Abstract:
The present invention provides exemplary mail processing systems and methods, including systems and methods for retrieving paper sheets, statements, inserts and/or cards, and inserting same into an envelope. In one embodiment, an apparatus ( 200 ) includes a paper feeding mechanism ( 210 ) to feed sheets of paper into a collection bin ( 220 ) that is adapted to receive in a stack the sheets of paper. The apparatus includes a retrieval mechanism ( 230 ) to remove a bottom one of said sheets of paper from the stack, and a deionizer ( 240 ) that reduces static electricity in the vicinity of the stack. In this manner, the deionizer helps facilitate removal by the retrieval mechanism of only one of the sheets of paper at a time, by reducing static electricity on the sheets.

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS  
       [0001]    This case is related to U.S. Application Serial No. ______ (Attorney Docket No. 20375-001800), entitled “Mail Handling Equipment and Methods,” filed contemporaneously herewith on November ______, 2001, and assigned to the assignee of the present invention, the complete disclosure of which is incorporated herein by reference. 
     
    
     
       BACKGROUND OF THE INVENTION  
         [0002]    The present invention is directed to mail processing systems and methods, and more particularly, to systems and methods for retrieving desired paper sheets, statements, inserts and/or cards and inserting same into an envelope.  
           [0003]    Financial institutions, long distance telephone carriers, and a number of other organizations often desire to send a card and accompanying paperwork to a client or potential client. For example, a new credit card customer may fill out a written form, and submit same to a financial institution. Upon approval of the customer&#39;s credit, the financial institution then prepares and sends a credit card to the new customer, along with a paper card carrier and/or documentation. In order to send the card and documents to a customer, the information often is sent to a card issuer such as First Data Merchant Services Corporation (FDMS).  
           [0004]    The card is typically matched with a carrier, such as a paper insert having an adhesive strip or slots adapted to receive the card. The card and carrier are then placed into an envelope using automated equipment, such as a machine from Böwe Systec Group, headquartered in Augsburg, Germany. In some cases, additional pages or inserts are matched with the new customer card for insertion into the envelope. The automated processing of the cards, carriers, inserts, statements and the like typically involves a multi-step process leading to an envelope stuffed for mailing.  
           [0005]    The handling of the number of different inserts, pieces of paper, and cards provides a multitude of opportunities for the processing equipment to be jammed or otherwise malfunction. Typically, equipment used to process the cards and associated statements can be expensive, on the order of one million dollars or more. Notwithstanding the excessive costs of these machines, such machines still can be subject to paper jams and other processing difficulties which may, in some cases, result in system shutdown for trouble shooting. For example, some prior art systems process a series of statements in sequence, with the systems having stacks of paper or statements in certain locations. The stacking and unstacking of paper tends to build up static electricity which, on some occasions, causes adjacent sheets of paper to stick to one another. Further, equipment used to pull individual inserts for insertion into a customer&#39;s envelope can present difficulties, including, the failure to pull a desired insert and/or the pulling of duplicate copies of a desired insert. These and other process related problems increase the length of time it takes to process a particular customer&#39;s order, cause downtime for the processing equipment and the like.  
           [0006]    The present invention relates to machines and techniques that address at least some of the problems of the current process equipment.  
         BRIEF SUMMARY OF THE INVENTION  
         [0007]    The present invention provides exemplary mail processing systems and methods, including systems and methods for retrieving paper sheets, statements, inserts and/or cards, and inserting same into an envelope.  
           [0008]    In one embodiment, a mail processing apparatus of the present invention includes a paper feeding mechanism that is adapted to feed sheets of paper, and a collection bin that is adapted to receive in a stack the sheets of paper from the paper feeding mechanism. The apparatus includes a retrieval mechanism that is configured to remove a bottom one of said sheets of paper from the stack, and a deionizer that is adapted to reduce static electricity in the vicinity of the stack. In this manner, the deionizer helps facilitate removal by the retrieval mechanism of only one of the sheets of paper at a time, by reducing static electricity on the sheets.  
           [0009]    In one aspect, the deionizer includes a deionizing static bar, such as is commercially available from Simco Industrial Static Control, of Hatfield, Pa. In a particular aspect, the deionizer is positioned so that the sheets fed by the paper feeding mechanism pass over the deionizer and are received by the collection bin.  
           [0010]    In one aspect, the retrieval mechanism includes a roller. In another aspect, the collection bin further includes at least one foot for facilitating the removal of only one sheet by stripping off adjacent sheets therefrom.  
