Claims
- 1. An in-line rotary inserter comprising:
- an envelope handling system for processing of insert-filled envelopes;
- an inserting station for insertion of inserts into envelopes and for delivering insert-filled envelopes to said envelope handling system;
- conveying means for conveying inserts to said inserting station;
- at least one rotary insert feeder module for dispensing inserts to said conveying means, said rotary insert feeder including means for thickness sensing of inserts;
- an envelope feeding system for feeding of envelopes to said inserting station, said envelope feeding system including an envelope diverter for selective diversion of envelopes and a vacuum gripper drum for delivering envelopes to said inserting station; and
- a pre-programmable computer system including input and output means and at least one control and display unit, said computer system serving for control and supervision of in-concert operation of said envelope feeding system, said at least one rotary insert feeder module, said conveying means, said inserting station, and said envelope handling system, said computer system providing sequential and associative tracking of individual inserts and collated insert packs, envelopes, and insert-filled envelopes;
- wherein said envelope handling system includes a vacuum belt transporter/diverter comprising a substantially horizontal surface and at least two parallel commonly driven endless belts having their uppermost surfaces slightly raised above said horizontal surface, said uppermost surfaces serving to receive thereupon insert-filled envelopes delivered thereto from said inserting station, said endless belts being oriented substantially orthogonally with respect to the direction of delivery thereto of insert-filled envelopes, said horizontal surface including a delivery region disposed in the area to which insert-filled envelopes are delivered, wherein said horizontal surface includes a plurality of vacuum openings disposed in said delivery region between said endless belts, said vacuum openings being supplied with vacuum to attract an insert-filled envelope and thereby increase friction with respect to said uppermost surfaces of said driven endless belts so that said belts transport insert-filled envelopes thereupon for further processing.
- 2. The in-line rotary inserter according to claim 1, wherein said vacuum gripper drum comprises first and second face discs each including a peripheral surface, said peripheral surface being operative for carrying of envelopes thereupon, said peripheral surface including a plurality of vacuum openings connected to a source of vacuum, said plurality of vacuum openings being operative in attracting and holding envelopes to said peripheral surface by the action of vacuum valved to said vacuum openings.
- 3. The in-line rotary inserter according to claim 1, wherein said envelope handling system comprises a turnover module, and wherein said turnover module comprises a belt and pulley system including at least first, second, third, and fourth pulleys, at least one of said pulleys being driven, said pulleys being disposed substantially in a common vertical plane, wherein said first and second pulleys define a first pulley pair and said third and fourth pulleys define a second pulley pair, said pulleys of each said pair being disposed proximally to and substantially above one another, wherein said pairs are spaced from each other, said pulley system including an endless flat belt disposed about said pulleys in resiliently tensioned manner in shape of a flattened figure `eight` having a crossover portion, said crossover portion including two mutually contacting length portions of said flat belt twisted about one another by an angle of substantially one hundred and eighty degrees, said crossover portion being operative in nipping between said two length portions an envelope delivered to said turnover module and transporting the envelope therethrough while turning the envelope over by substantially one hundred and eighty degrees.
- 4. The in-line rotary inserter according to claim 3, wherein said endless flat belt includes two discrete surfaces, each said discrete surface having a seven hundred and twenty degree twist.
- 5. The in-line rotary inserter according to claim 1, wherein said envelope handling system comprises a sealing module, wherein said sealing module comprises a moistening section, a sealing section, and first and second driven conveyor belts for conveying therethrough of an open-flap insert-filled envelope that is delivered thereto for sealing in an orientation having its flap pointing substantially vertically downwardly, wherein said moistening section includes a spray nozzle for spraying of water spray onto the gummed region of an envelope flap as the envelope passes by said nozzle, said spray nozzle directing spray in a generally horizontal direction substantially transversally to the conveying motion of an envelope passing by, said spray nozzle being spaced from the envelope flap to facilitate development of a spray pattern prior to spray impact on the flap, and wherein said sealing section includes a flap closing guide, said flap closing guide including a curved portion that slideably engages the outer flap surface while an envelope is conveyed from said moistening section to said sealing section, said flap closing guide being operative in deflecting the envelope flap to its closed position, said sealing section including a plurality of sealing pressure rolls resiliently loaded onto said second driven conveyor belt so that an envelope with moistened and closed flap is nipped and thereby sealed between said rolls and said belt and is conveyed farther thereby.
