Mail sorting apparatus and system

A system for routing correspondence from a first location including a plurality of slot entries to a predetermined conveyor path to a second, discharge location. A collection assembly is disposed at the discharge location for collection of routed correspondence along two adjacent conveyor paths.

TECHNICAL FIELD 
The invention relates to a routing system including a depository for both 
mail, a sorting station including a plurality of entry ways to individual 
distribution channels through which sorted mail is routed to a discharge 
location, and an assembly at the discharge location for collection of the 
routed mail. The invention, also, relates to the collection assembly for 
use in the routing system. 
BACKGROUND ART 
The sorting and routing of mail which may include mail from sources outside 
private and/or governmental installations received from the postal service 
and internal correspondence (hereinafter, collectively, "correspondence") 
to the proper addressee or location has posed a problem which becomes 
increasingly acute as that installation increases in size. Typically, 
correspondence is received at a single location, at which the function of 
sorting and routing is carried out to locate each individual piece of 
correspondence to a bag, pouch or other form of receptacle. The manner by 
which the individual pieces of correspondence are sorted and routed for 
delivery to the addressee or location may include operations calling for 
total manual capability, both manual and automatic capability, and a total 
automatic capability. For example, in U.S. Pat. No. 1,322,356 to Samuel 
Olsen, correspondence may be located manually to any one of several 
pockets in a desk at one location to be retained at least temporarily or 
to move automatically from the pocket through a chute to a conveyor and, 
finally to a downstream location. U.S. Pat. No. 1,219,067 to Charles H. H. 
Bailey et al discloses apparatus comprising a plurality of chutes, each 
chute having a plurality of individual routing channels, communicating a 
sorting location and a location to which respective correspondence is to 
be routed. U.S. Pat. No. 1,851,958 to Robert Hill discloses an apparatus 
substantially similar in operation to that of Bailey and Olsen. 
Each of the aforementioned patents, while they disclose a form of routing 
system, all suffer from a problem of collection of correspondence at a 
discharge location. To this end, none of the prior art systems disclose 
the use of a collection device which may be readily located to a position 
below a pair of conveyor paths, or a device having convertible capability 
of use in the support either of a box or one or a pair of bags for 
collection of correspondence from each conveyor path. 
SUMMARY OF THE DISCLOSURE 
The invention relates to routing apparatus for correspondence wherein the 
apparatus includes a housing and plurality of slots for entry of 
correspondence at an upstream point in a selected conveyor path. The 
correspondence thus, moves along each conveyor path to a discharge at a 
downstream location. A rack assembly for collection of correspondence is 
positioned at the discharge location and in position to collect 
correspondence from each of two adjacent conveyor paths. The rack assembly 
comprising a hanger assembly including a frame, the latter of which has a 
plurality of members arranged in a rectangular pattern. Each of the 
members is in the form of a substantially rectangular plate and each plate 
is connected to an adjacent plate along the side of minor dimension. A 
collection device for collecting correspondence from the paths is 
supported by the hanger assembly. The collection device provides an 
opening located to receive correspondence from either or both of the 
conveyor paths. The apparatus also includes structure for supporting the 
hanger assembly below said discharge location of each of the conveyor 
paths. 
The rack assembly for use with conveying apparatus comprises the hanger 
assembly heretofore described and at least one hanger member having a base 
and a pair of arms. One of the arms of the hanger is supported by one 
frame member and the other of the arms of the hanger is supported by 
another frame member of an opposed pair of frame members so that the base 
of the hanger extends between the opposed pair of frame members. The 
hanger is mounted for movement pivotally from a first to a second position 
and stop means serve to locate the hanger in each position. A collection 
device which may be a box or a bag is supported by the hanger assembly as 
heretofore mentioned. 
In a preferred embodiment, a second hanger member is similarly located and 
similarly movable from the first position, a position wherein each base is 
juxtaposed to an adjacent frame member of the other opposed pair of frame 
members, to a second position wherein the bases of the hangers are 
juxtaposed to one another. 