           [0011]    In some aspects, mail processing apparatus of the present invention further includes a printer for printing alpha-numeric characters on the sheets before the sheets are fed, a card attachment mechanism for attaching a card to the sheet, and/or a sheet folding mechanism for folding the sheet, either before or after the card is attached.  
           [0012]    In another embodiment, a mail processing apparatus of the present invention includes a track over which paper sheets pass in sequence, a moving mechanism to move the sheets along the track, and an inserting mechanism to add an insert to one of the sheets on the track. The inserting mechanism includes a grasping mechanism that is adapted to grasp and move the insert onto the sheet, and a nozzle positioned above the track for directing a gas stream onto the insert to hold the insert to the sheet. In this manner, the gas stream, such as a stream of forced air, helps facilitate the passage of the grasping mechanism over both the sheet and the insert when traveling to grasp a subsequent insert, such as for a subsequent sheet.  
           [0013]    In one aspect, the inserting mechanism includes a bin to hold a stack of inserts, and at least one vacuum finger to pull a bottom insert from the stack where it is grasped by the grasping mechanism. In alternative aspects, the nozzle is coupled to the grasping mechanism, and/or includes an elongate slit for directing the gas stream. In another aspect, the moving mechanism includes a pair of fingers that move along the track.  
           [0014]    In a particular aspect, the mail processing apparatus includes a sensor that is adapted to detect if the insert has been grasped by the grasping mechanism. The sensor may be a pressure sensor, an optical sensor, and the like.  
           [0015]    In another aspect, the apparatus includes an indicator that is adapted to indicate if the grasping mechanism fails to grasp the insert, and/or grasps more than one insert. In one aspect, the indicator includes an interrupt circuit coupled to and adapted to stop operation of the moving and inserting mechanisms if the grasping mechanism fails to grasp the insert, or grasps more than the desired number of inserts  
           [0016]    In still another embodiment, mail processing apparatus of the present invention includes a track, an envelope feeder adapted to feed an envelope onto the track, and an inserting mechanism for placing inserts into the envelope. The apparatus includes a nozzle system for directing a gas into the envelope to hold the envelope open for the inserts. The nozzle system includes a central nozzle adapted to direct gas into a central region of the envelope, and a side nozzle adapted to direct gas near an edge of the envelope.  
           [0017]    In one aspect, the apparatus includes a gas adjust nozzle to control a gas flow rate through the side nozzle. In still another aspect, a fixture holds the side nozzle to the central nozzle.  
           [0018]    The present invention further includes methods of processing mail and/or inserting inserts into envelopes. In one such embodiment, a method of processing mail includes passing first and second paper sheets along a track, and adding an insert to the first sheet. The insert is added by grasping the insert with a grasping mechanism, moving the insert onto the first sheet, and holding the insert to the first sheet so that the grasping mechanism may pass over both the first sheet and the insert when grasping a subsequent insert for the second sheet. The insert is held, at least partly, by directing a gas stream onto the insert.  
           [0019]    In one aspect, the method includes using a sensor to sense whether the grasping mechanism has grasped only one insert, and/or has failed to grasp the insert. In the event the sensor indicates an undesired number of inserts have been grasped, one aspect of the method includes stopping the mail processing. In a particular embodiment, an indicator is used to indicate where in the process line an error has occurred.  
           [0020]    In another embodiment, a method of the present invention includes providing a plurality of sheets of paper, feeding the sheets of paper sequentially into a collection bin to form a stack, and retrieving a bottom one of said sheets of paper from the stack with a retrieval mechanism. The collection bin includes a deionizer, such as a static bar over which the sheets pass, that is adapted to reduce static electricity in the vicinity of the stack.  
           [0021]    In still another method of the present invention, an insert to be placed into an envelope is provided, and the envelope is fed onto a track. The method includes directing a gas into an opening of the envelope to hold open the envelope, thereby facilitating receipt of the insert. The gas is directed with a central nozzle into a central region of the envelope opening, and with a side nozzle near an edge of the envelope opening.  
