Accumulation system for processing media items of various sizes and types
An accumulator system and method for collating a plurality of media items wherein the media items enter in seriatim at an media item entry point and become at least partially overlapped with each other at a media item exit point. A media item transport path connects the media item entry point and the media item exit point. A moveable member is mounted along the media item transport path between the entry point and the exit point. The moveable member forms part of a pocket into which media items are moved to create a collation of media items. The moveable member is moveable to change the size of the pocket. A protective member may be mounted to the moveable member and positioned to protect the trailing edge of media items in the pocket from the leading edge of media items to thereafter be moved into the pocket. The media item may be aligned in the collation position when moving the protective member to a media item trailing edge protective position. The transport means for media items can be controlled to partially move a media item along an exit path beyond the collation position. Media items of different lengths can be formed as part of the collation at the collation position with the trailing edge of the media items aligned.
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The present invention relates to media handling equipment, such as folder, insertion and other systems and, more particularly, to an accumulation system for processing media items of different sizes and types.
BACKGROUND OF THE INVENTIONVarious systems require the accumulation of media for further processing. Accumulator systems have been developed to assemble packets, often referred to as collations, for further processing. Prior accumulator systems have included fixed pitch pusher chain or belt arrangements, friction belts with a customer adjustable end stop arrangements and various other arrangements. Packets or collations of media items may be utilized in insertion systems, book binding systems and other systems.
Where the accumulator system is employed with insertion equipment, the accumulator system should, desirably, be capable of reliability handling a large variety of media that are to be processed. The media may be sheets to be folded, pre-folded and unfolded inserts, return enclosure envelopes, and the enclosure envelope into which the media item are to be inserted to build a mail piece. These media items may be of different sizes, thicknesses and types, such as glossy pamphlets, advertising brochures or very thin media. It has been particularly difficult to accumulate media of this variety whether for insertion into an envelope, other enclosure or other application. Often, when accumulating variable media items within the same collation, the collation or variation in fold types and sizes must be limited in order to prevent inter-leaving of materials as they enter the accumulator, as well as slippage and skewing of the completed collation as it exits the accumulator for insertion into an envelope, other enclosure or for a different application. Accordingly, prior accumulators have been
An accumulator system for collating a plurality of media items, wherein the media items enter in seriatim at a media item entry point and become at least partially overlapped with each other at a media item exit point, embodying the present invention includes a media item transport path connecting the media item entry point and the media item exit point. A moveable member is mounted along the media item transport path between the entry point and the exit point. The moveable member forms part of a pocket into which media items are moved to create a collation of media items. The moveable member is adjustable to change the size of the pocket.
In accordance with a feature of the present invention a protective shield is mounted to the moveable member and positioned to protect the trail edge of media items in the pocket from the lead edge of media items to thereafter be moved into the pocket.
An accumulator system for collating a plurality of media items, wherein the media items enter in seriatim at a media item entry point and become at least partially overlapped with each other at a media item exit point, also embodying the present invention includes a media items transport belt connecting the media item entry point and the media item exit point. A moveable shuttle is mounted for reciprocating movement below the media item transport belt and between the entry point and the exit point. The moveable shuttle forms part of a pocket into which media items are moved to form a collation of media items. A member is mounted to the shuttle providing a guide surface for media items moved into the pocket and a protective shield for the trail edge of media items.
A method of forming a collation of media items embodying the present invention includes the steps of moving a media item over a protective member and into a position for collation with other media items. Moving the protective member to a position where the protective member is not in engagement with the media item. And, moving the protective member to a position where the trail edge of the media item is protected from interference with other media items to be moved into the collation position.
A feature of the present invention includes the further step of aligning the media item in the collation position when moving the protective member to the media item trail edge protective position.
A method of creating a collation of media items also embodying the present invention includes moving a first media item of a first length into a position for collation with a second shorter length media item by partially moving the first media item along a collation exit path. And, moving the second shorter length media item into the collation position such that the trailing edge of the first media item and the second media item are aligned.
In accordance with aspects of the present invention additional shorter media items a first media item may be moved into and beyond the collation position or into but not beyond the collation position, depending on the length of the additional shorter length media items.
BRIEF DESCRIPTION OF THE DRAWINGSReference is now made to the various figures wherein like reference numerals designate similar items in the various view and in which:
Reference is now made to the various figures and more particularly to
The post-fold accumulator station 14 employs an accumulator mechanism 18, illustrated in
The fingers 22, 24, 26 and 28 provide a protective shield for the rear edge of the mail pieces in the pocket 50 by ensuring that the next media item fed into the pocket 50, the collation position, does not crash into the trail edge of media already in pocket 50. Other protective type shield structures may be employed. The protective shield can be a continuous member rather than fingers, segment pieces and other structures that provide the protective function by preventing the next media item fed into the pocket from crashing into the trail edge of media already in pocket 50.
