Patent Publication Number: US-8534661-B2

Title: System and method for preparing collations

Description:
FIELD OF THE INVENTION 
     The present invention relates to apparatus for preparing stacked sheets of material, and more particularly, to a system and method for preparing mailpiece collations. 
     BACKGROUND OF THE INVENTION 
     Various apparatus are employed for arranging sheet material in a package suitable for use or sale in commerce. One such apparatus, useful for describing the teachings of the present invention, is a mail piece inserter system employed in the fabrication of high volume mail communications, e.g., mass mailings. Such mailpiece inserter systems are typically used by organizations such as banks, insurance companies and utility companies for producing a large volume of specific mail communications where the contents of each mailpiece are directed to a particular addressee. Also, other organizations, such as direct mailers, use mailpiece inserters for producing mass mailings where the contents of each mail piece are substantially identical with respect to each addressee. Examples of inserter systems are the 8 series, 9 series, and APS™ inserter systems available from Pitney Bowes Inc. located in Stamford, Conn., USA. 
     In many respects, a typical inserter system resembles a manufacturing assembly line. Sheets and other raw materials (i.e., a web of paper stock, enclosures, and envelopes) enter the mailpiece inserter as inputs. Various modules or workstations in the mailpiece inserter work cooperatively to process the sheets until a finished mail piece is produced. The precise configuration of each inserter system depends upon the needs of each customer or installation. 
     Typically, mailpiece inserters prepare mail pieces by arranging preprinted sheets of material into a collation, i.e., the content material of the mail piece, on a transport deck. A typical collation may be created by stacking sheet material on the deck of a sheet accumulator which receives individual sheets from a pre-printed roll or web of sheet material. The roll dispenses a continuous stream of sheet material which is cut to size by a rotating guillotine cutter. Alternatively, pre-cut sheet material which is pre-printed may be stacked in a sheet feeder where a feeding device singulates individual sheets from the stack, i.e., typically the lowermost sheet of the stack. 
     From the accumulator, the collation of preprinted sheets may continue to a chassis module where additional sheets or inserts may be added to a targeted audience of mail piece recipients. From the chassis module the fully developed collation may continue to a stitcher module where the sheet material may be stitched, stapled or otherwise bound. While the stitched collation may be suitable for insertion directly into a mailpiece envelope, i.e., an envelope which is slightly oversized relative to the stitched collation, it is common for the collation to be folded to reduce the size of the envelope/mailpiece. Common fold arrangements include: bi-fold, tri-fold, Z-fold and gate fold configurations. 
     The bound/folded collation may then placed into a mailpiece envelope and conveyed to yet other stations for further processing. That is, collation may be inserted into an envelope, closed, sealed, weighed, printed, sorted and stacked. Alternatively, the folded collation may be closed by a tabbing device which places an adhesive tab around the free edges of the collation. Such tabbing devices eliminate the requirement for a mailpiece envelope inasmuch as the folded/tabbed collation is suitably bound for delivery. Additionally, a mailpiece inserter may include a module, i.e., a postage meter, for applying postage indicia based upon the weight and/or size of the mail piece. 
     While the principal measure of inserter performance is the number of mailpieces produced per unit time, i.e., the throughput of the inserter, a mailpiece inserter must also produce aesthetically pleasing mailpieces. With respect to the aesthetic appeal of a mailpiece, it will be appreciated that the appearance and condition of a mailpiece may be the first, and only, opportunity to offer/present a product or service to a prospective customer/client. A mailpiece having content material which is poorly fabricated, i.e., a collation which is misaligned, skewed or shingled, may inadvertently communicate a message that the product or service being advertised is, similarly, poor/low quality. Conversely, a high quality mailpiece, i.e., one having sharp lines with aligned edges, may communicate a message that the product being offered has a similar level of quality. Upon receipt of such mailpiece, a prospective customer/client may subconsciously think “a company which puts such thought/effort into its mailpiece must produce a high quality product/offer top-notch service”. 
     While contemporary mailpiece inserters, such as the Flowmaster® Inserter produced by Pitney Bowes Inc. located in Stamford, Conn., produce high quality mailpieces, multi-sheet collations, i.e., having a thickness greater than about ten sheets, can present difficulties, especially when stitched/bound and folded. More specifically, as the thickness of a collation increases, it will be appreciated that folding about a fold line can result in skewing wherein the edges thereof are stepped/staggered. 
