SYSTEMS AND METHODS FOR FEEDING SINGLE SHEETS

Abstract

A sheet feeder for feeding a single sheet of sheet material is disclosed. The sheet feeder can utilize a specially designed cutout and a suction cup to feed difficult, thin, or flimsy material one sheet at the time. The cutout can be located on a shuttle table, endless belt, or carousel, for example, and can be used in conjunction with one or more suctions cups. The cutout can be angled with respect to the sheet so that the leading edge of the sheet is substantially supported. A slot in the cutout can enable the suction cup to pull down the corner of the sheet. The slot can then continue to slice, or peel, the sheet of the bottom of a stack of sheets. The ability to pull only the corner of the sheet down initially prevents stiction from a variety of sources and enables a single sheet to be pulled from the stack.

Description

CROSS REFERENCE TO RELATED APPLICATIONS AND PRIORITY CLAIM

This application claims priority under 35 U.S.C. §119(e), and the benefit of, U.S. Provisional Patent Application No. 61/445,289 of the same title, filed 22 Feb. 2011, which is incorporated herein in its entirety as if set forth below.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to a system and method for feeding single sheets of product, and particularly to a system and method for feeding single sheets of thin or flexible paperstock from a stack.

2. Background of Related Art

A variety of single-sheet feeders exist that are designed to pull a single sheet of product from a stack of product. The product can be, for example and not limitation, paper, plastic, or cardstock. Feeders can be used in a variety of industries to pull single articles out for further processing including, but not limited to, printing, folding, sealing, or laminating. Kirk-Rudy has manufactured single sheet feeders since 1967. The Kirk-Rudy shuttle feeder uses vacuum to pull the bottom product under a gate into oscillating pinch rollers to pull the product out from under the stack. The Kirk-Rudy friction feeder, on the other hand, uses friction belts and a friction retard roller to separate the bottom product from the stack. The Kirk-Rudy rotary feeder uses suction cups to pull the bottom product from the stack into rotating gripper clamps that pull the product into a top and bottom belt drive that pulls the product away from the stack.

These feeders work well enough on a wide range of products. A problem occurs, however, when the product is particularly thin and/or flimsy such as, for example, very thin paper, Mylar®, or napkins (“extra thin product”). With extra thin products, the product is not stiff enough to overcome the attractive forces between the bottom sheet (or, “object sheet”) and the adjacent sheet in the stack. In other words, the static cling and other forces that tend to adhere one sheet to the next are greater than the stiffness of the individual sheets making it difficult to separate the sheets. This problem can be exacerbated in the commercial setting because of the large stacks of product used, which tend to magnify these forces. Due to these forces, when the bottom sheet of product is pulled down to be separated from the stack, one or more adjacent sheets tend to stick to the object sheet.

As a result, rather than pulling the object sheet cleanly off the bottom of the stack, two or more sheets are pulled off the stack. This can result in jams in the feeder, or downstream machines, and other problems that require clearing and maintenance. If the product is being pulled out of the stack for printing (e.g., custom printed napkins), for example, this can result in alignment problems or failure to print on each individual sheet because each sheet is not being pulled and fed into the printer individually.

Regardless of the downstream process being applied to the product, therefore, it is desirable to have a reliable, fast method for removing one sheet of extra thin product from the bottom of a stack. It is to such a system and method that embodiments of the present invention are primarily directed.

BRIEF SUMMARY OF THE INVENTION

The present invention relates generally to a system and method for feeding single sheets of thin product, and particularly to a system and method for feeding single sheets of thin, paper or plastic product from the bottom of a stack.

Embodiments of the present invention can comprise a feeder with a chassis, a shuttle table, and a product tray. In some embodiments, the shuttle table can reciprocate with respect to the chassis, while the product tray remains stationary. In other embodiments, the shuttle table can remain stationary with respect to the chassis, while the product tray reciprocates. The chassis can further comprise one or more electric motors, a crank arm, and one or more transport belts. The crank arm can further comprise a suction cup cam for operating a reciprocating suction cup.

