Information
-
Patent Grant
-
6808594
-
Patent Number
6,808,594
-
Date Filed
Friday, March 7, 200321 years ago
-
Date Issued
Tuesday, October 26, 200419 years ago
-
Inventors
-
Original Assignees
-
Examiners
Agents
- Lemm; Brian A.
- Chaclas; Angelo N.
-
CPC
-
US Classifications
Field of Search
US
- 156 4415
- 156 442
- 156 4421
- 156 4422
- 156 4423
- 156 4424
- 156 578
- 118 253
- 118 268
-
International Classifications
-
Abstract
A system and method for managing overflow of moistening fluid in a mailing machine is provided. An overflow pipe is provided in the reservoir, positioned over a sump located beneath the reservoir. The top of the overflow pipe in the reservoir is located slightly above the moistening fluid normal operating level in the reservoir. In the event the level of the moistening fluid rises above the normal operating level to a point above the top of the overflow pipe, the moistening fluid will flow through the overflow pipe and into the sump. The sump contains an absorbent material to absorb any moistening fluid that flows into the sump, thereby preventing the moistening fluid from sloshing out of the sump if the mailing machine is moved. The moistening fluid absorbed by the absorbent material will eventually evaporate, thereby preventing any leakage of the moistening fluid from the mailing machine.
Description
FIELD OF THE INVENTION
The invention disclosed herein relates generally to mailing systems, and more particularly to a system and method for managing overflow of moistening fluid in a mailing machine.
BACKGROUND OF THE INVENTION
Mailing systems, such as, for example, a mailing machine, often include different modules that automate the processes of producing mail pieces. The typical mailing machine includes a variety of different modules or sub-systems each of which performs a different task on the mail piece. The mail piece is conveyed downstream utilizing a transport mechanism, such as rollers or a belt, to each of the modules. Such modules could include, for example, a singulating module, i.e., separating a stack of mail pieces such that the mail pieces are conveyed one at a time along the transport path, a stripping/moistening module, i.e., stripping open the flap of an envelope, wetting and sealing the glued flap of an envelope, a weighing module, and a metering/printing module, i.e., applying evidence of postage to the mail piece. The exact configuration of the mailing machine is, of course, particular to the needs of the user.
Typically, a stripping/moistening module includes a structure for deflecting a flap of a moving envelope away from the envelope's body to enable the moistening and sealing process to occur. The deflecting structure typically includes a stripper blade that becomes inserted between the flap of the envelope and the body of the envelope as the envelope traverses the transport deck of the mailing machine. Once the flap has been stripped, the moistening device moistens the glue line on the envelope flap in preparation for sealing the envelope. Moistening systems generally fall into two categories: contact and non-contact moistening systems. Non-contact moistening systems generally spray moisture onto the envelope flap with a nozzle and mechanical pump system. The mechanical pump is supplied with moistening fluid from a reservoir and sprays the fluid through the nozzles and onto the envelope flap. The flap is then closed and sealed, such as, for example, by passing the closed envelope through a nip of a sealer roller to compress the envelope and flap together, and the envelope passed to the next module for continued processing.
A contact moistening system generally deposits a moistening fluid, such as, for example, water or water with a biocide, onto the glue line on a flap of an envelope by contacting the glue line with a wetted applicator. In contact systems, the wetted applicator typically consists of a contact media such as a brush, foam or felt. The applicator is in physical contact with a wick. The wick is generally a woven material, such as, for example, felt, or can also be a foam material. At least a portion of the wick is wetted with the moistening fluid from a reservoir. The moistening fluid is transferred from the wick to the applicator by physical contact pressure between the wick and applicator, thereby wetting the applicator. A stripped envelope flap is guided between the wick and applicator, such that the applicator contacts the glue line on the flap of the envelope, thereby transferring the moistening fluid to the flap to activate the glue. The flap is then closed and sealed, such as, for example, by passing the closed envelope through a nip of a sealer roller to compress the envelope and flap together, and the envelope passed to the next module for continued processing.
Regardless of the type of system used, as noted above it is necessary to have a reservoir that holds the moistening fluid to be used by the mailing machine. As the moistening fluid is used during processing of mail pieces, it is necessary to replace the fluid in the reservoir. This is generally performed utilizing a user replaceable bottle that is inserted into the reservoir and empties into the reservoir as the level of moistening fluid in the reservoir decreases. When the bottle has emptied, it is replaced with a new bottle-containing a new supply of moistening fluid.