           [0022]    Other objects, features and advantages of the present invention will become more fully apparent from the following detailed description, the appended claims and the accompanying drawings. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0023]    [0023]FIGS. 1A and 1B depict a simplified schematic of a mail processing system according to an embodiment of the present invention;  
         [0024]    [0024]FIG. 2 is an overall view of a portion of a mail processing apparatus according to the present invention;  
         [0025]    [0025]FIG. 3 is an overall view of a second portion of a mail processing apparatus for reading a card and affixing tape thereto;  
         [0026]    [0026]FIG. 4 depicts an insert bin according to the present invention;  
         [0027]    [0027]FIG. 5 depicts a portion of an insert grasping mechanism according to the present invention;  
         [0028]    [0028]FIG. 6 is an overall view of a portion of a mail processing system according to the present invention; and  
         [0029]    [0029]FIG. 7 is a simplified view of a portion of an envelope insertion apparatus according to the present invention. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0030]    [0030]FIGS. 1A and 1B depict a simplified schematic of a mail processing system  100  according to the present invention. System  100  includes a series of stations adapted to produce an envelope stuffed with a desired number of paper documents and one or more cards. Cards processed by system  100  can include credit cards, debit cards, company and stored-value cards, smart cards, phone cards, and the like. Documents processed by system  100  include one or more sheets of paper, such as a customer billing statement, a new cardholder agreement, a renewal card statement, a card carrier, and the like. Documents also may include a variety of paper inserts, such as advertisements and the like.  
         [0031]    In the embodiment shown in FIGS. 1A and 1B, system  100  includes a printer  110  adapted to print alpha numeric characters on a statement, a sheet of paper, a card carrier, or the like. Printer  100  prints information such as an account number, a customer name and mailing address, a monetary account limit, and the like, and further may print one or more bar codes. In one embodiment, at least one of the bar codes identifies which inserts, from a plurality of different inserts, are to be sent to the customer with the statement or card.  
         [0032]    The printed statements or card carriers (not shown) travel down a belt  112  and are stacked in a stacking unit  114 . Further details on stacking unit  114  are discussed in conjunction with FIG. 2, which in one embodiment also operates to at least partially fold the statement or card carrier. The sheets are then sequentially drawn from stacking unit  114  into unit  116 .  
         [0033]    In one embodiment, unit  116  includes a bar code reader for reading a bar code or other identification mark on the statement or card carrier. The bar code may, for example, identify which inserts are to be later matched up with the card carrier. In another embodiment, unit  116  also reads a number, such as a three digit number, associated with the card carrier to facilitate proper matching with a card having a corresponding number.  
         [0034]    In one embodiment, the carrier is transferred from unit  116  into unit  118 . A card is received from unit  120  and matched with the corresponding card carrier in unit  118 . In one embodiment, the card is glued, placed in slots or otherwise affixed to the card carrier in unit  118 . Additional details on unit  120  are described in conjunction with FIG. 3. The mated card carrier and card are transferred to unit  119 . If a processing error has occurred, unit  119  deflects the card and card carrier into a bypass tray or receiving area  117 . Processing errors may include, for example, mismatched cards and card carriers, and the like. If no error has occurred, unit  119  deflects the card and card carrier into a folding unit  121 .  
         [0035]    Folding unit  121  performs a fold of the statement or card carrier. In one embodiment, folding unit  121  performs a second fold of the card carrier, resulting in a card carrier that is approximately the size of a business class envelope. In a particular embodiment, the first and second folds of the card carrier produce a Z-fold card carrier. Folding unit  121  further includes a card detection assembly, which operates to detect if the card is missing or if too many cards have been placed in the card carrier. In one embodiment, the card detection assembly tests a thickness of the card carrier to determine if the appropriate number of cards are contained in the card carrier.  
         [0036]    If the card detection assembly indicates an error, such as too many cards or a missing card, the card carrier is transferred to a bypass tray or receiving area in the direction shown by arrow  123 . Transfer may occur along a conveyor belt, a track, or the like. In one particular embodiment, system  100  operates to place cards in card carriers, but is not used for processing further inserts. In this embodiment, all or substantially all card carriers and cards are passed down conveyor  122  in the direction of arrow  123 , and removed from system  100 . The card carriers may, if desired, be transported to an envelope stuffing apparatus, a mail room or the like.  
         [0037]    If the card detection assembly does not indicate an error, in one embodiment card carriers are then passed to a paddle wheel assembly  124  to continue processing. As shown in FIG. 1A, paddle wheel  124  operates to place the carrier and card on a track or conveyor belt  130 . The card carriers proceed down belt  130 , passing under a second paddle wheel assembly  126 . In one embodiment, second paddle wheel assembly  126  places a second statement, sheet of paper or the like on top of the card carriers as they pass underneath.  