The shuttle table can further comprise one or more rollers, a special cutout, and a spring-loaded pinch roller. The one or more rollers can enable a stack of sheets located in the product tray to remain stationary as the shuttle table reciprocates beneath it. The special cutout can be angled with respect to the stack of sheets and can further comprise a slot. In some embodiments, the slot can be located at one end of the special cutout and can enable the suction cup to pull a corner of the bottommost sheet (or, “object sheet”) down through the special cutout.

In some embodiments, the suction cup can reciprocate vertically below the shuttle table such that it rises just above the level of the shuttle table in a first position to grasp the corner of the object sheet. The suction cup can then move downward to a second position to pull the corner of the object sheet through the special cutout and below the shuttle table. As the shuttle table moves rearward, the object sheet can become trapped between the spring-loaded pinch roller and the one or more transport belts. The transport belt can pull the object sheet completely under the table and off the stack. The object sheet can then be transported to the next station for further processing or collating.

In some embodiments, the product can reciprocate and the shuttle table can remain stationary. In this configuration, the product tray can reciprocate over the special cutout in the shuttle table to pull individual sheets off the stack. In other embodiments, the special cutouts can be utilized in an endless belt or carousel configuration. In this manner, multiple objects sheets can be pulled at the same time.

Embodiments of the present invention can comprise a machine for feeding single sheets of material. In some embodiments, the machine can comprise a first product tray for holding a plurality of sheets of material in a first stack, a first angled slot comprising a special cutout located at a first end of the slot, a first suction cup for reciprocating proximate the special cutout for pulling a single sheet from the bottom of the first stack through the special cutout, and a device for creating relative motion between the first stack and the first angled slot. The relative motion between the first angled slot and the first stack can enable the slot to remove a single sheet of material from the bottom of the first stack.

In some embodiments, the device can be a reciprocating shuttle table. In other embodiments, the device can be a rotating belt or a carousel comprising a plurality of angled slots. In a preferred embodiment, the special cutout is triangular, though other shapes, such as, for example and not limitation, a rectangle, trapezoid, parallelogram, or circle are possible. In some embodiments, the machine can further comprise a first spring-loaded pinch roller disposed on the underside of the device, and a transport belt for pulling the single sheet off the bottom of the first stack. In this configuration, when the suction cup pulls the single sheet through the special cutout, the single sheet can become trapped between the first spring-loaded pinch roller and the transport belt and can be removed from the bottom of the first stack.

Embodiments of the present invention can also comprise a machine for feeding single sheets of material. In some embodiments, the machine can comprise a chassis, a product tray for holding a plurality of sheets of material in a stack, and a shuttle table. The shuttle table can comprise, for example, an angled slot comprising a special cutout, one or more rollers for supporting the shuttle table in rolling engagement with the chassis, and a spring-loaded pinch roller disposed on the underside of the shuttle table. The machine can further comprise, a suction cup, reciprocating proximate the special cutout, for pulling a single sheet from the bottom of the stack through the special cutout, and a transport belt for pulling the single sheet off the bottom of the stack. As before, when the suction cup pulls the single sheet through the special cutout, the single sheet becomes trapped between the spring-loaded pinch roller and the transport belt and is removed from the bottom of the stack.

In a preferred embodiment, the first angled slot comprises an angled parallelogram and the special cutout comprises a triangle disposed on a first end of the parallelogram. In another preferred embodiment, the shuttle table reciprocates with respect to the chassis to pull a single sheet off of the bottom of the stack. In some embodiments, the machine can further comprise a suction cup cam comprising a first cam profile, and a suction cup arm for reciprocating the suction cup in response to the first cam profile.

Embodiments of the present invention can also comprise a machine for feeding multiple, single sheets of material comprising a chassis and a carousel. In some embodiments, the carousel can comprise a plurality of angled slots, with each angled slots comprising a special cutout, a plurality of spring-loaded pinch rollers disposed on the underside of the carousel, one or more product trays, each tray for holding a plurality of sheets of material in one or more stacks, and a plurality of suction cups reciprocating proximate each of the special cutouts, each suction cup for pulling a single sheet from the bottom of the one or more stacks through the a plurality of special cutouts. In this configuration, each of the plurality of suction cups can pull a single sheet through one of the plurality of special cutouts, enabling the single sheet to become trapped between a spring-loaded pinch roller and the carousel to be dropped below the carousel.