The post-fold accumulator mechanism 18 includes fixed idler rollers 60 and 62, which cooperate with the post-fold accumulator drive belt 38. No matter what the position of the shuttle in making a changing pocket size, a sufficient number of idler rollers always engage the post-fold accumulator transport belt 38 to securely and properly feed and transport media items of various sizes. This is because the fixed idler rollers 60 and 62 in conjunction with the idler rollers 30, 32, 34 and 36 mounted on shuttle 20 all engage associated transport belts. Media is fed into the post-fold accumulator mechanism 18 at the nip 64 formed by drive rollers 43 and 45 and the idler roller 66, which operates in conjunction with drive roller 45, and an idler roller, not shown, which operates in conjunction with drive roller 43. This arrangement ensures that the media items will be positively moved into engagement with belts 38a, 38b, and 38c, and the associated idler rollers for transport within the accumulator mechanism 18. The entry of media items into the post-old accumulator station 12 can be from either of two media paths, path 68 (where a media item is shown) or path 69.
The insertion station 14 includes the belt 56 and idler roller 58, which drive media items and/or collations past the throat opening of finger 70 and into an envelope 72. The envelope flap 72a is captured between a drive roller 74 and an idler roller 76. The insertion mechanism is described in the above-identified U.S. patent application Ser. No. 11/084,233 (Pitney Bowes Docket No. F-953).
Reference is now made to
Reference is now made to
Reference is now made to
The fingers 22, 24, 26 and 28 rise up and overlap the trail edge of the media item 80. As is shown in
After the accumulation is complete, the insertion belt 56 is tuned on and the shuttle continues to move to the right, as shown in
Reference is now made to
In this arrangement different shorter length media items moved into the pocket 50 after the longer length media items. When all the media items are brought into and/or partially ingested beyond the pocket 50, the location of the trailing edges of all of the media items in the collation are located such that they can be protected by the fingers 22, 24, 26 and 28. It should be recognized that the fingers 22, 24, 26 and 28 are of a length to accommodate certain variation in the length of various media items to be part of the collation without employing partial movement of media items out of the pocket and into the collation exit transport path. For example, the fingers 22, 24, 26 and 28, may be designed to accommodate a variation of media item length of up to 12 mm.
Because the shuttle 20 moves under servo control of the motor 48, the pocket 50 size can be automatically adjusted for all common size media and also oversize materials by employing the partial ingestion process. The initial movement or ingestion of the largest media is such that subsequent movement or ingestion of the shorter but still too large media items will have the media items properly situated so that the fingers 22, 24, 26 and 28 will engage and protect the trailing edge of these media items. As is shown in
The term media and media items are intended to be a broad term encompassing various items that may be accumulated by an accumulator mechanism. The terms are intended include items such as different types of mail pieces such as letter mail, postcards and flats. The USPS considers mail pieces to be flats when the mail piece exceeds at least one of the dimensional regulations of letter-sized mail (e.g. over 11.5 inches long, over 6 inches tall, or over ¼ inch thick) but does not exceed 15 inches by 11.5 by ¾ inch thick. Flats include such mail as pamphlets, annual reports and the like. Other examples of media items include sheets of paper, checks, compact discs, DVD discs, books, packages of greeting cards, and any other items that can be accumulated by an accumulator mechanism. The term belt is also intended to be a broad term encompassing segmented belt drive systems and single and plural belt drive systems as well as other type drive systems that function similar to a belt drive system.
It should be recognized that many modifications can be made to the present system. Many different drive arrangements can be employed for moving media items into, within and out of the post fold accumulator station. Any suitable design can be used such as those involving belts, rollers, pushers, lead screws, rack and pinions. Additionally, although the accumulator mechanism 18 is illustrated as a post-fold accumulator station in an inserter system, the accumulator mechanism may be employed in other systems and applications where media items are to be accumulated. Moreover, the pocket, the shuttle, and the guide and protective member can be of any suitable design that provides the various functions of these components. For example, the fingers could be constructed as flexible spring steel or mylar fingers or spring loaded plastic fingers. The shuttle could be various arrangements of sheet metal or plastic parts driven into the desired adjustment by a lead screw or belt or other drive mechanism.
Claims
1.) An accumulator system for collating a plurality of media items wherein the media items enter in seriatim at an media item entry point and become at least partially overlapped with each other at a media item exit point, comprising:
- a media item transport path connecting said media item entry point and said media item exit point;
- a moveable member mounted along said media item transport path between said entry point and said exit point, said moveable member forming part of a pocket into which media items are moved to create a collation of media items; and,
- said moveable member moveable to change the size of said pocket.
2.) An accumulator system for collating a plurality of media items as defined in claim 1 wherein said moveable member is movable to push media items in said pocket into said media item exit point.
3.) An accumulator system for collating a plurality of media items as defined in claim 1 further comprising a protective shield mounted to said moveable member and positionable to protect the trail edge of media items in said pocket from the lead edge of media items to thereafter be moved into said pocket.
4.) An accumulator system for collating a plurality of media items as defined in claim 3 further comprising means connected to said protective shield for urging said shield to rise above the top surface of said moveable member adjacent said trail edge of media items in said pocket.
5.) An accumulator system for collating a plurality of media items as defined in claim 4 wherein said means for urging is a spring.