         [0038]    As shown in FIG. 1A, a second printer  160  is adapted to print out alpha-numeric characters and/or bar codes on a second statement or sheet of paper. For example, printer  160  may print a sheet with additional information pertinent to the client or the client account, a cardholder agreement, one or more pages of checks for use by the card user, and the like. In one embodiment, printer  160  is electrically coupled to the bar code reader in unit  116 . In this manner, bar code reader  116  reads the bar code or other identification mark on the card carrier processed through unit  116 , and informs printer  160  that a second statement or page is needed. In one embodiment, controller  140  facilitates the communication between unit  116  and printer  160 .  
         [0039]    The printed second statement or page passes from printer  160  along a belt  162  and into a stacking unit  164 . Stacking unit  164  is similar to stacking unit  114 , and performs similar functions. For example, stacking unit  164  stacks a plurality of statements, folds each statement, and then passes the statements one at a time to unit  166 . Unit  166  is similar to unit  116 , and may include a bar code reader for reading a bar code or other identification mark on the second page. Unit  166  further may perform a first fold of the second statement in an embodiment in which the first fold is not performed in unit  164 . The second page then passes to unit  168 , in which a second fold of the statement is performed. In one embodiment, the second statement is a Z-folded second statement to match the general size of the first statement or card carrier.  
         [0040]    The second statement passes into unit  170 , which in one embodiment is a deflection unit  170  similar to unit  119  described above. Deflection unit  170  passes statements to bypass station  172  in the event the second statement is not to be matched with a first statement. For example, bypass station  172  receives second statements that may have been printed in error. Deflection unit  170  further directs second statements to belt  174  for transporting second statements to second paddlewheel  126 . The second statement is then matched with the first statement or card carrier as described above.  
         [0041]    As best seen in FIG. 1A, the matched pages and card combination proceed along a track or conveyor belt  130 , passing under one or more insert bins  128 . FIG. 1B depicts three (3) insert bins  128 , although a larger or smaller number of bins  128  also may be used within the scope of the present invention. In one particular embodiment, system  100  includes six (6) insert bins  128 .  
         [0042]    Insert bins  128  contain inserts, such as paper advertisements and informational inserts. These inserts may be added to a particular customer&#39;s stack of documents and card passing beneath on belt  130 . Inserts contained within bins  128  may be selectively chosen based upon a number of criteria, including customer interest and other factors. For the system  100  shown in FIG. 1 having three bins  128 , some customers may receive all three inserts, other customers may receive less than three inserts, while still other customers may receive no inserts. Additional details on insert bins  128 , and methods and apparatus for selecting inserts, are found discussed in conjunction with FIGS. 4 and 5.  
         [0043]    In one embodiment, the statements and cards traverse along belt  130  positioned underneath bins  128 . In one embodiment, belt  130  provides continuous, fluid movement of the statements. In another embodiment, belt  130  provides incremental movement of the statements, with each statement stopping below each bin  128 . Inserts desired to be matched with a particular customer&#39;s statements are pulled from bins  128  and placed atop the customer&#39;s statement. Upon reaching the end of belt  130 , the stack of documents to be sent to the customer are transferred to unit  132  for insertion into an envelope. Additional details on unit  132  are discussed in conjunction with FIG. 6.  
         [0044]    The now stuffed envelope, containing a particular customer&#39;s statement, inserts and card(s), is sent to an envelope sealing unit  134 . Envelope sealing unit  134  sprays a mist of water or other fluid on the envelope flap and seals the moistened flap. In another embodiment, unit  132  applies the fluid and/or seals the envelope flap. Unit  134  flips the stuffed envelope over to expose the envelope front. In one embodiment, envelopes processed through system  100  are windowed envelopes, with the customer name and mailing address printed on the card carrier and exposed through the envelope window.  
         [0045]    The envelopes proceed along belt  137 , and may be diverted into one or more diverters  136 . Diverters  136  divert stuffed envelopes for one or more of a variety of reasons, including but not limited to, additional processing errors, and envelopes requiring special or additional handling. In one embodiment, at least one diverter  136  is used for stuffed envelopes to be sent by overnight courier, such as Federal Express. In another embodiment, at least one diverter  136  receives envelopes intended to be sent by airmail, or the like.  