       FIGS. 1   a - 1   c  schematically depict a typical folding apparatus  300  ( FIG. 1   a ), and enlarged views of the relevant details of folded multi-sheet collations  310   a ,  310   b  ( FIGS. 1   b  and  1   c ). In  FIG. 1 , a collation  310  of sheet material is received by the folding apparatus  300  from an upstream stitcher (not shown) where the collation  310  is bound by staples  315  at a centerline CL of the collation  310  and passed upwardly along an inclined tray  320  of the folding apparatus  300  by a pair of nip rollers, i.e., first and second nip rollers  340 ,  350 . As the collation  310  is driven up the tray  320 , the leading edge LE of the collation  310  contacts a stop or abutment surface  354  disposed at the uppermost end of the tray  320 . Upon engaging the abutment surface  354 , the collation  310  bends downwardly along its centerline CL, i.e., towards a fold nip  356 , defined by and between a third roller  360  and the first roller  340 . As the nip rollers  340 ,  350  continue to drive the trailing edge TE of the collation  310 , the collation  310  is captured by the fold nip  356  to fold the collation  300  along the centerline CL. 
     By examining  FIGS. 1   b  and  1   c , it will be appreciated at least one of the edges forms a stepped/staggered configuration as a result of folding the multi-sheet collation about a fold axis FA. In the context used herein, the term “fold axis” is defined as the virtual axis about which the innermost sheet  300  folds upon itself. It will be appreciated that sheets  301 - 307  are disposed radially outboard of the fold axis FA and fold around the fold axis FA. Furthermore, sheets  301 - 307  which are progressively farther outboard of the axis FA, i.e., along arrow R, result in the trailing edge TE of the collation  310  being stepped/staggered so as to define a slope or inclined plane MX 1 , MX 2   a , MX 2   b . Depending upon the location of the staple  315  and the alignment of the leading edge prior to binding, the collation  310  may develop a long shallow slope MX 1 , along the trailing edge TE (as shown in  FIG. 1   b ) or sloped edges MX 2   a , MX 2   b  along both leading and trailing edges LE, TE of the collation  310  (as shown in  FIG. 1   c ). 
     While the lack of edge registration can typically be tolerated for thin collations, e.g., collations having two (2) or three (3) sheets, such poor edge registration is more problematic for larger, thicker collations, e.g., collations having seven (7) or more sheets. That is, as collations increase in thickness, the fold exacerbates the misalignment. If a “cleaner”, more exacting, folded collation is required, then subsequent trimming/cutting operations are required to align the edges, i.e., effect a perpendicular alignment of the collective edges. It will be appreciated, however, that such additional trimming operations introduce additional registration and cutting apparatus which are costly to implement and maintain. 
     A need, therefore, exists for a system and method for preparing collations suitable for folding operations. The system and method effects edge registration without the requirement for costly processing operations and/or additional cutting/registration apparatus. 
     SUMMARY OF THE INVENTION 
     A system is provided for preparing a collation of sheets for a subsequent folding operation. The sheets are prepared such that, subsequent to folding, the edges of the collation are aligned thereby eliminating the need for additional trimming operations. The system comprises: a cutting device operative to cut each sheet of the collation based upon a length dimension of each of the inner and outer sheets, an accumulating device operative to stack the sheets to form the collation, a registration device operative to register at least one edge of the collation, a conveyance device for transporting the sheet material along a feed path to the cutting, accumulating and registration devices, and a processor operatively coupled to, and controlling, the cutting, accumulating, registration and conveyance devices. More specifically, the processor determines a fold configuration of the collation and a length dimension of each sheet of the collation based upon the fold configuration. The processor calculates the length dimension of each sheet such that at least one of the outer sheets is greater than the length dimension of the inner sheet. As a result the system prepares the collation such that the edge geometry thereof is aligned following a folding operation. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Further details of the present invention are provided in the accompanying drawings, detailed description, and claims. 
         FIG. 1   a  depicts a schematic view of a folding apparatus commonly employed in a mailpiece inserter system. 
         FIGS. 1   b  and  1   c  are broken away edge views of a folded multi-sheet collation wherein the fold operation effects skewing/distortion of the trailing and/or leading edges of the collation. 
         FIG. 2  is an isometric view of a stitcher/stapler module having a transport and alignment system including a pair of belts having pusher fingers to convey a multi-sheet collation along a feed path, and a system of alignment mechanisms disposed alongside and between the fingers to jog and align the edges of the collation. 
         FIG. 3  is a block diagram of various components of a mailpiece inserter system including a processor for controlling the operation of a stitcher/stapler module and processing thickness data/sheet count information derived from one of a variety of sources. 