There are problems, however, with conventional moistening systems in which a reservoir is utilized. In many applications, the moistening fluid from the reservoir is supplied to the moistening device (either contact, i.e., wick/applicator, or non-contact, i.e., mechanical pump) via a gravity pump. As such, it is not possible to completely seal the reservoir, as this could cause changes in pressure within the reservoir and disrupt the operation of the gravity pump. Typically, the top of the reservoir is open to prevent the build-up of any back-pressure and allow the replaceable bottle to be inserted therein. To prevent the moistening fluid in the reservoir from overflowing, it is generally desirable to limit the amount of moistening fluid in the reservoir during normal operation. There are circumstances, however, that can result in the level of the moistening fluid within the reservoir exceeding the normal operating level. For example, repeated raising and lowering of the replacement bottle, such as, for example, to determine if there is moistening fluid still present in the bottle, can cause the moistening fluid within the reservoir to attain a higher than intended level. Additionally, improper sealing of the replacement bottle or failure of the valve device on the replacement bottle can each cause the moistening fluid level within the reservoir to exceed the normal operating level. Since it is not possible to seal the reservoir completely, there is a risk of moistening fluid escaping from the reservoir and causing damage to surrounding components, especially electrical components, or leaking onto the surface supporting the mailing machine, i.e., the customer's tabletop. Additionally, even if the reservoir has not overflowed or exceeded the intended level, the problem still exists as to moving the mailing machine without the moistening fluid sloshing over the sides of the reservoir and leaking out of the mailing machine.
Typically, in any circumstance where there is leakage of the moistening fluid from the mailing machine and onto the customer's tabletop, the customer interprets it as a potential operational or safety problem and initiates a service call. If the leakage was due to a defective or improperly sealed replacement bottle or movement of the machine, the service call is unnecessary and the customer incurs additional unnecessary expenses as well as down time of the mailing machine.
Thus, there exists a need for a system and method for managing overflow of moistening fluid in a mailing machine.
SUMMARY OF THE INVENTION
The present invention alleviates the problems associated with the prior art and provides a system and method for managing overflow of moistening fluid in a mailing machine.
In accordance with the present invention, an overflow pipe is provided in the reservoir. The overflow pipe is positioned over a sump located beneath the reservoir. The top of the overflow pipe in the reservoir is located slightly above the moistening fluid normal operating level in the reservoir. Under normal operating conditions, i.e., the moistening fluid remains at or below the normal operating level within the reservoir, the overflow pipe has no impact on the moistening system. In the event the level of the moistening fluid rises above the normal level to a point above the top of the overflow pipe, the moistening fluid will flow through the overflow pipe and into the sump. The sump contains an absorbent material to absorb any moistening fluid that flows into the sump, thereby preventing the moistening fluid from sloshing out of the sump if the mailing machine is moved. The moistening fluid absorbed by the absorbent material will eventually evaporate, and the overflow of the moistening fluid will have been completely contained within the mailing machine without any type of operator assistance or possibly even knowledge of an overflow. Thus, in the event the moistening fluid level rises above the normal operating level within the reservoir, the moistening fluid will drain into the sump before the reservoir overflows and moistening fluid escapes from the reservoir onto any surrounding components or the supporting surface of the mailing machine.
Therefore, it should now be apparent that the invention substantially achieves all the above aspects and advantages. Additional aspects and advantages of the invention will be set forth in the description that follows, and in part will be obvious from the description, or may be learned by practice of the invention. Moreover, the aspects and advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
DESCRIPTION OF THE DRAWINGS
The accompanying drawings illustrate presently preferred embodiments of the invention, and together with the general description given above and the detailed description given below, serve to explain the principles of the invention. As shown throughout the drawings, like reference numerals designate like or corresponding parts.
FIG. 1
illustrates a mailing machine having a system and method for managing overflow of moistening fluid according to the present invention;
FIG. 2
illustrates an internal view of a portion of the mailing machine illustrated in
FIG. 1
showing the moistening fluid overflow management system according to the present invention;
FIG. 3
illustrates a cross-sectional view of the moistening fluid overflow management system according to the present invention;
FIG. 4
illustrates a cross-sectional view of a reservoir having an overflow pipe according to another embodiment of the present invention; and
FIG. 5
illustrates a cross-sectional view of a reservoir having an overflow pipe according to another embodiment of the present invention.