- 6. The in-line rotary inserter according to claim 1, wherein said envelope handling system includes a sealing module, said sealing module comprising a moistening section, a sealing section and first and second driven conveyor belts for conveying therethrough of an open-flap insert-filled envelope that is delivered thereto for sealing in an orientation having its flap pointing substantially vertically downwardly, wherein said moistening section includes a spray nozzle for spraying of water spray onto the gummed region of an envelope flap as the envelope passes by said nozzle, said spray nozzle directing spray in a generally horizontal direction substantially transversely to the conveying motion of an envelope passing by, said spray nozzle being spaced from the envelope flap to facilitate development of a spray pattern prior to spray impact on the flap, and wherein said sealing section includes a flap closing guide, said flap closing guide including a curved portion that slideably engages the outer flap surface while an envelope is conveyed from said moistening section to said sealing section, said flap closing guide being operative in deflecting the envelope flap to its closed position, said sealing section including a plurality of sealing pressure rolls resiliently loaded onto said second driven conveyor belt so that an envelope with moistened and closed flap is nipped and thereby sealed between said rolls and said belt and is conveyed further thereby.
- 7. The in-line rotary inserter according to claim 1, wherein said vacuum gripper drum comprises first and second face discs each including a peripheral surface, said peripheral surface being operative for carrying of envelopes thereupon, said peripheral surface including a plurality of vacuum openings connected to a source of vacuum, said plurality of vacuum openings being operative in attracting and holding envelopes to said peripheral surface by the action of vacuum valved to said vacuum openings.
- 8. In an in-line rotary inserter, said inserter including an envelope handling system for processing of insert-filled envelopes, a turnover module comprised in said envelope handling system, said turnover module comprising a belt and pulley system including at least first, second, third, and fourth pulleys, at least one of said pulleys being driven, said pulleys being disposed substantially in a common vertical plane, wherein said first and second pulleys define a first pulley pair and said third and fourth pulleys define a second pulley pair, said pulleys of each said pair being disposed proximally to and substantially above one another, wherein said pairs are spaced from each other, said pulley system including an endless flat belt disposed about said pulleys in resiliently tensioned manner in shape of a flattened figure `eight` having a crossover portion, said crossover portion including two mutually contacting length portions of said flat belt twisted about one another by an angle of substantially one hundred and eighty degrees, said crossover portion being operative in nipping between said two length portions an envelope delivered to said turnover module and transporting the envelope therethrough while turning the envelope over by substantially one hundred and eighty degrees.
- 9. In an in-line rotary inserter, the turnover module according to claim 8, wherein said endless flat belt includes two discrete surfaces, each said discrete surface having a seven hundred and twenty degree twist.
- 10. A method for operating inserter, including steps of:
- handling and processing of insert-filled envelopes;
- inserting of inserts into envelopes;
- delivering insert-filled envelopes for said step of handling and processing;
- conveying inserts for said step of inserting;
- dispensing inserts for said step of conveying;
- feeding envelopes for said step of inserting; and
- controlling and supervising in-concert operation of said steps of handling and processing, inserting, delivering, conveying, feeding, and dispensing by a preprogrammable computer system; characterized by that said handling and processing of insert-filled envelopes comprises the steps of:
- receiving insert-filled envelopes upon at least two parallel commonly driven belts in a receiving region, said commonly driven belts being oriented substantially orthogonally to the direction of said step of delivering, said commonly driven belts having a plurality of vacuum openings disposed therebetween;
- supplying vacuum to said vacuum openings and thereby attracting insert-filled envelopes received upon said commonly driven belts thereto; and
- transporting insert-filled envelopes upon said commonly driven belts for further processing.
- 11. The method according to claim 10, wherein said step of feeding envelopes includes a step of carrying envelopes upon the periphery of a gripper drum, said step of carrying characterized by steps of:
- valving vacuum to openings in the periphery of said gripper drum;
- attracting envelopes to the periphery of said gripper drum by virtue of said step of valving vacuum;
- delivering envelopes for said step of inserting; and,
- discontinuing vacuum to said openings in the periphery of said gripper drum and thereby releasing envelopes from the periphery of said gripper drum.
- 12. The method of claim 10, characterized by that said step of feeding envelopes includes a step of selectively diverting envelopes from their delivery path prior to said step of inserting.