         FIG. 4  is a broken away isometric view of the stitcher/stapler module of  FIG. 2  to reveal the relevant details of the transport and alignment system including an feed input station for stacking a multi-sheet collation, and first and second processing stations disposed downstream of the feed input station for aligning the leading, trailing and lateral side edges of the multi-sheet collation. 
         FIG. 5  is a schematic side view of the first and second processing stations each including pairs of repositionable alignment mechanisms which may be: (i) extended upward between the first and second conveyor belts to jog/align the leading and trailing edges of the multi-sheet collation, and (ii) retracted below the support surfaces of the conveyor belts to facilitate to transport along the feed path immediately prior to, and following alignment of, the multi-sheet collation. 
         FIGS. 6   a  and  6   b  depict exploded and assembled views, respectively, of a typical trailing edge alignment mechanism including a four-bar linkage arrangement for displacing a registration member of the alignment mechanism from an idle position below the conveyor belts to an active position above the conveyor belts. 
         FIGS. 7   a  and  7   b  depict exploded and assembled views, respectively, of a typical leading edge alignment mechanism including a four-bar linkage arrangement for displacing the registration member from the idle to active positions, and a linear guide/actuator assembly for imparting pure linear motion to the registration member when jogging the multi-sheet collation during alignment operations. 
         FIGS. 8   a  and  8   b  depict schematic views of a reconfigurable stitch head adapted to vary the length of each binding stitch based upon thickness data/sheet count information of the multi-she  FIGS. 8   a  through  8   d  depict schematic views of a reconfigurable stitch head adapted to vary the length of each binding stitch based upon thickness data/sheet count information of the multi-sheet collation. 
         FIG. 9  depicts a schematic diagram of a mailpiece inserter according to an embodiment of the invention including a feed module, a cutting module, and a registration/binding module for producing a folded collation having vertically aligned edges. 
         FIG. 10   a  is a broken-away side view of a registration/binding module wherein registration members define inclined surfaces to misalign the edges during registration/binding operations such that the edges are aligned following a folding operation. 
         FIG. 10   b  is an enlarged side view of the registration/binding module of  FIG. 10   a  having a central stitcher to bind the collation at centerline location and forward/aft registration members adapted to prepare the collation for folding about the centerline. 
         FIG. 10   c  is an enlarged side view of the registration/binding module of  FIG. 10   a  having an edge stitcher to bind the collation proximal to a leading edge, and forward/aft registration members adapted to prepare the collation for folding about one or more fold axes. 
         FIG. 11  is a broken-away edge view of a multi-sheet collation according to the present invention wherein the leading and trailing edges are vertically aligned, i.e., relative to a vertical plane, subsequent to the folding operation. 
         FIG. 12  is a broken-away side view of the registration/binding module wherein the registration members are displaced by a linear actuator to effect a desired collation edge geometry. 
         FIG. 13  is a broken-away side view of the registration/binding module including a registration element pivotably mounted to the registration member and an actuation device operative to position the registration element relative to the registration member to effect a desired collation edge geometry. 
         FIG. 14  is a broken-away side view of the registration/binding module including a system for displacing the binding device relative to an edge of the collation. 
     
    
    
     DETAILED DESCRIPTION 
     The following detailed description discusses various systems/devices/modules of a mailpiece inserter for processing sheet material collations. One embodiment of the invention relates to a stitcher/stapler for binding multi-sheet collations and method for controlling the same. Another embodiment relates to a transport and alignment system for producing variable thickness collations. Yet another embodiment relates to an adjustable stitcher for binding consecutive variable thickness collations. Still another embodiment relates to preparing a multi-sheet collation for a folding operation. Still yet another embodiment relates to a system for selectively conveying a collation to one of several registration/binding stations within a multi-station registration/binding device. In this embodiment, the collation is prepared and conveyed to a registration station and/or a binding station based upon the fold configuration and/or thickness of the collation. 
     This invention described herein is directed to the embodiment described in the section entitled “System and Method for Preparing Collations” and will be described in the context of a mailpiece inserter. While the inventions may be particularly useful for processing/producing mail communications, it should be appreciated that the inventions are broadly applicable to any apparatus/system which requires binding, transport and alignment of stacked sheets of material, i.e., a multi-sheet collation. As used herein, the term “collation” is any multi-sheet stack of material, i.e., having at least two (2) sheets, such as that required for fabricating, books, pamphlets, mailpiece content material etc. 