DETAILED DESCRIPTION OF THE PRESENT INVENTION
In describing the present invention, reference is made to the drawings, wherein there is seen in
FIG. 1
a mailing machine
10
that includes a system and method for managing overflow of moistening fluid according to the present invention. Mailing machine
10
comprises a base unit, designated generally by the reference numeral
14
, the base unit
14
having a mail piece input end, designated generally by the reference numeral
16
, and a mail piece output end, designated generally by the reference numeral
18
. A control unit
20
is mounted on the base unit
14
, and includes one or more input/output devices, such as, for example, a keyboard
22
and a display device
24
. One or more cover members
26
are pivotally mounted on the base
14
so as to move from the closed position shown in
FIG. 1
to an open position (not shown) to expose various operating components and parts for service and/or repair as needed.
The base unit
14
further includes a horizontal feed deck
30
which extends substantially from the input end
16
to the output end
18
. A plurality of nudger rollers
12
are suitably mounted under the feed deck
30
and project upwardly through openings in the feed deck so that the periphery of the rollers
12
is slightly above the upper surface of the feed deck
30
and can exert a forward feeding force on a succession of mail pieces placed in the input end
16
. A registration wall
32
defines a mail piece registration surface substantially perpendicular to the feed deck
30
that extends substantially from the input end
16
to the output end
18
. Mail pieces placed in the input end
16
are fed by the nudger rollers
12
along the feed deck
30
, with the top edge of the mail piece being registered against the wall
32
. The mail pieces may be passed through one or more modules, such as, for example, a singulator module and a moistening module that includes an overflow management system according to the present invention as described below. Each of these modules is located generally in the area indicated by reference numeral
36
. The mail pieces are then passed to a metering/printing module located generally in the area indicated by reference numeral
38
.
Referring now to
FIG. 2
, there is illustrated an internal view of a portion of the mailing machine
10
illustrated in
FIG. 1
showing a moistening fluid overflow management system
50
according to the present invention. System
50
includes a replaceable bottle
52
that can be inserted into a reservoir
54
. Reservoir
54
is preferably mounted to the base unit
14
and internal support structures (not shown) of the mailing machine
10
by, for example, one or more mounting brackets
58
. Bottle
52
can be provided with gripping areas
56
a
,
56
b
to allow an operator to grasp the bottle
52
for easy removal and insertion into the reservoir
54
. Under normal operation, moistening fluid contained in the bottle
52
empties into the reservoir
54
such that the level of moistening fluid in the reservoir
54
maintains a predetermined desired level as further described below. The reservoir
54
supplies the moistening fluid to a moistening system (not shown) utilizing tubing (not shown) via a gravity pump. The moistening system can be, for example, either a contact or non-contact moistening system.
In accordance with the present invention, reservoir
54
is provided with an overflow pipe
70
that extends through the bottom of the reservoir
54
. The overflow pipe
70
empties into a sump
72
, preferably provided beneath the overflow pipe
70
such that the bottom of the overflow pipe
70
is located over an open portion
74
of the sump
72
. Sump
72
may be integrally formed with the base
14
of the mailing machine
10
, or may be secured to the base
14
of mailing machine
10
. Preferably, sump
72
is large enough such that it can hold the entire volume of the moistening fluid from bottle
52
.
Referring now to
FIG. 3
, there is illustrated generally a cross-sectional view of the overflow management system
50
taken along line
3
-
3
′ of FIG.
2
. The bottle
52
is inserted into the reservoir
54
, and may be supported by one or more ribs
62
within the reservoir
54
. A valve device
80
allows the moistening fluid within the bottle
52
to discharge in a controlled manner into the reservoir
54
. Specifically, when the bottle
52
is inserted into the reservoir
54
, a rib
64
contacts a piston
82
of the valve
80
. As the bottle
52
is further inserted into the reservoir
54
, a spring
84
around the piston
82
is compressed and the piston
82
is pushed up into the bottle
52
. As the piston
82
is pushed into the bottle
52
, a plunger
86
is raised from a sealed position, in which the plunger
86
seals the bottle
52
, to an open position in which gaps
88
are created between the plunger
86
and an internal neck portion
90
of the valve
80
. The gaps
88
allow air to enter the bottle
52
, which allows the moistening fluid in the bottle
52
to flow out of the gaps
88
, through the internal neck portion
90
and an external neck portion
92
, and into the reservoir
54
. When the level of moistening fluid in the reservoir
54
reaches the normal operating level, illustrated by line
100
, the moistening fluid will have reached the height of the external neck portion
92
of the valve
80
, thereby effectively sealing the external neck portion
92
and preventing any additional air from entering the bottle
52
. This stops the release of any additional moistening fluid from the bottle
52
into the reservoir
54
, thereby keeping the level of moistening fluid within the reservoir
54
at approximately the normal operating level
100
. As moistening fluid is used through normal operation of the moistening system (not shown) coupled to the reservoir
54
, the level of moistening fluid will decrease until it drops below the external neck portion
92
of the bottle
52
, thereby allowing air to once again enter the bottle
52
. As the air again enters the bottle
52
, moistening fluid will again be released from the bottle
52
into the reservoir
54
until it reaches the intended normal operating level
100
. When the bottle
52
is removed from the reservoir
54
, the spring
84
will decompress, thereby pulling the piston
82
from the bottle
52
and moving the plunger
86
back to the sealed position. It should be understood, of course, that any type of valve device can be utilized and the present invention is not limited to valve device
80
as described above.