In the event that the collection device includes a box, the hanger members 
are located to the first position. In the event that the collection device 
includes two bags, each said hanger member is located to the second 
position so that each bag is supported partially by the hanger member and 
partially by the hanger assembly. A single bag may be supported by the 
hanger assembly with the hanger members in the first position. 
As an additional aspect of the invention, the hanger assembly may be 
mounted for movement relative to the supporting structure and the 
conveying paths.

BEST MODE FOR CARRYING OUT THE INVENTION 
As previously indicated, at least in larger facilities, correspondence, 
including mail and internal correspondence to be sorted and routed to a 
proper addressee or location, typically is brought to a collection 
location (see FIG. 1) represented by a table 10. The table either is 
mounted for rotation or mounted stationarily by conventional structure, 
and preferably a working zone (not shown) for a single individual or for 
several individuals will be located adjacent the table, in easy reach of 
the correspondence thereon. A console 12 is located adjacent the table. 
The console includes a plurality of slots 14, 14.sub.1, 14.sub.2, . . . 
14.sub.n with each slot, as will be described, providing an entry to a 
respective one of a plurality of conveying paths along which 
correspondence is conveyed to a discharge location. 
The console 12 is formed by a housing having a component 16 arranged 
vertically and a component 18 arranged horizontally, reference being to a 
surface 20 (see FIGS. 3 and 4). As illustrated in FIG. 1, approximately 
one-half of the slots may be located in each housing component. In this 
manner, the uppermost slot 14 in the housing component 16, likewise will 
be in easy reach of the individuals at the working zone. 
The slots 14, 14.sub.1, 14.sub.2, and so forth in the housing component 16 
each communicate with a chute (not shown) of the outline of the region 
between opposed sides of the console and individual pairs of walls 22 
extending from the slot. Each chute connects a slot to a position between 
respective pairs of spaced walls 24 within the lower portion of console 
12. The walls are located in vertical disposition and pairs of walls in 
the housing component 18 comprise the individual chutes. The chutes are 
rectangular or substantially rectangular in cross-section and 
correspondence moves by gravity from a slot into which it is received, 
through a chute, to a system of conveyance for movement of individual 
pieces of correspondence between an upstream location, at console 12, and 
selected downstream locations. 
The system of conveyance and routing of sorted correspondence is generally 
denoted by the numeral "26". The system includes a plurality of conveying 
paths 28, equal in number to the number of slots 14, 14.sub.1, . . . 
14.sub.n. Each conveying path is formed by a pair of walls 30 and a belt 
32 of an individual conveyor. The walls 30 are arranged in vertical 
orientation, at a spacing equal to the spacing of walls 24, and located in 
end-to-end relation with the latter walls so that the correspondence 
entering a slot, and which will fall by gravity through a chute, may move 
in the downstream direction along a respective conveyor path. 
Both the console 12 and the structure of the conveying system 26 are 
supported by a framework (not shown) as may be conventional. The 
framework, in turn, provides support for individual pulley or guide 
wheels, their supporting shafts, drive means for driving a shaft of each 
pair of pulleys and so forth (not shown, but conventional in the art) 
below the walls 30. Therefore, each belt 32 will locate the lower surface 
of a channel between walls 30 which comprise the conveying paths. 
FIG. 1 illustrates a plurality of conveying paths extending in one 
direction from table 10. A second plurality of conveying paths may extend 
in an opposite direction or in a direction normal to the first direction, 
and there may be provision of a plurality of slot entries to communicate 
with each channel of each plurality of conveying paths. 