     Stitcher/Stapler for Binding Multi-Sheet Collation and Method of Operation 
     In  FIGS. 2 and 3 , a stitcher/stapler  10  is adapted to stack, transport, align and bind consecutive multi-sheet collations  12  which vary in thickness. That is, the stitcher/stapler  10  is adapted to process consecutive collations which comprise as few as two (2) sheets to as many as one-hundred and fifty (150) sheets. It should be appreciated, however, that total number of sheets in a particular collation will generally be governed by the ability of a processing station to bind sheet material. 
     In the described embodiment, the stitcher/stapler  10  includes three serially-arranged processing stations including an feed input station  14 , a first processing station  16 , and a second processing station  18  The stitcher/stapler  10  receives sheet material  12 S from an upstream sheet feeding module (discussed in greater detail herein after in the section entitled “System and Method for Fabricating Multi-sheet Collations” and accumulates/stacks of sheet material at the feed input station  14 . The thickness of the multi-sheet collation  12  is determined to ascertain which of the subsequent processing stations  16 ,  18  will be most effective to bind the multi-sheet collation  12 . The first processing station  16 , immediately downstream of the feed input station  14 , includes a stitcher  20  (described and illustrated in greater detail below) to bind the collation by a variable length “stitch”, i.e., a length of wire which is cut/formed to produce a pair of prongs connected by a central web (similar to a staple, however, the ends of each prong are not sheared so as to form a penetrating point). The second processing station  18  includes a stapler  22  which binds the collation by a fixed length “staple”, i.e., a conventional U-shaped fastener having a pair of penetrating legs connected by a central crown. 
     The principle difference between the two, i.e., the stitcher  20  of the first processing station  16  and the stapler  22  of the second processing station  18 , relates to the capacity and/or ability of each to bind a collation. The stitcher  20  provides the capability to bind many collations before a requirement to reload a supply of stitching wire. That is, the stitcher  20  employs a relatively large spool of wire to provide a large supply of stitching material to bind multiple collations/documents. However, due to the requirement to shape each stitch from a supply of wire spool, the gauge of the wire and/or its yield strength properties, must be relatively low to facilitate the formation of the stitch, i.e., bending the wire to shape. A stapler  22 , on the other hand, provides the ability to bind thick collations, e.g., a thickness greater than about forty-five thousands of an inch (0.45″) or greater than about ninety (90) sheets of bond grade paper, but is limited in terms of the number of collations/documents that can be bound. With respect to the latter, the staples, which are “preformed”, are fabricated from high yield strength, high stiffness materials. As a result, the legs of each staple can be fabricated to a length sufficient to penetrate thick collations without buckling. However, since the staples are preformed and packaged in strips having a finite number, only a small number of collations may be bound before the stapler  22  must be reloaded. In view of these differences, the stitcher/stapler module  10  of the present invention obtains information concerning the thickness of the multi-sheet collation such that each may be directed to the most appropriate downstream station for subsequent processing. This feature is discussed in greater detail in the subsequent paragraphs. 
     In  FIG. 3 , thickness/sheet count information  30  is used for several operations of the stitcher/stapler  10  including operations which: (i) select the processing station  16 ,  18  best suited to bind the collation  12 , (ii) control the transport and alignment of the multi-sheet collations  12  at each of the processing stations  16 ,  18 , and (iii) control the stitching operation at the first processing station  16  (i.e., the length of stitch, spacing between the anvil/clincher and the striker/ram, etc.) Specifically, the thickness information  30  may be obtained by (i) reading a scan code data  32  printed on the first sheet of the multi-sheet collation  12 , (ii) employing a sheet counter  34  in combination with sheet thickness data input by an operator, (iii) obtaining the number of sheets directly from the job data  36  of the mail run (i.e., from the application program code which generates each sheet printed in the mail run), (iv) directly measuring the thickness via a thickness measurement probe  38 , once the collation  12  has been stacked. In the described embodiment, a scanner (not shown), upstream of the stitcher/stapler module  10 , reads the scan code data  32  to obtain the number of sheets contained in the collation  12 . A processor  40 , controlling the operation of the mail piece inserter  24  (including the stitcher/stapler module  10 ), determines the thickness of the collation  12  as the product of the number of individual sheets  12 S multiplied by the thickness of each sheet. An operator may be prompted i.e., via a keyboard or other input device  42  to enter the type or characteristics (i.e., weight, bond, copy, etc.), of the sheet material such that the processor  40  may calculate the thickness of the collation  12  to be bound. 