         [0046]    Envelopes intended for standard mail delivery, such as by U.S. Postal Service First Class mail, proceed past diverters  136  along belt or track  137  to first and/or second postage meters  138 ,  140 . In one embodiment, first postage meter  138  applies a one ounce postage to envelopes requiring only a single ounce of postage, and second postage meter  140  applies postage on envelopes requiring a two ounce postage. Alternatively, first postage meter  138  may apply a first ounce of postage to all envelopes, with envelopes requiring a second ounce of postage receiving same from second postage meter  140 . The envelopes, having now been properly stuffed, sealed, and postaged in one embodiment, proceed to an output station  142 . The envelopes then may be received from output station  142  for delivery to the intended customers.  
         [0047]    System  100 , in one embodiment, includes one or more controllers  140  for monitoring and/or controlling the process through system  100 . An operator may view the status of documents on the computer screen associated with a particular controller  140 , and/or input data as needed into controller  140  to facilitate operation of system  100 . Further, controllers  140  facilitate the coordination between printers  110 ,  160 , bar code readers in system  100  and insert bins  128 , to ensure each customer receives the desired card(s) and document(s).  
         [0048]    It will be appreciated by those skilled in the art that changes may be made to system  100  within the scope of the present invention. For example, system  100  may have fewer or more processing units or stations. In one embodiment, envelopes are removed from system  100  after processing through unit  132 , or through unit  134 .  
         [0049]    Turning now to FIG. 2, additional details on a statement stacking unit or apparatus  200  will be described. In one embodiment, unit  200  corresponds to unit  114  shown in FIG. 1A. Statement stacking apparatus  200  receives a series of statements or card carriers. The statements may be generated from printer  110 , as shown in FIG. 1A, and pass along belt  112  prior to entering apparatus  200 . The statements enter apparatus  200  one at a time by traveling over a plurality of rollers  210  in the direction indicated by arrow  205  in FIG. 2. The statements are stacked one on top of another in a receiving area  220 . The stacked statements in receiving area  220  are subsequently drawn by a roller  230  in the direction indicated by arrow  215 . Statements are drawn by roller  230  and proceed to an adjacent machine for processing. In one embodiment, roller  230  is a continuously moving roller having a 360° rotational movement. In this manner, roller  230  pulls the bottom statement from the stack of statements in receiving area  220 .  
         [0050]    The transfer of paper statements into apparatus  200 , over rollers  210  and into receiving area  220  tends to create, over time, a build-up of static electricity on the stacked statements. The creation of static electricity on the paper statements can cause two or more sheets to stick together. As a result, roller  230  draws, on some occasions, more than one paper statement therethrough. As will be appreciated by those skilled in the art, two or more customer statements stacked together can result in the shutdown of system  100 , and the manual manipulation of one or more units of system  100  to locate the mis-stacked statements.  
         [0051]    One aspect of the present invention involves the use of a deionizer  240  in unit  200  to deionize the air surrounding the stacked statements. In a particular embodiment, deionizer  240  is placed in or near receiving area  220 , so that the paper statements pass over deionizer  240  just prior to dropping on the stack formed in receiving area  220 . In a particular embodiment, deionizer  240  is a deionizing static bar  240 , such as that commercially available from Simco Industrial Static Control Company of Hatfield, Pa. In this manner, the use of deionizer  240  reduces the static electricity on the sheets, thereby reducing or eliminating the likelihood that more than one sheet will be drawn by roller  230 .  
         [0052]    In one embodiment, statements or card carriers are drawn from receiving area  220  and folded, prior to passing from unit  114 . In a particular embodiment, unit  114  performs a one-third fold by folding up the bottom approximately one-third of the sheet/carrier, or folding down the top approximately one-third of the sheet/carrier. As mentioned in conjunction with FIGS.  1 A- 1 B, in one embodiment the statement or card carrier passes from unit  114  and is matched with a card. Cards are attached to the card carriers in unit  118  (FIG. 1A), with cards being received from card reader  120 .  
         [0053]    [0053]FIG. 3 depicts an apparatus  300  which, in one embodiment, corresponds to unit  120  shown in FIG. 1A. Apparatus  300  includes one or more magazines  310  adapted to hold a stack of cards (not shown). In one embodiment, apparatus  300  has four magazines  310  on a rotating carousel  314 . As each magazine  310  empties, carousel  314  rotates to position the next magazine  310  with cards for processing. Magazines  310  place the cards one at a time on a belt or track under a lid  312 . The cards travel in series along the belt and pass by a mag stripe read head (under lid  312 ) which reads the mag stripes on the cards. In one embodiment, cards pass by two mag stripe read heads. The cards are placed in a buffer  316 . Cards then pass down a track  320 , and receive a label or sticker from a tape roll  322 . Cards then exit apparatus  300 , and are mated to their appropriate statement or card carrier in apparatus  118  (FIG. 1A).  
