Abstract:
A gate assembly for diverting substantially flat articles is provided. The gate assembly comprises a mounting bracket having an upright support member and a mounting member secured to the upright support member and a diverter vane having a slot for slidably receiving at least a portion of the upright support member of the mounting bracket. A motion mechanism secured to the mounting bracket for selectively moving the combined mounting bracket and diverter vane thereby diverting the articles to a predetermined desired location.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    1. Field of the Invention  
           [0002]    This invention relates generally to a gate assembly for diverting articles and the like and, more particularly, the invention relates to a gate assembly for diverting mail and other substantially flat articles in a sorting machine.  
           [0003]    2. Description of the Prior Art  
           [0004]    Machines for automatically sorting flat articles, such as mail, into one of an array of selected bins or compartments, are known. Typically, such sorting machines have a feeding station, including an intake drive member such as a rubber-covered wheel or belt, sensing and detecting equipment for determining the appropriate output compartment for the article to be sorted, diverting gates or other article directing mechanisms, and an array of output compartments or bins for the sorted articles. An example of a conventional sorting machine is the DBSCII sorting device, available from Siemens ElectroCom, L. P., Arlington, Tex.  
           [0005]    To feed articles into the sorting machine, an operator positions a bundle of mail to be sorted and shakes or jostles the mail to generally align the bottom edges, making a stack, either horizontal or vertical. The operator then places the stack of mail against the feed member of the sorting machine. The feed member then feeds the articles into the sorting machine, one at a time, to be sorted in the sorting machine.  
           [0006]    In postal and credit operations, as well as other mass document handling devices, certain documents and envelopes are coded using a bar code and/or optical character keying and printing module, and thereafter the documents are sorted by using a bar code or optical character reader and a sorter. Certain sorting systems in current use also employ image lift address verification units, which electronically recreate the address information normally found on one side of a document, piece of mail, or package.  
           [0007]    At the output of the sorting machine, the sorted articles are routed to the appropriate receiving compartments or bins by diverter gates where the sorted articles are stacked. The feeding and sorting of articles continues until one or more of the receiving compartments become sufficiently full of a stack of sorted articles or mail. When the receiving compartment is full, an operator removes a stack of the sorted articles from the full compartment and places the stack of articles into a box. This removal of stacked articles may be termed “sweeping” of the compartment. The stack of sorted articles placed by the operator into a box can be further reprocessed through the same sorting machine, can be transferred to another sorting machine for additional sorting, or can be transported to a delivery person, such as a mail carrier, or may be transmitted for ultimate delivery to the intended location, address or recipient when all desired sorting is completed.  
           [0008]    Although automatic sorting machines have improved prior processes for manual article sorting, the weak point of the sorting machines is the diverter gates which direct the mail or articles to the appropriate receiving compartments. The diverter gates are typically comprised of a vane pivotally mounted to a bracket controlled by a solenoid. The pivoting of the vane about the bracket diverts the articles to the desired bin or location. Over time, due to the wear of the articles passing through and against the vanes, the vane of the diverter gate frequently chips or otherwise becomes damaged and must be repaired and/or replaced. As currently designed, changing or replacing the diverter gates is a time consuming and costly endeavor since the sorting machine must be shut down during the repair and replacement of the vane.  
           [0009]    Accordingly, there exists a need for a gate assembly for diverting articles and the like which can be easily maintained. Additionally, a need exists for a gate assembly for diverting articles and the like which has a vane mounted to a bracket with the vane being easily mounted and removed from the vane when necessary.  
         SUMMARY  
         [0010]    The present invention is a gate assembly for diverting substantially flat articles. The gate assembly comprises a mounting bracket having an upright support member and a mounting member secured to the upright support member and a diverter vane having a slot for slidably receiving at least a portion of the upright support member of the mounting bracket. A motion mechanism secured to the mounting bracket for selectively moving the combined mounting bracket and diverter vane thereby diverting the articles to a predetermined desired location.  
           [0011]    The present invention additionally includes a gate device for diverting and directing articles in a sorting machine. The gate device comprises a bracket member mounted to the sorting machine. A vane member is mounted to the bracket member with the vane member removable from and mountable to the bracket member without removing the bracket member from the sorting machine wherein combined bracket member and the vane member selectively movable to direct the articles to a predetermined desired location.  
           [0012]    The present invention further includes a method for replacing a diverter vane in a sorting machine. The method comprises providing a bracket having an upright support member and a mounting member secured to the upright support member, releasably mounting the diverter vane on at least a portion of the upright support member of the bracket, and releasably securing the diverter vane on the bracket. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0013]    [0013]FIG. 1 is an exploded perspective view illustrating a gate assembly, constructed in accordance with the present invention, with the gate assembly having a diverter vane mountable to a mounting bracket;  
         [0014]    [0014]FIG. 2 is a perspective view illustrating the mounting bracket of the gate assembly, constructed in accordance with the present invention;  
         [0015]    [0015]FIG. 3 is a top view illustrating the mounting bracket of the gate assembly of FIG. 2, constructed in accordance with the present invention;  
         [0016]    [0016]FIG. 4 is a side view illustrating the mounting bracket of the gate assembly of FIG. 2, constructed in accordance with the present invention;  
         [0017]    [0017]FIG. 5 is an end view illustrating the mounting bracket of the gate assembly of FIG. 2, constructed in accordance with the present invention;  
         [0018]    [0018]FIG. 6 is a perspective view illustrating the vane of the gate assembly, constructed in accordance with the present invention;  
         [0019]    [0019]FIG. 7 is a top view illustrating the diverter vane of the gate assembly of FIG. 6, constructed in accordance with the present invention;  
         [0020]    [0020]FIG. 8 is a side view illustrating the diverter vane of the gate assembly of FIG. 6, constructed in accordance with the present invention; and  
         [0021]    [0021]FIG. 9 is an end view illustrating the diverter vane of the gate assembly of FIG. 6, constructed in accordance with the present invention. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0022]    As illustrated in FIG. 1, the present invention is a gate assembly, indicated generally at  10 , for diverting substantially flat articles (not shown) and the like during sorting and/or distribution of the substantially flat articles. The gate assembly  10  of the present invention can be used on automatic sorting machines (not shown) and other machines used for diverting and sorting substantially flat articles such as mail, checks, invoices, papers, etc.  