     The processor  40  uses the thickness data/sheet count information to convey the multi-sheet collation  12  from the input feed station  14  to the stitcher  20  at the first processing station  16 , or to the stapler  22  at the second processing station  18 . That is, the processor  40  is responsive to a thickness value signal TS and, if the thickness of the collation is greater than (or less than) a threshold value (X), the collation  12  is transported to one of the processing stations  16 ,  18 . In the described embodiment, if it is determined that the collation  12  is less than or equal to about forty-five thousands inches (0.45″) in thickness, the collation  12  is transported to the first station  16  for processing. Therein, the collation  12  is bound by the stitcher  20  which is capable of varying the length of the stitch such that the stitch optimally extends through the collation. That is, the wire of the stitcher  20  is cut to a length such that the prongs thereof extends through the collation and the anvil of the stitcher  20  clinches the ends to an optimal length, i.e., sufficiently long to capture all of the sheets without overlapping the ends of each prong. In the described embodiment, the stitcher  20  is capable of varying the length of each stitch, i.e., from one collation to a subsequent collation. While this aspect of the invention will be discussed in greater detail below i.e., when describing the reconfigurable stitcher illustrated in  FIGS. 8   a  though  8   d , suffice it to say at this juncture, that the stitcher  20  is adapted to: (i) vary the length of the wire which forms each stitch, (ii) center the web relative to the striker/ram which drives the stitch through the collation, and (iii) vary the strike distance i.e., the distance between the striker/ram and the anvil. 
     If it is determined that the thickness of the collation  12  is greater than about forty-five thousands inches (0.45″), the collation  12  is transported to the second station  18  for processing. Therein, the collation  12  is bound by the stapler  22  which is capable of penetrating the thick collation without bending/buckling. That is, since each staple is fabricated from a high yield strength material, the legs of each staple are highly stabile in buckling and penetrate the collation without bending. 
     Transport and Alignment System for Producing Variable Thickness Collations 
     As discussed above, the multi-sheet collation  12  is conveyed along a feed path FP of the stitcher/stapler  10  to one of the processing stations  16 ,  18  depending upon the collation thickness/sheet count information  30 . In  FIGS. 4 and 5 , the transport and alignment system comprises first and second belts  54   a ,  54   b  (best seen in  FIG. 4 ) which wrap around, and are driven by, a plurality of rolling elements  56 . That is, one or more rotary drive motors M is coupled to, and drives, at least one of the rolling elements  56  associated with each of the belts  54   a ,  54   b . In the described embodiment, the belts  54   a ,  54   b  are cogged to engage teeth disposed about the periphery of the rolling elements  56 . The first and second belts  54   a ,  54   b  slideably engage, and are each supported by, a rigid support structure disposed beneath the respective belts  54   a ,  54   b  to mitigate catenation thereof between the rolling elements  56 . In the described embodiment, the rigid support structures are elongate bars  58  (see  FIG. 2 ) having a width dimension (transverse to the feed path FP of the collation  12 ) approximately equal to the width of each belt. As a consequence, the belts  54   a ,  54   b  and bars  58  define a space or gap therebetween to allow for binding apparatus, i.e., the stitcher  20  and stapler  22 , to access the underside of the multi-sheet collation  12 . Furthermore, the spacing between the first and second belts  54   a ,  54   b  mitigates skewing of the multi-sheet collation  12 . 
     Each of the belts  54   a ,  54   b  includes a plurality of spaced-apart fingers  60  which are aligned along the conveyance/feed path FP to convey the multi-sheet collation  12  from the feed input station  14  to one of the downstream processing stations  16 ,  18 . The fingers  60  project upwardly, i.e., orthogonally, from each of the belts  54   a ,  54   b  and engage the trailing edge  12 T of the multi-sheet collation  20  at two points. Furthermore, the belts  54   a ,  54   b  are aligned across the feed path FP and driven in unison to “push” the collation  12  along the feed path FP to one of the two processing stations  16 ,  18 . 
     In  FIGS. 4 and 5 , perspective and side views, respectively, of the belts  54   a ,  54   b  are shown to reveal opposing alignment mechanisms  62   a ,  62   b  comprising pairs of registration members  64   a ,  64   b  disposed along the feed path FP and between the first and second conveyor belts  54   a ,  54   b . Functionally, the alignment mechanisms  62   a ,  62   b  are operative to align the opposed edges, e.g., leading and trailing edges, of the multi-sheet collation  12  as each collation comes to rest at one of the processing stations  16 ,  18 . Once aligned, the collation  12  is bound by either the stitcher  20  or stapler  22 , depending upon which processing station  16 ,  18  has been selected to bind the collation  12 , i.e., as determined by the processor  40 . 