In some embodiments, each of the single sheets can be dropped below the carousel onto a transport belt. In some embodiments, the transport belt can comprise, for example, a rotating flight chain rotating in the same direction as the carousel. In other embodiments, the transport belt can comprises a rotating flight chain rotating in the opposite direction as the carousel. The machine can further comprise a first product tray for holding a plurality of sheets of a first material in a first stack, and a second product tray for holding a plurality of sheets of a second material in a second stack. In this manner, the first material and the second material can be collated as they are dropped below the carousel.

Similarly, embodiments of the present invention can also comprise a machine for feeding multiple, single sheets of material comprising a chassis and a rotating belt. The rotating belt can comprise a plurality of angled slots, each angled slots comprising a special cutout. The machine can also comprise one or more product trays, each tray for holding a plurality of sheets of material in one or more stacks, and disposed proximate a top surface of the rotating belt, and a plurality of suction cups reciprocating proximate each of the special cutouts. Each suction cup can be used to pull a single sheet from the bottom of the one or more stacks through the plurality of special cutouts. As before, when each of the plurality of suction cups pulls a single sheet through one of the plurality of special cutouts, the belt can remove a single sheet from the bottom of the one or more stacks to be dropped below the belt.

In some embodiments, the machine can further comprise a lugged collating base dispose proximate a bottom surface of the rotating belt and comprising a plurality of lugs for collating the plurality of sheets. In other embodiments, the machine can further comprise a motor and a plurality of pulleys in mechanical engagement with the rotating belt. At least one of the plurality of pulleys can be detachably coupled to the motor to rotate the rotating belt. In some embodiments, the machine can further comprise a reciprocating linkage mechanically coupling the plurality of suction cups for timing the reciprocal motion of the plurality of suction cups.

These and other objects, features and advantages of the present invention will become more apparent upon reading the following specification in conjunction with the accompanying drawing figures.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a perspective view of a feeding machine, in accordance with some embodiments of the present invention.

FIGS. 2a and 2b illustrate top and bottom perspective views of a shuttle table 110 for the feeding machine of FIG. 1, in accordance with some embodiments of the present invention.

FIGS. 3-6 illustrate a side view of feeding machine of FIG. 1 in various positions of operation, in accordance with some embodiments of the present invention.

FIG. 7a illustrates a top view of an endless belt embodiment, in accordance with some embodiments of the present invention.

FIG. 7b illustrates a side view of an endless belt feeder, in accordance with some embodiments of the present invention.

FIG. 8 illustrates a side, perspective view of a carousel-style feeder, in accordance with some embodiments of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Embodiments of the present invention relate generally to a system and method for accurately feeding single sheets of thin product, and particularly to a system and method for feeding single sheets of thin paper or plastic products from the bottom of a stack of thin product. The system can comprise, among other things, a reciprocating shuttle table, a spring-loaded pinch roller, and a specially designed cutout. The system can enable particularly thin or flimsy articles (“extra thin product”) to be pulled reliably from the bottom of a stack. This enables thin products that previously were not suitable for operations such as automatic collating, sorting, or printing to be reliably and automatically processed.

To simplify and clarify explanation, the system is described below as a system for use with thin paper articles or sheets (“sheets”). One skilled in the art will recognize, however, that the invention is not so limited. The system can be deployed to handle a variety of thin or flimsy materials such as, for example and not limitation, napkins, pamphlets, flyers, or foil that tend to be flexible and/or stick together. In some embodiments, the system can also be used for heavier items such as, for example and not limitation, cardstock, cardboard, or paperboard provided the necessary adjustments to the system are made (e.g., suction strength).

The materials described hereinafter as making up the various elements of the present invention are intended to be illustrative and not restrictive. Many suitable materials that would perform the same or a similar function as the materials described herein are intended to be embraced within the scope of the invention. Such other materials not described herein can include, but are not limited to, materials that are developed after the time of the development of the invention.