         [0054]    [0054]FIG. 4 depicts an insert bin  400 , which in one embodiment corresponds to bins  128  shown in FIG. 1B. Bin  400  includes a stacking region  410  for receipt of a stack of like inserts (not shown). Bin  400  further includes one or more adjustable pins  420  which slide in one or more corresponding grooves  430 . Pins  420  are adjusted to conform to the outer dimensions of the stacked inserts. In this manner, bin  400  may be adapted to receive a variety of insert sizes for different applications.  
         [0055]    The stacked inserts in region  410  rest on one or more suction devices  440 . Suction devices  440  operate to draw the lower-most insert at least partially through a slot  450 . The insert then exits the bottom of bin  400  and is matched with the corresponding client statement traversing below bin  400  as referenced in FIG. 1B. Each bin  400  has one or more indicator lights  460  and an illuminated reset button  470 . In one embodiment, indicator lights  460  are designed to illuminate when a malfunction occurs in bin  400 . Malfunctions resulting in indicator light  460  illumination may include a paper jam, the absence of inserts in region  410 , and the like. In a particular embodiment, indicator light  460  illuminates when an insert is not pulled through slot  450 , and/or more than one insert is pulled through slot  450 . In another embodiment, reset button  470  also illuminates when an insert is not pulled through slot  450  at a time when an insert is desired. In a particular embodiment, system  100  includes a controller (not shown in FIG. 4), with the controller ceasing operation of system  100 , including bins  400 , upon a malfunction. Indicator light  460  will illuminate on the bin  400  which caused the system shutdown. Once an operator has cleared the paper jam or otherwise resolved the malfunction, reset button  470  may be pressed to indicate bin  400  is ready to resume operations.  
         [0056]    Inserts from bin  400  are grasped by a grasping mechanism  500  as shown in FIG. 5. In one embodiment, each bin  400  has a corresponding grasping mechanism  500 . Mechanism  500  includes a grasping device or grasper  510  which translates, swings or otherwise moves from left to right as shown in FIG. 5. In one embodiment, grasper  510  includes a piston  512  and a spring  514 , and swings about an approximate hinge point  516 . Grasper  510  moves up and to the right in FIG. 5 in order to grasp an insert from bin  400 . In one embodiment, suction devices  440  and/or rollers (not shown) in bin  400  draw the lower-most insert at least partially through slot  450 , where it can be grasped by grasper  510 . Grasper then moves down and to the left in FIG. 5 to position the insert on top of the statement or card carrier passing below on belt  130 . The insert grasped by grasper  510  contacts a deflector  520 , which helps remove the insert from grasper  510 . In one embodiment, deflector  520  includes a pair of arms between which grasper  510  translates or swings. As a result, the insert is released and placed on the underlying documents, which may include a previously deposited insert from another bin  400 .  
         [0057]    As grasper  510  translates or swings to grasp a subsequent insert, little clearance exists between a tip of grasper  510  and the previously deposited insert. In some circumstances, the previously deposited insert catches on tips  520  causing dislodging of the insert, paper jams, and the like.  
         [0058]    In one embodiment of the present invention, an air direction device  530  is positioned near deflector  520 , and in a particular embodiment is coupled to deflector  520 . Air direction device  530  has an opening (not shown), which in one embodiment is an elongate slit. The device opening is configured to direct a stream of air towards the previously grasped insert. Air direction device  530  directs the air in a downward direction for the embodiment shown in FIG. 5. Further, while described in one embodiment as a device for directing air, other fluids or gases also may be used within the scope of the present invention. In one embodiment, direction device  530  is coupled to a fluid source, which in one embodiment is an air source.  
         [0059]    In this manner, the direction of the fluid from device  530  towards the previously deposited insert helps hold down the deposited insert. This feature helps reduce or eliminate the likelihood that grasper  510  will catch on the insert as grasper  510  proceeds toward grabbing a subsequent insert. Device  530 , in one embodiment, includes a control valve for controlling a rate of gas flow from device  530 . The gas flow rate may be varied depending on a wide range of variables, including the amount of static electricity on the sheets, the humidity in the facility containing system  100 , the weight and size of the inserts, and the like.  