     More specifically, and referring  FIGS. 4 ,  5 , and  6   a  through  7   b , each of the registration members  64   a ,  64   b  extends transversely across the feed path FP and has a generally L-shaped cross section defined by a base  66  and a registration wall  68  disposed orthogonally from the base  66 . Each registration wall  68  defines a registration surface  68 R which is repositionable from an idle position (shown in dashed lines in  FIG. 6   b ), below the support surface  54 S (also referred to as the “transport deck”) of each of the belts  54   a ,  54   b , to an active position (shown in solid lines in  FIG. 6   b ) above the support surface  54 S of the belts  54   a ,  54   b . In the idle position, the collation  12  moves over one or both of the registration members  64   a ,  64   b  and may be conveyed from the feed input station  14  to either of first or second processing stations  16 ,  18 . Alternatively, with all of the registration members  64   a ,  64   b  in the idle position, the collation  12  may be conveyed across the entire stitcher/stapler  10  to another downstream processing station, i.e., without being bound at either the first or second processing stations  16 ,  18 . 
     In the active position, at least one of the registration members  64   a ,  64   b  is adapted to oscillate forward and aft, i.e., along the feed path FP, to align the edges of the collation  12 . In the described embodiment, the downstream registration member  64   b  (see  FIGS. 4 and 7   b ) of each pair, i.e., the registration member  64   b  in contact with the leading edge  12 L of the collation  12 , oscillates forward and aft to align the sheets of the collation  12 . Although, it should be appreciated that either or both of the registration members  64   a ,  64   b  may be displaced to align the collation  12 . 
     To ensure complete and accurate registration of large collations, e.g., those having more than ninety (90) sheets or having a thickness greater than about 0.3 inches, the downstream registration member  64   b  of each pair oscillates for eight (8) cycles and is displaced a distance of about 0.25 inches with each cycle. However, to increase throughput, i.e., the number of collations processed (i.e., bound via the stitcher  20  or stapler  22 ), the number of cycles may be varied depending upon the thickness of the collation  12 . For example, a collation  12  having as few as ten (10) sheets, or a thickness less than about 0.1 inches, the registration member  64   b  may be cycled three (3) times. Similar to the selection of the appropriate processing station  16 ,  18 , thickness data  30 , or the number of sheets in each collation  12 , is used by the stitcher/stapler module  10  to determine the optimum number of cycles for aligning the sheets of each collation  12 . That is, the processor  40  acquires the thickness information  30  and varies the number of cycles depending upon the collation thickness or sheet count. 
     To further improve throughput, the processor  40  may control the conveyance system, (i.e., the belts  54   a ,  54   b , rolling elements  56  and drive motor M), to use the first and second processing stations  16 ,  18  as buffer stations. That is, when the stitcher/stapler  10  is not active, i.e., functioning only as a transport system, the processing stations  16 ,  18  may serve to hold/retain collations  12  (unbound collations) so that other mailpiece inserter stations e.g., folding, insertion and/or print stations (not shown) downstream of the first and second processing stations  16 ,  18  may process the mailpiece content material. 
     In  FIGS. 5 through 7   b , each of the registration members  64   a ,  64   b  pivotally mounts to a first displacement mechanism  70  operative to: (i) raise and lower the registration members  64   a ,  64   b  into and out of the idle and active positions, and (ii) oscillate at least one of the registration members  64   a ,  64   b  to align the sheets of the collation  12 . In the described embodiment, the displacement mechanism  70  comprises a plurality of links  72 ,  74  pivotally mounting at one end to an intermediate fitting  76 , and pivotally mounting at the other end to the base  66  of a respective one of the registration members  64   a ,  64   b . The intermediate fitting  76  includes a mounting plate  78  and at least one arm  80   a  projecting upwardly therefrom. In the described embodiment, the intermediated fitting  76  includes a pair of clevis arms  80   a ,  80   b  projecting from each side of the mounting plate  78  for additional stability. 
     The mounting plate  78  of each intermediate fitting  76  is mounted to a center rail  10 R (see  FIG. 4 ) of the stitcher/stapler  10  by a clamp attachment  82 . As such, the entire displacement mechanism  70  and respective one of the registration members  64   a ,  64   b  may be released, repositioned, and reaffixed to the rail  10 R via locking cams  84 . That is, to facilitate adjustment of the registration members  64   a ,  64   b , i.e., the spacing therebetween to accommodate dimensional changes in the size of collations  12 , the locking cams  84  provide an ability to quickly disconnect/reconnect the displacement mechanism  70  along the center rail  10 R. 