As described above, a problem with conventional sheet feeding machines is that they are often unable to reliably pull a single sheet of extra thin product off the bottom of a stack of the material. This can be due to, among other things, the thickness of the product itself, static cling, and/or friction. Puling more than one sheet at a time can obviously result in jams, misalignments, and misprints in the feeder itself and, more likely, in downstream machines. This can create issues during production as jams needs to be cleared, for example, while misprints and misalignments represent costly product waste. As mentioned above, this problem can be exacerbated in a commercial setting in which a large stack of extra thin product can serve to increase the forces between the bottommost sheet and the stack.

What is needed, therefore, is a machine that can reliably and quickly pull a single sheet of product off the bottom of a large stack of product. It is to such a machine that embodiments of the present invention are primarily directed.

As shown in FIG. 1, embodiments of the present invention can comprise an improved sheet feeding machine, or sheet feeder 100. In some embodiments, the sheet feeder 100 can comprise a chassis 105, a shuttle table 110, and a product tray 115. Product can be placed in a stack on the shuttle table 110 and be held in place by the product tray 115. The product tray 115 can be adjustable for, for example and not limitation, the width and/or the length of the product.

As discussed below, no provision is provided, or required, to adjust for the thickness of the product as the machine 100 simply pulls the bottommost sheet off the stack regardless of thickness. The feeding machine 100 can be driven, for example and not limitation, by one or more electric, hydraulic, or pneumatic motors. In some embodiments, various features of the feeder 100 can be connected with a variety of mechanical linkages to enable one motor to drive multiple operations on the feeder 100.

As shown in FIGS. 2a and 2b, the shuttle table 110 can comprise a plurality of rollers 205, a special cutout 210, and a spring loaded pinch roller 215. The special cutout 210 enables a corner of the leading edge of the product to be pulled down, while still supporting the remainder of the leading edge of the product. This minimizes sticking between the object sheet and adjacent sheets by minimizing the amount of friction and static cling. In other words, the forces acting on the corner are lower than the forces acting across, for instance, the entire leading edge or the entire sheet. Bending the corner is also maximized by supporting the remainder of the leading edge, which tends to better separate the sheets. This combination of actions tends to prevent the object sheet from sticking to and pulling down the adjacent sheet or sheets (i.e., the sheets in the stack directly above the object sheet).

As the shuttle table 110 moves rearward, the object sheet is “sliced,” or peeled, off the bottom of the stack, through the cutout, or slot 210, and pulled below the table 110. Because the slot 210 is angled, it slices across the leading edge of the product gradually as the shuttle table 110 moves rearward. In this manner, a portion of the leading edge of product is supported until the entire leading edge has been peeled of the stack. As the shuttle table 110 continues to move rearward, the product is trapped by the spring-loaded pinch roller 215 located on the underside of the shuttle table 110.

As shown in FIGS. 2a, 2b, and 3, in some embodiments, the corner of the object sheet 305 can be pulled down with a suction cup 310. The suction cup 310 can be disposed underneath the shuttle table 110 in a slot 210a in the special cutout 210. The slot 210a can be, for example and not limitation, rectangular, square, wound or oblong. In a preferred embodiment, as shown in FIGS. 2a and 2b, the slot 210a can be triangular. In some embodiments, the suction cup 310 can reciprocate along a generally vertical path in a suction cup guide 315 such that the suction cup 310 starts approximately even with, or slightly proud of, the surface of the shuttle table 110 and then moves below the table 110 to pull the object sheet 305 down through the slot 210a. In other embodiments, the suction cup 310 can travel along an arcuate path. Of course, other suitable methods could be used to pull the corner down, such as, for example and not limitation, a hook, a suitable adhesive, or an air blast, and are contemplated herein.