         [0060]    Apparatus  500  further includes a sensor  540  for detecting whether grasper  510  successfully grasps the desired insert. In alternative embodiments, sensor  540  is a pressure sensor, an optical sensor, and the like. In a particular embodiment, sensor  540  is a diffraction grating adapted to induce a phase shift to light reflected therefrom. Sensor  540  operates in conjunction with a light source  550  and a light collector  560 . Light source  550  is positioned to direct light at sensor  540 , which in this embodiment is a reflective grating  540 . If grasper  510  has successfully grasped an insert, light will reflect off the insert to collector  560 . If grasper  510  has failed to grab an insert, light from light source  550  reflects off grating  540 , with a phase shift induced by grating  540 . Light collector  560  then receives the reflected, phase-shifted light and is capable of distinguishing the phase-shifted light from light reflected by an insert. As a result, a controller coupled to apparatus  500 , and/or to system  100  can shut down apparatus  500  and/or system  100  for corrective actions, if desired. In one embodiment, indicator light  470  (FIG. 4) illuminates in the event grasper  510  fails to grab an insert. In this manner, an operator can identify which grasper  510  has missed the insert. In another embodiment, indicator light  460  illuminates in the event grasper  510  grabs more than one insert.  
         [0061]    [0061]FIG. 6 depicts a simplified overall view of a portion of system  100 . FIG. 6 indicates a series of bins  400  as described in conjunction with FIG. 4, as well as a controller  610 . FIG. 6 also includes an envelope insertion device  700 , best shown in FIG. 7.  
         [0062]    In one embodiment, envelope insertion device  700  corresponds to unit  132  shown in FIG. 1B. Device  700  operates to insert the client statement and/or card carrier, card, and the selected inserts into an envelope for mailing. In one embodiment, apparatus  700  includes a main nozzle  720  and a side nozzle  730  for directing one or more fluid streams towards the envelope. In one embodiment, main nozzle  720  and side nozzle  730  are coupled to separate fluid sources, such as compressed air or other gas sources, using a gas line  710  and a gas line  770 , respectively. In another embodiment, both main nozzle  720  and side nozzle(s)  730  are coupled to the same fluid source by gas line  710 . A fixture  735  operably couples the two nozzles  720 ,  730 . In this manner, nozzles  720  and  730  are maintained in a desired orientation.  
         [0063]    As shown in FIG. 7, main nozzle  720  is designed to direct a fluid stream into the approximate center of an envelope  740 . In this manner, fluid stream from nozzle  720  helps open, and maintain open, an opening  750  of envelope  740 . While directing the fluid stream toward the center of envelope opening  750  can successfully open the center portion of envelope  740 , main nozzle  720  alone may not open envelope  740  along one or more interior edges  760  of envelope  740 . Without edges  760  being held open, the stacked papers, card(s) and insert(s) may not be successfully inserted into envelope  740 . This is particularly the case when the statement and inserts are similar in dimension to the envelope interior.  
         [0064]    In one embodiment of the present invention, applicant has incorporated a side nozzle  730  which directs fluid to and towards edges  760  of envelope  740 . As a result, envelope opening  750  is more fully opened, increasing the likelihood that the paper inserts are successfully received by envelope  740 .  
         [0065]    While FIG. 7 depicts only a single side nozzle  730 , an alternative embodiment of apparatus  700  uses a second side nozzle  730  directed to the opposing edge of envelope  740 . In still another embodiment, main nozzle  720  is directed into the approximate center of envelope opening  750  at an angle sufficient to also direct the air towards one of the envelope edges  760 . Side nozzle  730  then directs air towards the opposing edge  760 .  
         [0066]    In an additional embodiment, device  700 , or an adjacent apparatus, operates to seal envelope  740  after receipt of the card and documents. In one particular embodiment, a fluid reservoir (not shown) containing fluid for sealing envelope  740  is coupled to device  700 . The reservoir may include a gauge on the outside of the reservoir for indicating the level of fluid therein. In this manner, the level of fluid in the reservoir may be conveniently monitored.  
         [0067]    The invention has now been described in detail for purposes of clarity and understanding. However, it will be appreciated that certain changes and modifications may be practiced within the scope of the appended claims.