     Each displacement mechanism  70  includes a first pneumatic actuator  86  which is disposed between the base  66  of the respective registration member  64   a  or  64   b , and the mounting plate  78 . In the described embodiment, the first pneumatic actuator  86  includes a linear piston/cylinder disposed between the clevis arms  80   a ,  80   b  of the intermediate fitting  76 . A pneumatic valve  88  provides pressurized air PA 1  (see  FIG. 6   b ) to the actuator  86  of respective displacement mechanism  70  to displace the registration wall  68  into and out of the idle and active positions. 
     In  FIG. 6   b , an examination of the displacement mechanism  70  reveals that the links  72 ,  74 , intermediate fitting  76 , and base  66 , produce a four-bar linkage defined by line segments AB, BC, CD and DA. The four-bar linkage arrangement can be configured, i.e., depending upon the length of the links  72 ,  74  and the location of the respective pivot points A,B,C,D, to perform the dual functions of rotation and translation of the respective one of the registration members  64   a ,  64   b . That is, the four-bar linkage arrangement can displace the respective one of the registration members  64   a ,  64   b  to rotate above and below the surface  54 S of the belts  54   a ,  54   b  while also producing a substantially linear displacement i.e., forward and aft along the feed path FP, to jog and align the edges  12 L,  12 E of the collation  12 . With respect to the latter, such linear displacement will be accompanied by a small angular displacement, which, depending upon the geometry of the stitcher/stapler  10 , may or may not be tolerated. 
     In  FIGS. 7   a  and  7   b , pure linear translation of the displacement mechanism  70  may be effected by a linear guide  90  disposed in combination with a second pneumatic actuator  92 . More specifically, the linear guide  90  is disposed between the intermediate fitting  76  and the clamp attachment  82  and includes at least one sled fitting  94  affixed to the underside of the intermediate fitting  76 , i.e., to the underside of the mounting plate  78 , for slideably engaging a linear guide rail  95  affixed to an upper surface of the clamp attachment  82 . The second pneumatic actuator  92  is attached at one end, via a flange fitting  96 , to the clamp attachment  82 , and at the other end, via a bracket  97 , to the underside of the mounting plate  78 . A pneumatic valve  98  provides pressurized air PA 2  (see  FIG. 7   b ) to the second pneumatic actuator  92  to effect linear translation of the displacement mechanism within the linear guide  90 . Recalling that only the registration members  64   b  associated with the leading edge of the collation  12  may be used to jog the collation  12 , only the displacement mechanism  70  associated with downstream registration member  64   b , associate with each processing station  16 ,  18  may be adapted to include the linear guide  90  and pneumatic actuator  92 . 
     Thus far, the transport and alignment system has been described in the context of a stitcher/stapler  10  having a requirement to jog and align the leading and trailing edges of the multi-sheet collation  12 . While the transport and alignment system may employ conventional alignment devices/apparatus for guiding/aligning the lateral side edges of the collation  12 , e.g., rotating cams or converging side rails (not shown), the present invention employs a novel side registration system  100 , seen in  FIGS. 2 and 4 , which spans all of the processing stations, i.e., the feed input station  14 , and the first and second processing stations  16 ,  18 . More specifically, the side registration system  100  comprises a second pair of registration members  104   a ,  104   b  each having registration surfaces  104 R (only one of the registration members  104   b  is shown in  FIG. 4 ) disposed adjacent each of the first and second conveyor belts  54   a ,  54   b . The registration members  104   a ,  104   b  extend the length of the processing stations  14 ,  16 ,  18  and, similar to the first pair of registration members  64   a ,  64   b , have a generally L-shaped cross sectional configuration. The spacing between the registration members  104   a ,  104   b , i.e., the spacing across the feed path FP, may be adjusted to accommodate collations  12  which may vary in width dimension. Inasmuch as these registration members  104   a ,  104   b  do not cross the feed path, there is no requirement to raise or lower each relative to the surface  54 S of the conveyor belts  54   a ,  54   b . On the other hand, similar to the first pair of registration members  64   a ,  64   b , at least one of the second pair of registration members  104   a ,  104   b  is adapted to oscillate in a transverse direction, i.e., toward and away from the conveyor belts  54   a ,  54   b  to align the side edges  12 SE of the multi-sheet collation  12 . Although, it should be appreciated that either or both of the registration members  104   a ,  104   b  may be displaced to align the side edges  12 SE of the collation  12 . 