- 13. The method of claim 10, characterized by that said step of feeding envelopes includes steps of:
- carrying envelopes upon the periphery of a vacuum gripper drum;
- valving vacuum to openings in the periphery of said vacuum gripper drum;
- attracting envelopes to the periphery of said vacuum gripper drum by virtue of said step of valving vacuum;
- delivering envelopes for said step of inserting; and
- discontinuing vacuum to said openings in the periphery of said vacuum gripper drum and thereby releasing envelopes from the periphery of said vacuum gripper drum.
- 14. The method of claim 10, wherein said step of handling and processing of insert-filled envelopes includes a step of turning over of envelopes, said step of turning over characterized by steps of:
- driving an endless flat belt disposed in a pulley system having at least four pulleys disposed substantially in a common plane, said pulleys being arranged in two pairs, said two pairs being spaced from one another, said pulleys of each pair being disposed vicinally to one another;
- carrying said endless flat belt upon and about said at least four pulleys in resiliently tensioned manner in the shape of a flattened figure `eight` including a belt crossover portion, said belt crossover portion including two mutually contacting length portions of said endless flat belt twisted about one another by an angle of substantially one hundred and eighty degrees;
- delivering an envelope to a nip ingress between said two mutually contacting length portions;
- nipping the envelope between said two mutually contacting length portions; and transporting and turning over the envelope in said belt crossover portion.
- 15. The method of claim 14 characterized by that said endless flat belt consists of a length of flat belting joined end-to-end, wherein said length of endless flat belting is provided with a seven hundred and twenty degree twist along its length.
- 16. The method of claim 10, wherein said step of handling and processing insert-filled envelopes includes a step of envelope sealing, said step of envelope sealing characterized by steps of:
- conveying envelopes through a moistening section, said envelopes having their open flaps pointed substantially vertically downwardly;
- spraying gummed areas of envelope flaps by water spray nozzle means and thereby moistening said areas while envelopes are conveyed through said moistening section past said water spray nozzle means;
- deflecting and guiding moistened envelope flaps by a flap closing guide to closed position while said envelopes are being conveyed to a sealing section; and
- sealing envelope flaps closed in said step of deflecting and guiding while envelopes are conveyed between a conveyor belt and a plurality of resilient sealing rolls.
- 17. A method for handling and processing of insert-filled envelopes including a step of transporting/diverting characterized by steps of:
- receiving insert-filled envelopes upon at least two parallel commonly driven belts in a receiving region, said commonly driven belts being oriented substantially orthogonally to the direction of said step of delivering, said commonly driven belts having a plurality of vacuum openings disposed therebetween;
- supplying vacuum to said vacuum openings and thereby attracting insert-filled envelopes received upon said commonly driven belts thereto; and
- transporting insert-filled envelopes upon said commonly driven belts for further processing.
- 18. In an in-line rotary inserter, said inserter including an envelope handling system for processing of insert-filled envelopes, a vacuum belt transporter/diverter comprised in said envelope handling system, said vacuum belt transporter/diverter comprising a substantially horizontal surface and at least two parallel commonly driven endless belts having their uppermost surfaces slightly raised above said horizontal surface, said uppermost surfaces serving to receive thereupon insert-filled envelopes delivered thereto from said inserting station, said endless belts being oriented substantially orthogonally with respect to the direction of delivery thereto of insert-filled envelopes, said horizontal surface including a delivery region disposed in the area to which insert-filled envelopes are delivered, wherein said horizontal surface includes a plurality of vacuum openings disposed in said delivery region between said endless belts, said vacuum openings being supplied with vacuum to attract an insert-filled envelope and thereby increase friction with respect to said uppermost surfaces of said driven endless belts so that said belts transport insert-filled envelopes thereupon for further processing.
- 19. A method of handling and processing of envelopes including a step of turning over of envelopes, characterized by steps of:
- driving an endless flat belt disposed in a pulley system having at least four pulleys disposed substantially in a common plane, said pulleys being arranged in two pairs, said two pairs being spaced from one another, said pulleys of each pair being disposed vicinally to one another;
- carrying said endless flat belt upon and about said at least four pulleys in resiliently tensioned manner in the shape of a flattened figure `eight` including a belt crossover portion, said belt crossover portion including two mutually contacting length portions of said endless flat belt twisted about one another by an angle of substantially one hundred and eighty degrees;
- delivering an envelope to a nip ingress between said two mutually contacting length portions;
- nipping the envelope between said two mutually contacting length portions; and
- transporting and turning over the envelope in said belt crossover portion.