As illustrated in
FIG. 3
, in accordance with the present invention, the overflow pipe
70
preferably extends through the bottom
60
of the reservoir
54
. Overflow pipe
70
is preferably located along the center line of the reservoir
54
, near the rib
64
that contacts the valve device
80
. Overflow pipe
70
is also preferably located vertically through the bottom
60
of the reservoir
54
. Alternatively, as illustrated in
FIG. 4
, the overflow pipe
70
need not be vertical through the bottom
60
of the reservoir
54
but instead could pass through at an angle. As another alternative, the overflow pipe
70
could pass through a side wall
68
of the reservoir
54
as illustrated in FIG.
5
. Regardless of the location or orientation of the overflow pipe
70
, the top opening
102
of overflow pipe
70
is situated above the normal operating level
100
of the moistening fluid in the reservoir
54
. Preferably, the top opening
102
of the overflow pipe
70
is approximately 3-5 mm above the normal operating level
100
of the moistening fluid in the reservoir
54
. In the event that the level of the moistening fluid within the reservoir
54
exceeds the normal operating level
100
and goes above the top opening
102
of the overflow pipe
70
, i.e., an overflow condition, for any reason, the moistening fluid will enter the top opening
102
of the overflow pipe
70
. For example, an improper seal of the valve device
80
with the bottle
52
, or failure of the valve device
80
, could cause the moistening fluid within the bottle
52
to be released into the reservoir
54
such that the level of moistening fluid exceeds the normal operating level
100
. Additionally, repeated raising and lowering of the bottle
52
, such as, for example, to determine if there is moistening fluid still present in the bottle
52
, can cause the moistening fluid within the reservoir
54
to exceed the: normal operating level
100
. Furthermore, if the mailing machine
10
is moved when the moistening fluid is at the normal operating level
100
, it is possible that the mailing machine
10
can be tipped to a position in which the moistening fluid will exceed the normal operating level
100
on one side of the reservoir
54
and possibly leak over the side of the reservoir
54
. Additionally, movement of the mailing machine
10
can cause movement of the moistening fluid within the reservoir
54
, i.e., sloshing, thereby exceeding the normal operating level
100
at some point and possibly leaking over the sides of the reservoir
54
.
Moistening fluid that has entered the top opening
102
of the overflow pipe
70
will drain from the reservoir
54
and through the opening
74
of sump
72
. Preferably, an absorbent material
76
is provided in the sump
72
. The absorbent material
76
could be, for example, a sponge, foam material or any other type of material that has absorbent properties. As the moistening fluid enters the sump
72
, it will be absorbed by the absorbent material
76
. Since the sump
72
is preferably open to the atmosphere, through opening
74
, any moistening fluid that has drained into the sump
72
will evaporate after a period of time. The use of the absorbent material
76
provides several advantages. For example, any moistening fluid that has drained into the sump
72
will not slosh around should the mailing machine
10
be moved from one position to another. Additionally, the additional surface area of the absorbent material
76
will aid in evaporation of the moistening fluid.
Thus, according to the present invention, a system and method for managing overflow of moistening fluid from the reservoir
54
of a mailing machine
10
is provided. In the event the level of the moistening fluid rises above the normal operating level
100
to a level above the top opening
102
of the overflow pipe
70
, the moistening fluid will flow through the overflow pipe
70
and into the sump
72
. Accordingly, the moistening fluid will drain into the sump
72
before the reservoir
54
overflows or moistening fluid escapes from the reservoir
54
and onto any surrounding components or the supporting surface of the mailing machine
10
. The overflow of moistening fluid from the reservoir
54
is safely contained within the mailing machine
10
, thereby preventing the user from placing an unnecessary service call.