The suction cup 310 can be made to reciprocate in a variety of ways. In some embodiments, the suction cup 310 can be connected, via one or more linkages, to a central crank arm 320. As shown, in some embodiments, the crank arm 320 can be connected to the shuttle table 110 and can be fitted with a suction cup cam 325 to provide reciprocal motion for the suction cup 310. In some embodiments, the suction cup 310 can be connected to a suction cup arm 322, which reciprocates in response to the profile on the suction cup cam 325. In other embodiments, the suction cup 310 or the suction cup arm 322, for example, can be directly connected to the crank arm 320. Of course, a variety of cranks and linkages could be used to achieve the same effect and are contemplated herein.

The sheet feeder 100 can further comprise one or more transport belts 330. The transport belts 330 can be affixed to the chassis 105 of the feeder 100 and can be driven by one or more pulleys 335a, 335b and an electric motor 340, for example. As shown, in some embodiments, the rear pulley 335a can be larger than the front pulley 335b. In some embodiments, the pulleys 335a, 335b can be equally sized, but mounted at an angle, for example. In this manner, as the shuttle table 110 moves rearward, slicing off the object sheet 305, the spring-loaded pinch roller 215 can contact the transport belt 330, pinching the object sheet 305 between the pinch roller 215 and the transport belt 330. Because the transport belt 330 is rotating in a forward direction (in this case clockwise), the object sheet 305 is also pulled forward. The transport belt 330 can then carry the object sheet 305 forward, for example, or drop in onto another belt or machine for further processing.

The product tray 115 can be adjustable for width and/or length of product. The product tray 115 can be adjusted to hold a stack of product and prevent the stack from falling or skewing. Because the object sheet 305 is being pulled off from the bottom, however, no thickness adjustment is provided or necessary. The suction cup 310 can simply pull the corner of a single sheet of product 305 down into the slot 210a to be sliced off by the cutout 210 as the shuttle table 110 moves forward. In a preferred embodiment, the plurality of rollers 205 on the shuttle table 110 can enable the shuttle table 110 to roll along the chassis 105 as it reciprocates. The rollers 205 can also enable the stack to remain stationary as the shuttle table 110 reciprocates below it. The guides on the product tray 115 act to hold the stack in place as the rollers 205 on the shuttle table 110 roll beneath it. Of course, the product tray 115 could be designed to reciprocate with the respect to the shuttle table 110 with similar results.

FIG. 3 depicts the starting, or rest, position for the sheet feeder 100. As shown, the crank arm 320 can be in the rest position such that the shuttle table 110 is in a forward position. In addition, the suction cup arm 322 can be in contact with a flat on the suction cup cam 325. In this position, the suction cup 310 is in its highest position with respect to the shuttle table 110. In this configuration, the spring-loaded pinch roller 215 can be out of contact, or in slight contact, with the transport belt 330.

As shown in FIG. 4, as the feeder 100 begins to cycle, the shuttle table 110 can begin its rearward motion. At the same time, the lobe on the suction cup cam 325 begins to act on the suction cup arm 322 causing it to move in a downward direction, away from the shuttle table. As mentioned above, this pulls the corner of the object sheet 305 down and begins to slice it off the bottom of the stack. As the shuttle table 110 moves rearward, therefore, the spring-loaded pinch roller 215 comes into contact with, or becomes more loaded by, the transport belt 330 (i.e., depending on whether the initial setting for the spring-loaded pinch roller 215 was out of contact, or in slight contact, with the transport belt 330).

In FIG. 5, the shuttle table 110 is shown in the substantially rearward position and the suction cup 310 has reached its lowest position. At this point, the leading edge of the object sheet 305 has been fully sliced off the stack and drawn under the shuttle table 110 and into contact with the transport belt 330. At the same time, the spring-loaded pinch roller 215 has moved rearward enough to catch the leading edge of the object sheet 305 and pinch it between the roller 215 and the transport belt 330. The transport belt 330 can then pull the object sheet 305 completely out of the stack for further processing (e.g., printing, collating, or folding).

In FIG. 6, the feeder 100 has returned to the rest position and the object sheet 305 is traveling down the transport belt 330 for further processing. The transport belt 330 can, for example, pull each sheet out individually to deposit them on a conveyor belt for downstream processing. In some embodiments, the sheets can be pulled out and deposited in a carousel for collating or other functions. In other embodiments, the present invention can be incorporated directly into, for example and not limitation, folding, tabbing, or printing machines that then subject the object sheet 305 to further processing including, but not limited to, folding, sealing, laminating, or printing.