         [0023]    The gate assembly  10  of the present invention includes a diverter vane  12  mountable to a mounting bracket  14 . The diverter vane  12  and the mounting bracket  14  are preferably constructed from a plastic material although constructing the diverter vane  12  and the mounting bracket  14  from other materials including, but not limited to, metal, ceramic, wood, etc., is within the scope of the present invention.  
         [0024]    Still referring to FIG. 1, the mounting bracket  14  is mounted to a solenoid  16  or other control means for controlling the movement of the mounting bracket  14  and the diverter vane  12  relative to the solenoid  16 . The solenoid  16  includes sufficient electronics causing and controlling the selective movement of the mounting bracket  14  and diverter vane  12  to direct the substantially flat articles to a predetermined, desired destination.  
         [0025]    The solenoid  16  further includes a rotatable mounting post  18  for receiving the mounting bracket  14 . As the solenoid  16  rotates the mounting post  18  in response to commands for particular article movement, the mounting bracket  14  also moves accordingly. A spring member (not shown) is positioned between the solenoid  16  and the mounting post  18  causing the mounting bracket  14  to return to a start position after the selective movement by the solenoid  16 .  
         [0026]    The mounting post  18  of the solenoid  16  has a first mounting post end  20  and a second mounting post end  22 . As illustrated in FIGS.  2 - 5 , the mounting bracket  14  includes a substantially circular upright support  24  having a first end  26  and a second end  28  and a mounting body  30  secured to the upright support  24  along the length of the upright support  24 . First mounting means  32  are formed on the mounting body  30  adjacent the first end  26  of the upright support  24 . The first mounting means  32  preferably includes a D-shaped aperture  34  for receiving the first mounting post end  20  of the mounting post  18 . Preferably, the first mounting post end  20  of the mounting post  18  has a similar configuration to allow a snug fit between the first mounting means  32  and the mounting post  18  such that upon rotation of the mounting post  18 , the mounting bracket  14  rotates in a similar manner.  
         [0027]    Second mounting means  36  are formed on the mounting body  30  adjacent the second end  28  of the upright support  24 . The second mounting means  36  of the mounting bracket  14  preferably includes a slot  38  for receiving the second mounting post end  22  of the mounting post  18 . A complementary mounting piece (not shown) is positioned about the second mounting post end  22 . A pair of aligned apertures  40  in the second mounting means  36  of the mounting bracket  14  and the mounting piece receives screws (not shown) or the like for securing the second mounting post end  22  of the mounting post  18  therebetween.  
         [0028]    Referring now to FIGS.  6 - 9 , the diverter vane  12  includes a substantially keyhole-shaped slot  42  extending along the length of the diverter vane  12 . The upright support  24  and at least a portion of the mounting body  30  of the mounting bracket  14  are received within the keyhole-shaped slot  42  of the diverter vane  12 . Securement means including, but not limited to, E-rings  44 , are mounted within annular grooves  46  about each end of the upright support  24  of the mounting bracket  14 . The E-rings  44  limit the extent of longitudinal movement of the diverter vane  12  relative to the mounting bracket  14  when mounted thereon.  
         [0029]    In another embodiment, the first end  26  of the upright support  24  can have an annular shoulder  48  which also limits the longitudinal movement of the diverter vane  12  relative to the mounting bracket  14 . In still another embodiment, a screw or wing-nut (not shown) can be secured into the upright support  24  of the mounting bracket  14  after sliding the diverter vane  12  onto the mounting bracket  14 . Once again, the diverter vane  12  is secured between the screw and the annular shoulder  48  limiting the extent of longitudinal movement of the diverter vane  12  relative to the mounting bracket  14 . It should be noted that while certain manners of releasable securement of the diverter vane  12  to the mounting bracket  14  has been described, using other means to secure the diverter vane  12  to the mounting bracket  14  are within the scope of the present invention.  
         [0030]    In operation, the solenoid  16  moves the mounting bracket  14  and the diverter vane  12  to direct the articles to the predetermined, desired location in response to commands from sensing and detecting equipment. If the mounting bracket  14  should become worn or broken, the mounting bracket  14  can be removed by loosening the screws. If the diverter vane  12  should become worn or broken, the securement means can simply be removed and the diverter vane  12  can be replaced.  
         [0031]    The foregoing exemplary descriptions and the illustrative preferred embodiments of the present invention have been explained in the drawings and described in detail, with varying modifications and alternative embodiments being taught. While the invention has been so shown, described and illustrated, it should be understood by those skilled in the art that equivalent changes in form and detail may be made therein without departing from the true spirit and scope of the invention, and that the scope of the present invention is to be limited only to the claims except as precluded by the prior art. Moreover, the invention as disclosed herein, may be suitably practiced in the absence of the specific elements which are disclosed herein.