While the present invention has been described with respect to a mailing machine, it should be understood that the present invention is not so limited and can be utilized with any device that has a moistening/sealing system, such as, for example, an inserter and the like. Those skilled in the art will also recognize that various modifications can be made without departing from the spirit of the present invention. For example, the sump
72
need not be located directly beneath the reservoir
54
, but instead can be located in some other area and the overflow pipe
70
coupled to the sump
72
with tubing. As another example, the sump
72
and reservoir
54
could be a single integral piece.
While preferred embodiments of the invention have been described and illustrated above, it should be understood that these are exemplary of the invention and are not to be considered as limiting. Additions, deletions, substitutions, and other modifications can be made without departing from the spirit or scope of the present invention. Accordingly, the invention is not to be considered as limited by the foregoing description but is only limited by the scope of the appended claims.
Claims
- 1. A moistening system comprising:a reservoir to hold moistening fluid at a first level under normal operating conditions, the reservoir having a bottom surface and a plurality of side walls; an overflow pipe having a first end inside the reservoir and a second end outside of the reservoir, the first end of the overflow pipe having a top opening situated at a second level, the second level being higher than the first level at which the moistening fluid is maintained under normal operating conditions and lower than a height of the side walls; and a sump associated with the reservoir, wherein if the level of moistening fluid rises above the second level, moistening fluid will flow into the top opening of the first end of the overflow pipe and pass out of the second end of the overflow pipe into the sump, thereby preventing the moistening fluid from flowing over any of the side walls.
- 2. The moistening system of claim 1, wherein the second level is approximately 3-5 mm above the first level.
- 3. The moistening system of claim 1, wherein the overflow pipe passes through the bottom surface of the reservoir.
- 4. The moistening system of claim 3, wherein the overflow pipe is substantially vertical through the bottom surface of the reservoir.
- 5. The moistening system of claim 3, wherein the overflow pipe is angled through the bottom surface of the reservoir.
- 6. The moistening system of claim 1, wherein the overflow pipe passes through one of the plurality of a side walls of the reservoir.
- 7. The moistening system of claim 1, wherein at least a portion of the sump is located beneath the second end of the overflow pipe.
- 8. The moistening system of claim 1, wherein the second end of the overflow pipe is coupled to the sump by a tube.
- 9. The moistening system of claim 1, further comprising:an absorbent material located in the sump.
- 10. The moistening system of claim 9, wherein the absorbent material is foam.
- 11. The moistening system of claim 9, wherein the absorbent material is a sponge.
- 12. The moistening system of claim 1, further comprising:a bottle adapted to couple with the reservoir, the bottle supplying the reservoir with moistening fluid.
- 13. A mailing machine comprising:a reservoir having a bottom surface and a plurality of side walls to hold moistening fluid for sealing mail pieces being processed by the mailing machine, the moistening fluid being maintained at a first level under normal operating conditions; an overflow pipe having a first end inside the reservoir and a second end outside of the reservoir, the first end of the overflow pipe having a top opening situated at a second level, the second level being higher than the first level at which the moistening fluid is maintained under normal operating conditions and lower than a height of the side walls; and a sump associated with the reservoir, wherein if the level of moistening fluid rises above the second level, moistening fluid will flow into the top opening of the first end of the overflow pipe and pass out of the second end of the overflow pipe into the sump, thereby preventing the moistening fluid from flowing over any of the side walls.
- 14. The mailing machine of claim 13, wherein the second level is approximately 3-5 mm above the first level.
- 15. The mailing machine of claim 13, wherein the overflow pipe passes through the bottom surface of the reservoir.
- 16. The mailing machine of claim 15, wherein the overflow pipe is substantially vertical through the bottom surface of the reservoir.
- 17. The moistening system of claim 15, wherein the overflow pipe is angled through the bottom surface of the reservoir.
- 18. The mailing machine of claim 13, wherein the overflow pipe passes through one of the plurality of side walls of the reservoir.
- 19. The mailing machine of claim 13, wherein the reservoir is secured to a base of the mailing machine and the sump is located beneath the reservoir such that at least a portion of the sump is located under the second end of the overflow pipe.
- 20. The mailing machine of claim 13, wherein the second end of the overflow pipe is coupled to the sump by a tube.
- 21. The mailing machine of claim 13, further comprising:an absorbent material located in the sump.
- 22. The machine of claim 21, wherein the absorbent material is foam.
- 23. The machine of claim 21, wherein the absorbent material is a sponge.
- 24. The mailing machine of claim 13, further comprising:a bottle adapted to couple with the reservoir, the bottle supplying the reservoir with moistening fluid.
US Referenced Citations (14)