Embodiments of the system can be used in different configurations to achieve different goals. For example, as shown in FIGS. 7a and 7b, embodiments of the present invention can be incorporated into an “endless belt” sheet feeder 700. In this configuration, the special cutout 710, formerly in the shuttle table 110, can be integrated into an endless belt 705 that can be rotated by two or more pulleys 715 to act on multiple stacks of product 720. A plurality of suction cups 725 can be mounted below the belt 705 and, in some embodiments, can be connected via mechanical linkages 730. As above, the suction cups 725 can be timed such that they rise into the slot 710a in the special cutout 710 to pull the corner of the object sheets down as the slot 710a passes. Each slot 710a can then peel off one object sheet from each stack 720 as it passes, pulling off multiple (single) sheets at the same time (i.e., one sheet from each stack). As shown, in some embodiments, the sheets can be peeled of onto a lugged collating base 735. This can enable the sheets to be collated into multiple stacks for, for example, further processing.

In some embodiments, as shown in FIG. 8, the special cutout 810 can be incorporated into a carousel feeder 800. As shown, a carousel 805 can comprise multiple cutouts 810 and multiple suctions cups 815. Similar to the belt system 700, the carousel 805 can rotate to enable the special slots 810 to slice sheets off the bottom of one or more product hoppers 820. In some embodiments, as shown, the carousel 805 can comprise multiple product hoppers 820 enabling the carousel 805 to rotate, slicing off sheets from multiple stacks disposed in a circular pattern above the carousel 805. As the carousel 805 rotates, therefore, it can slice a sheet off of each stack, which can then be gravity fed into, for example and not limitation, a hopper or a transport belt below.

In this configuration, the carousel 805 can, for example, collate multiple sheets into a collated stack or can simply be used to pull multiple sheets off onto multiple transport belts, for example. In some embodiments, the sheets can drop onto a conveyor belt, or flight chain 825, traveling in the same, or opposite, direction as the carousel 805. In some embodiments, the carousel 805 can be direct driven by an electric, hydraulic, or pneumatic motor. In other embodiments, as shown, the carousel 805 can be chain or belt driven by an electric motor and sprocket system 830.

While several possible embodiments are disclosed above, embodiments of the present invention are not so limited. For instance, while several possible configurations have been disclosed (e.g., the shuttle table configuration and the endless belt configuration), other suitable materials and configurations could be selected without departing from the spirit of embodiments of the invention. In addition, the location and configuration used for various features of embodiments of the present invention can be varied according to, for example, the size or construction of the feeding machine, space requirements, or article size and material. Such changes are intended to be embraced within the scope of the invention.

The specific configurations, choice of materials, and the size and shape of various elements can be varied according to particular design specifications or constraints requiring a device, system, or method constructed according to the principles of the invention. Such changes are intended to be embraced within the scope of the invention. The presently disclosed embodiments, therefore, are considered in all respects to be illustrative and not restrictive. The scope of the invention is indicated by the appended claims, rather than the foregoing description, and all changes that come within the meaning and range of equivalents thereof are intended to be embraced therein.

Claims

1. A machine for feeding single sheets of material comprising:

a first product tray for holding a plurality of sheets of material in a first stack;

a first angled slot comprising a special cutout located at a first end of the slot;

a first suction cup for reciprocating proximate the special cutout for pulling a single sheet from the bottom of the first stack through the special cutout; and

a device for creating relative motion between the first stack and the first angled slot;

wherein the relative motion between the first angled slot and the first stack removes a single sheet of material from the bottom of the first stack.