- 20. The method of claim 19 characterized by that said endless flat belt consists of a length of flat belting joined end-to-end, wherein said length of endless flat belting is provided with a seven hundred and twenty degree twist along its length.
- 21. A method of handling and processing insert-filled envelopes including a step of envelope sealing, said step of envelope sealing characterized by steps of:
- conveying envelopes through a moistening section, said envelopes having their open flaps pointed substantially vertically downwardly;
- spraying gummed areas of envelope flaps by water spray nozzle means and thereby moistening said areas while envelopes are conveyed through said moistening section past said water spray nozzle means;
- deflecting and guiding moistened envelope flaps by a flap closing guide to closed position while said envelopes are being conveyed to a sealing section; and
- sealing envelope flaps closed in said step of deflecting and guiding while envelopes are conveyed between a conveyor belt and a plurality of resilient sealing rolls.
SUMMARY OF THE INVENTION
This is a continuation-in-part of application Ser. No. 338,171, filed Apr. 14, 1989, now U.S. Pat. No. 5,029,832.
1. Field of the Invention:
This invention relates to apparatus and method for handling high volume mail and, in particular, it relates to in-line rotary inserter devices having a plurality of hopper-held insert feeding assemblies positioned along conveyors to dispense inserts onto the conveyors, and having devices for stuffing envelopes with the inserts.
2. Prior Art and Other Considerations:
Many present devices for stuffing inserts into envelopes employ conveyors to convey stack-dispensed inserts to an envelope stuffing device. Multiple inserter devices rely on a plurality of hoppers disposed along conveyors and dispensing inserts onto the conveyor in predetermined manner to achieve collated insert packages that are subsequently inserted into envelopes.
Such equipment is required to operate at increasingly higher celerities with high reliability and shortest possible down-times. Many problems, which either do not exist or which are inconsequential in low-speed operation, need to be overcome in high-speed operation. For instance, such problems involve frictional, inertial, and other speed-related effects of moving apparatus components and of handled document materials.
Prior art inserter devices include U.S. Pat. Nos. 4,043,551 and 4,079,576 to Morrison et al, U.S. Pat. No. 4,177,979 to Orsinger et al, U.S. Pat. No. 4,649,691 to Buckholz, U.S. Pat. No. 3,825,247 to Fernandez-Rana et al, U.S. Pat. No. 3,423,900 to Orsinger, U.S. Pat. No. 2,621,039 to Kleineberg et al, and U.S. Pat. No. 3,809,385 to Rana.
It is an important feature of the present invention to provide apparatus and method for automatically inserting into envelopes at high celerities a plurality of inserts in predetermined and preprogrammed continuous manner and to further automatically process such insert-filled envelopes through diverting, flap-sealing, turn-over, stacking, and other operations associated therewith, substantially under computer control and supervision, while providing higher production rates than heretofore practically feasible.
U.S. Pat. No. 4,177,979 (Orsinger et al), entitled "Signature Gathering Machine", and commonly assigned herewith, is incorporated herein be reference.
In accordance with principles of the present invention, envelopes are conveyed from a hopper to an inserting station, where envelopes are opened and inserts are inserted therein. The inserts are furnished by a plurality of modular insert hoppers which are positioned in line above an endless insert conveyor of the pusher pin type. Envelopes having inserts inserted therein are transported to a vacuum-belt transporter/diverter unit and are directed and transported thereby along at least one path that includes a turn-over module, a sealing module, and an on-edge stacking unit.
The inserter apparatus operates under preprogrammable computer control and supervision. Automatic error handling and visual display of operational status and program information are provided.
US Referenced Citations (22)
Foreign Referenced Citations (4)
| Number |
Date |
Country |
| 0102700 |
Mar 1984 |
EPX |
| 2543491 |
Mar 1984 |
FRX |
| 1237873 |
Jun 1971 |
GBX |
| 1567603 |
May 1980 |
GBX |
Continuation in Parts (1)
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Number |
Date |
Country |
| Parent |
338171 |
Apr 1989 |
|
Patent Grant
5042232
