the entry nip (26a) via a screw adjustment (20d) at the egress end of the housing (20b), i.e. adjacent the discharge magazine (40), and so allowing an adjustment of the stacking apparatus (10) to compensate for different sizes of envelopes (12).

Abstract: A web trim collection system having an air pressure system to move web trim. A divert bin operable in a first position to allow the web trim to be deposited in a collection bin. The divert bin is also operable in a second position to intercept the web trim, so as to allow the collection bin to be removed from the collection system while the collection system continues to collect trim.

Abstract: A web trim collection system having an air pressure system to move web trim. A divert bin operable in a first position to allow the web trim to be deposited in a collection bin. The divert bin is also operable in a second position to intercept the web trim, so as to allow the collection bin to be removed from the collection system while the collection system continues to collect trim.