2. The machine of claim 1, wherein the device is a reciprocating shuttle table.

3. The machine of claim 1, wherein the device is a rotating belt comprising a plurality of angled slots.

4. The machine of claim 1, wherein the device is a rotating carousel comprising a plurality of angled slots.

5. The machine of claim 1, wherein the special cutout is triangular.

6. The machine of claim 1, further comprising:

a first spring-loaded pinch roller disposed on the underside of the device; and

a transport belt for pulling the single sheet off the bottom of the first stack;

wherein, when the suction cup pulls the single sheet through the special cutout, the single sheet becomes trapped between the first spring-loaded pinch roller and the transport belt and is removed from the bottom of the first stack.

7. A machine for feeding single sheets of material comprising:

a chassis;

a product tray for holding a plurality of sheets of material in a stack;

a shuttle table comprising: an angled slot comprising a special cutout; one or more rollers for supporting the shuttle table in rolling engagement with the chassis; and a spring-loaded pinch roller disposed on the underside of the shuttle table;

a suction cup, reciprocating proximate the special cutout, for pulling a single sheet from the bottom of the stack through the special cutout; and

a transport belt for pulling the single sheet off the bottom of the stack;

wherein when the suction cup pulls the single sheet through the special cutout, the single sheet becomes trapped between the spring-loaded pinch roller and the transport belt and is removed from the bottom of the stack.

8. The machine of claim 7, wherein the special cutout is triangular.

9. The machine of claim 7, wherein the first angled slot comprises an angled parallelogram and the special cutout comprises a triangle disposed on a first end of the parallelogram.

10. The machine of claim 7, wherein the shuttle table reciprocates with respect to the chassis to pull a single sheet off of the bottom of the stack.

11. The machine of claim 7, further comprising:

a suction cup cam comprising a first cam profile; and

a suction cup arm for reciprocating the suction cup in response to the first cam profile.

12. A machine for feeding multiple, single sheets of material comprising:

a chassis;

a carousel comprising: a plurality of angled slots, each angled slots comprising a special cutout; a plurality of spring-loaded pinch rollers disposed on the underside of the carousel;

one or more product trays, each tray for holding a plurality of sheets of material in one or more stacks; and

a plurality of suction cups reciprocating proximate each of the special cutouts, each suction cup for pulling a single sheet from the bottom of the one or more stacks through the a plurality of special cutouts;

wherein, when each of the plurality of suction cups pulls a single sheet through one of the a plurality of special cutouts, the single sheet becomes trapped between a spring-loaded pinch roller and the carousel and is dropped below the carousel.

13. The machine of claim 12, wherein the transport belt comprises a rotating flight chain rotating in the opposite direction as the carousel.

14. The machine of claim 12, wherein each of the single sheets are dropped below the carousel onto a transport belt.

15. The machine of claim 14, wherein the transport belt comprises a rotating flight chain rotating in the same direction as the carousel.

16. The machine of claim 14, further comprising:

a first product tray for holding a plurality of sheets of a first material in a first stack; and

a second product tray for holding a plurality of sheets of a second material in a second stack;

wherein the first material and the second material are collated as they are dropped below the carousel.

17. A machine for feeding multiple, single sheets of material comprising:

a chassis;

a rotating belt comprising a plurality of angled slots, each angled slots comprising a special cutout;

one or more product trays, each tray for holding a plurality of sheets of material in one or more stacks, and disposed proximate a top surface of the rotating belt; and

a plurality of suction cups reciprocating proximate each of the special cutouts, each suction cup for pulling a single sheet from the bottom of the one or more stacks through the a plurality of special cutouts;

wherein, when each of the plurality of suction cups pulls a single sheet through one of the a plurality of special cutouts, the belt removes a single sheet from the bottom of the one or more stacks to be dropped below the belt.

18. The machine of claim 17, further comprising:

a lugged collating base dispose proximate a bottom surface of the rotating belt and comprising a plurality of lugs for collating the plurality of sheets.

19. The machine of claim 17, further comprising:

a motor; and

a plurality of pulleys in mechanical engagement with the rotating belt;

wherein at least one of the plurality of pulleys is detachably coupled to the motor to rotate the rotating belt.

20. The machine of claim 17, further comprising:

a reciprocating linkage mechanically coupling the plurality of suction cups for timing the reciprocal motion of the plurality of suction cups.