6.) An accumulator system for collating a plurality of media items wherein the media items enter in seriatim at an media item entry point and become at least partially overlapped with each other at a media item exit point, comprising:
- a media item transport belt connecting said media item entry point and said media item exit point;
- a moveable shuttle mounted for reciprocating movement below said media item transport belt and between said entry point and said exit point, said moveable shuttle forming part of a pocket into which media items are moved to create a collation of media items; and,
- a member mounted to said shuttle providing a guide surface for each media item being moved and a protective shield for the trail edge of each media item after being moved into said pocket.
7.) An accumulator system for collating a plurality of media items as defined in claim 6 wherein said moveable shuttle is moveable to change the size of said pocket such that media items of various sizes can be collated.
8.) An accumulator system for collating a plurality of media items as defined in claim 6 wherein said shuttle is controllable to be stopped from movement at a position for non-collation transport of media items though said collation exit path.
9.) An accumulator system for collating a plurality of media items as defined in claim 6 further comprising idler rollers mounted on said shuttle and positioned to cooperate with said media item transport belt for transport of media items toward said pocket.
10.) An accumulator system for collating a plurality of media items as defined in claim 9 further comprising idler rollers mounted in a fixed location and positioned to cooperate with said media item transport belt for transport of media items toward said pocket.
11.) An accumulator system for collating a plurality of media items as defined in claim 6 further comprising means connected to said member for urging said member to move above the trail edge of media items in said pocket.
12.) An accumulator system for collating a plurality of media items as defined in claim 11 wherein said means connected to said member is a spring connected to urge said member to move in a direction such that said member will function as a protective shield for the trail edge of media items in said pocket.
13.) A method of creating a collation of media items, comprising the steps of:
- moving a media item over a protective member and into a position for collation with other media items;
- moving said protective member to a position where said protective member is not in engagement with said media item; and,
- moving said protective member to a position where the trail edge of said media item is protected from interference with other media items to be moved into said collation position.
14.) A method of creating a collation of media items as defined in claim 13 further comprising the step of aligning said media item in said collation position when moving said protective member to said media item trail edge protective position.
15.) A method of creating a collation of media items as defined in claim 14 wherein said step of aligning includes urging said media item against a media item stop.
16.) A method of creating a collation of media items as defined in claim 15 wherein said media item stop is at an exit point for media items in said collation.
17.) A method of creating a collation of media items as defined in claim 13 comprising the further step of selectively controlling a transport means to partially move said media item along a collation exit path such that said media item and other media items of different lengths from said media item can be formed as part of said collation at said collation position.
18.) A method of creating a collation of media items as defined in claim 17 comprising the further step of positioning said media item and other media items of different lengths from said media item with the trail edge of said media item and said other media items aligned.
19.) A method of creating a collation of media items as defined in claim 13 comprising the further steps of repeating each of said steps for each of said other media items to be moved into said collation position.
20.) A method of creating a collation of media items as defined in claim 16 comprising the further steps of repeating each of said steps for each of said other media items to be moved into said collation.
21.) A method of creating a collation of media items as defined in claim 13 wherein said protective member is mounted on a moveable member controlled for reciprocating movement.
22.) A method of creating a collation of media items as defined in claim 13 wherein said position for collation is a pocket where each media item in said collation is positioned as said collation is being formed.
23.) A method of creating a collation of media items as defined in claim 13 wherein said position for collation is a pocket where each media item in said collation is positioned as said collation is being formed and comprising the further the steps of controlling a movable member to form said pocket and moving said moveable member to urge a completed collation of media items through a collation exit point and along a collation exit path.
24.) A method of creating a collation of media items as defined in claim 13 wherein said position for collation is a pocket where each media item in said collation is positioned as said collation is being formed and comprising the further the step of controlling a movable member to form said pocket of a size to accommodate the length of media items to be formed into said collation.
25.) A method of creating a collation of media items, comprising the steps of:
- moving a first media item of a first length into a position for collation with a second shorter length media items by partially moving said first media item along a collation exit path; and,
- moving said second shorter length media item into said collation position such that the trailing edge of said first media item and said second media item are aligned.
26.) A method of creating a collation of media items as defined in claim 25 wherein moving said second shorter length media item includes partially moving said second media item along said collation exit path.
27.) A method of creating a collation of media items as defined in claim 26 comprising the further step of moving a third media item of shorter length than said second media item into but not beyond said collation position such that the trailing edge of said first media item, said second media item and said third media are aligned.
28.) A method of creating a collation of media items as defined in claim 25 wherein moving said second shorter length media item includes moving said second shorter length media item into but not beyond said collation position.
29.) A method of creating a collation of media items as defined in claim 25 comprising the further step of ordering the processing of media items to be moved into said collation position by moving the longest length media item into the collation position followed by shorter length media items.
Type: Application
Filed: Nov 15, 2005
Publication Date: May 17, 2007
Applicant: Pitney Bowes Incorporated (Stamford, CT)
Inventors: Thomas Lyga (Southbury, CT), Ming Xiao (Woodbridge, CT), Joseph Gelb (Milford, CT), Michael Chen (Trumbull, CT), James Fairweather (Milford, CT), James Salomon (Cheshire, CT)
Application Number: 11/274,794
International Classification: B65H 5/22 (20060101);