A photoelectric system 34 or the equivalent may be located in each console 
12 to provide a readout of the number of pieces of correspondence both 
sorted and routed. To this end, a source may provide a light beam along an 
axis normal to the direction of movement of correspondence along a 
conveying path. The light source may be supported by a wall 24, comprising 
the outer wall of the console 12, and a photosensitive device will be 
supported by the opposite outer wall. If each wall located therebetween is 
provided with an opening through which the light beam may pass, 
correspondence moving along a conveying path will interrupt the beam of 
light. Each interruption will be recorded. 
Discharge locations, such as locations 36, 36.sub.1, 36.sub.2, . . . 
36.sub.n are provided along the conveying system from the upstream console 
12. These discharge locations are on one side of the apparatus and similar 
locations 38, 38.sub.1, 38.sub.2, . . . 38.sub.n may be found along the 
other side of the apparatus. A rack assembly, for collection of 
correspondence, is disposed at each discharge location. 
The rack assembly 40 may be seen perhaps to best advantage in FIGS. 3 and 
4. The rack assembly is also illustrated in FIG. 1, in phantom; and in 
FIGS. 5, 6 and 7 which, additionally, illustrate various collection 
devices for collection of the sorted and routed correspondence as mounted 
by a hanger assembly. 
The rack assembly 40 is in the form of a weldment having a base 42, an 
upper support 44 mounting the hanger assembly 46 and a pair of posts or 
stanchions 48, 50 which mount the upper support over the base. The upper 
support and the base both include a plurality of members, and each 
respective member of the upper support is substantially coextensive in 
length and similarly oriented to a member of the base. Particularly, the 
upper support 44 (and the base 42) includes a rear member 52 (54) and a 
pair of arms 56, 58 (60, 62) extending from the rear member in spaced, 
parallel relation. A pair of elements 64, 66 extend between the stanchions 
and the arms of the upper support, and a further pair of elements 68, 70 
extend between the stanchions and the arms of the base. The elements 
impart a measure of structural rigidity and serve to increase the strength 
of the rack assembly. As may be apparent, material selection for the rack 
assembly and other structure of the apparatus heretofore mentioned and 
hereafter to be mentioned will be with a view to these requirements. 
The various members, arms and elements of the rack assembly may be 
connected in any conventional manner, and each, for example, may be formed 
of rectangular tubular material. 
The hanger assembly 46 generally is in the form of a rectangular frame, 
opened at both the top and bottom. As may be seen in the Figures, the 
frame includes front and rear plates 72, 74 and side plates 76, 78 
respectively. The plates may be attached together in any manner as may be 
conventional. The opposed pairs of plates are similar in overall outline, 
and of the same height, although the front and rear plates are longer. 
Further, the side plates each include a cutout 80 located along the upper 
surface. The cutouts are coextensive, of rectangular outline and centrally 
located in each side plate. 
The hanger assembly 46 is mounted to the upper support 44 thereby to be 
movable as indicated by arrow 82, relative to the upper support as a 
drawer is movable in a desk. To this end, a guide 84 is carried along each 
of the arms 56, 58 and a roller assembly 86 having upper and lower rollers 
received in upper and lower tracks of the guide is mounted on each side of 
the hanger assembly, along the lower surface of side plates 76, 78. 
An important aspect of the invention resides in the capability of the rack 
assembly 46 to support any of a plurality of collection devices. Referring 
to FIGS. 5, 6 and 7, there is illustrated a bag 88, a pair of bags 90, 92 
and a tote box 94, respectively. This aspect of the invention particularly 
relates to the convertibility of the rack assembly from one manner of use 
to another. 
A hanger 96, and preferably a pair of hangers are mounted by the frame of 
hanger assembly 46. Each hanger, see FIGS. 5 and 6, is of U-shaped outline 
including a base 98 and a pair of arms 100, 102. The hangers are mounted 
for movement between a pair of positions including a retracted, 
non-operative position (FIGS. 5 and 7) and an operative position (FIG. 6). 
