Mail sorting system

Abstract

A method for sorting mail pieces includes the steps of loading mail pieces to be sorted into individual holders, sorting the holders using an automated system that stores and reorders the holders so that the holders are ordered according to a sort scheme for the mail pieces, storing the sorted holders in a storage area during sorting, and then unloading the mail pieces from the holders in order according to the sort scheme. The storage step occurs during sorting in the sense that a series of reordered holders is gradually created in one of a variety ways by the sorting process, and a storage area is provided for this purpose. Preferably the method further includes steps of unloading the sorted holders from the storage area and transporting the holders to an unloading station at which the unloading step is carried out.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

In the accompanying description, wherein like numerals represent like elements:

FIG. 1 is a schematic diagram of a mail sorting system according to the invention;

FIG. 2 is a perspective view of a tote and holders according to the invention on a conveyor section;

FIGS. 3A-3C are a series of elevation views of a splitter mechanism according to the invention;

FIG. 4 is a perspective view of shifting frame section of FIGS. 3A-3C;

FIGS. 5A to 5D are a series of views of a multiple shifting frame mechanism according to the invention at different stages of operation;

FIGS. 6A and 6B are front views of a gate mechanism according to the invention in closed and open states respectively;

FIG. 7 is a partial perspective view of a sorting carousel according to the invention whereon holders carrying mail pieces are ordered according to a sort scheme;

FIG. 8 is a schematic representation of a folder opening and mail traying system according to the invention;

FIG. 9 is a schematic representation of a mail packaging system as an alternative to traying in FIG. 8;

FIG. 10 is a schematic representation of an alternate mail sorting system according to the invention;

FIG. 11 is a schematic representation of a transfer station and linear sorting lane suitable for use in connection with the mail handling system of FIG. 10;

FIG. 12 is a schematic diagram of a two-pass sorting embodiment of the invention; and

FIG. 13 is a partial side view of the system of FIG. 12.

Claims

1. A method for sorting mail pieces, comprising: loading a batch of mail pieces to be sorted into individual holders;sorting the holders using an automated sorting system that reorders the holders so that the holders are ordered according to a sort scheme for the mail pieces;storing the sorted holders in a storage area during sorting; andthen unloading the mail pieces from the holders in order according to the sort scheme.

2. The method of claim 1, further comprising unloading the sorted holders from the storage area and transporting the holders to an unloading station at which the unloading step is carried out.

3. The method of claim 1, wherein the holders comprise folders each having a machine readable label that is associated during sorting with the mail piece contained in the folder.

4. The method of claim 1, wherein the sorting and storing steps further comprise: sorting the holders into the storage area using first pass sort scheme logic;removing the holders from the storage area and recirculating the holders to the automated sorting system; andthen re-sorting the holders using second pass sort scheme logic.

5. The method of claim 1, wherein the sorting step comprises: passing the holders along a conveyor to a splitter;determining destination information for the mail piece contained in a holder entering the splitter;operating the splitter to route the holder to one of several takeaway conveyors; andtransporting the holder to a section of the storage area associated with that takeaway conveyor.

6. A method for sorting mail pieces, comprising: sorting a majority of the mail pieces using an automated sorting system;sorting residual mail not sortable on the automated sorting system by loading the residual mail pieces into individual holders, sorting the holders using an automated system that reorders the holders so that the holders are ordered according to a sort scheme for the mail pieces, then unloading the mail pieces from the holders in order according to the sort scheme; andmerging the mail pieces sorted with the automated sorting system with the sorted residual mail.

7. A system for sorting mail pieces, comprising: at least one loading station at which mail pieces to be sorted are loaded into individual holders;a conveyor system including a conveyor sections that transport holders containing mail pieces from the loading station to a splitter that diverts each holder to one of a set of conveyor lanes based on a sort scheme, thereby dividing the holders up into subgroups based on the sort scheme;an ordering system that receives the holders from the conveyor system, including a plurality of holder reordering devices that each receive a designated subgroup of the mail pieces and reorder that subgroup according to the sort scheme; andan unloader that receives the holders from the reordering system and removes the mail pieces from the holders in order according to the sort scheme.

8. A mail sorting system, comprising: a control computer;a plurality of holders configured for receiving and holding mail pieces therein;at least one holder loading station for loading the holders with mail pieces, the holder loading station including an input device for inputting destination data for the mail pieces to the control computer;a plurality of totes configured to receive and transport groups of holders;a conveyor system including a first conveyor for directly transporting holders containing mail pieces in series, and a second conveyor configured to transport the totes to different locations in the mail sorting system;at least one tote loading station including a loading mechanism that loads holders into totes;an ordering track for receiving and supporting the holders containing mail pieces and a mechanism for reordering holders on the track according to a sort scheme; anda unloading station including an unloading mechanism that removes mail pieces from the holders and a traying device that places the unloaded mail pieces in mail trays.