To this end, each arm 100, 102 is pivotally mounted to a respective side 
plate 76, 78 between the end of the plate and the cutout 80. Typically, 
the mounting may include a bolt 104 received through apertures both in the 
arm and side plate with which it is in juxtaposition, a lock nut and 
washer (not shown) supported by the head of the bolt internally both of 
the frame, and arm, and a nut 106 threaded on the bolt. The aperture 108 
in the arms preferably will be elongated thereby to permit adjustment of 
the hanger toward and away from a front or rear wall in either position. 
Pivotal movement of the hanger is through approximately a 180.degree. 
path, limited at each extreme by a stop 110. The stop also serves to 
support the hanger or hangers when moved to the operative position. 
The rack assembly 40 may be mounted permanently to surface 20, which may be 
the floor, or the rack assembly may merely reside in movable relation on 
the floor. In either case, the rack assembly is supported by a plurality 
of feet 112, each having well-known leveling capability. A pair of 
brackets 114, may be associated with each of the front feet and a pair of 
gussets 116 may be associated with the rear feet in the event of permanent 
mounting of the rack assembly to the floor. Permanent mounting may be 
completed by bolting each of the brackets and gussets to the floor, as at 
118. 
As illustrated in FIG. 4, the brackets are received around a threaded bolt 
comprising a portion of the front feet and the gussets are bolted to the 
rear member 52. A plate portion 120 of each gusset 116 includes an 
elongated slot to permit adjustment of the rear leveling foot and the rack 
assembly. 
In operation, correspondence, following sorting, is located to a respective 
slot 14 in console 12. A listing (not shown) may be located on the console 
to identify a slot with a particular discharge location. The 
correspondence falls in a chute by gravity to one of the conveying paths 
28 of the system for conveyance. Referring to FIG. 2, there is illustrated 
a pair of conveying paths, identified as path A and B, each formed by a 
pair of walls 30 and a belt 32 whose upper track defines the lower surface 
of the channel. The upper track also supports the correspondence in 
movement downstream in the direction of the solid arrow. The lower track 
(not shown in FIG. 2) is represented by the dashed arrow. 
As the correspondence moves downstream, it approaches the designated 
discharge location. According to one form of the invention, adjacent 
conveyor paths, such as those illustrated in FIG. 2, may route 
correspondence to a pair of discharge locations for collection of the 
correspondence by one or a pair of collection devices supported by a 
single rack assembly 40. As illustrated in FIG. 2, correspondence moves 
with belt 32 along conveyor path A to a position at which a wall 122 
diverts it from the path, the correspondence then falling into a 
collection device which may be a bag 88, bag 92 or tote box 94. 
Corrrespondence moving with belt 32 along conveyor path B likewise falls 
into a collection device which may be bag 88, or tote box 94, or bag 90. 
To this end, the belt 32 in conveyor path B has a run shorter than the run 
of belt 32 in conveyor path A. Actually, the belt in conveyor path B 
terminates at an opening 124 in the frame structure above the collection 
device. 
As discussed, a single bag 88 may be supported by the hanger assembly. A 
pair of bags 90, 92, or one of them, may be supported by the hanger 
assembly in substantially similar manner. To this end, the region of the 
opening of the bag is folded either about the frame of the hanger assembly 
or about a portion of the frame and one or the other of the hangers 96 to 
extend through the open bottom. Additionally, the tote box 94 may be 
supported by the frame of the hanger assembly in substitution for any one 
of bags 88, 90 and 92. The tote box is of a size to be received within the 
frame with the hangers in the retracted, non-operative position. A pair of 
shoulders 126 are formed on opposite sides of the box and as seen in FIG. 
9, the shoulders interact with cutouts 80 to locate the tote box relative 
to the frame of hanger assembly 46. When the respective collection 
device(s) at any discharge location is to be replaced, the hanger assembly 
is merely relocated on its track away from the rear member 52 of the upper 
support 44 of rack assembly 40. This movement positions the frame of 
hanger assembly 46 so that the manipulation in locating and removing the 
collection device, as discussed, may be carried out easily.