     In the described embodiment, a second displacement mechanism  106  is attached to each of the registration members  104   a ,  104   b  and at least one of the second displacement mechanisms  106  is operative to oscillate and jog the side edges of the multi-sheet collation  12 . While the second displacement mechanism  106  and registration members  104   a ,  104   b  may function to align the side edges  12 SE at any or all of the processing stations  14 ,  16 ,  18 , side registration of a collation  12  will generally commence at either the first or second processing stations  16 ,  18  where the collation  12  will be bound, i.e., by the stitcher  20 , or stapler  22 . Similar to the first pair of registration members  64   a ,  64   b , at least one of the second pair of registration members  104   a  or  104   b  is operative to cyclically or repetitively engage a lateral side edge  12 SE of the collation  12 . In the described embodiment, the displacement of each oscillation for aligning the side edges  12 SE will be about 0.25 inches, i.e., the same as the displacement required for aligning the leading and trailing edges  12 L,  12 T. The other of the registration members  104   a , or  104   b  remains essentially stationary to react the impact forces generated by the opposing one of the registration members  104   a ,  104   b . With respect to the latter, the second displacement mechanism  106  associated therewith is principally operational to adjust the location of the respective one of the displacement mechanisms  106 . 
     The processor  40  controls the second displacement mechanisms  106  associated with the side registration system  100 , i.e., to oscillate at least one of second pair of registration members  104   a ,  104   b , using the same thickness data  30  or sheet count information obtained for cycling the first displacement mechanism  70 . That is, should the thickness data  30  or sheet count require eight (8) cycles by one or both of the first displacement mechanism  70 , e.g., collations  12  having more than ninety (90) sheets, then the processor  40  will command one or both of the second displacement mechanisms  106  to cycle by an equivalent number. Similarly, should the thickness data  30  or sheet count require three (3) cycles, the processor  40  will control the second displacement mechanism  106  accordingly. The number of cycles will generally decrease from a maximum of about eight (8) cycles to a minimum of about three (3) cycles as the thickness/sheet count, of the collation  12  decreases from greater than about ninety (90) sheets to a minimum of two (2) sheets. It will be recalled that such variation in the number of cycles, i.e., as a function of the collation thickness/sheet count, serves to optimize throughput. 
     The second displacement mechanism  106  may use any of a variety of actuators to displace and cycle the registration members  104   a ,  104   b . In the described embodiment, the second displacement mechanism  106  employs a pair of linear actuators  108  (see  FIG. 4 ) disposed at each end of the respective one of the registration members  104   a ,  104   b  to ensure proper alignment of the collation  12 , whether the collation  12  is processed at the first or second processing stations  16 ,  18 . 
     Reconfigurable Stitcher for Binding Consecutive Variable Thickness Collations 
     As previously discussed, the thickness data and sheet count information  30  is used to control the stitching operation at the first processing station  16 . The thickness data/sheet count  30  may be generated by any of a variety of modules/sensor of the mailpiece inserter  24  or stitcher/stapler  10  including: (1) scan code data  32  (see  FIG. 3 ) printed on a sheet of the mailpiece content material, e.g., the first sheet of each collation  12 , (ii) a sheet counter  34  in combination with sheet thickness data input by an operator, (iii) mail run data  36 , i.e., obtained directly from the application software (mail run data file) used to produce the content material, or (iv) a thickness measurement device, e.g., a thickness probe  38 . 
     In  FIGS. 8   a  through  8   d , the stitcher  20  may be reconfigurable to vary the length of each binding stitch  120  based upon the thickness T of the multi-sheet collation  12 . More specifically, the stitcher  20  comprises a stitch head  122  disposed beneath the collation  12  and a clinch head or anvil  124  disposed above the collation  12 . Consequently, the stitcher  20  drives the prongs P (see  FIG. 8   d ) of each binding stitch  120  upwardly through the lowermost or bottom sheet  12 B while the clinch head  124  crimps the ends PE of each prong P against the top or uppermost sheet  12 U of the collation  12 . In the described embodiment, the stitch head  122  is disposed between the first and second conveyor belts  54   a ,  54   b , though it will be appreciated that the stitch head may be disposed to either side of the belts  54   a ,  54   b . Furthermore, while a single stitcher  20  is depicted, it will be appreciated that several stitchers  20  may be juxtaposed across the width, or disposed in tandem along the length, of the multi-sheet collation  12 , to bind the collation  12  at several locations. 
     In  FIG. 8   a , the processor  40  receives thickness data  30  in connection with each collation  12  conveyed to the first processing station. The processor  40  uses this data/information  30  to determine the length of wire  120 W used to generate the respective binding stitch  120 , i.e., a stitch specifically tailored in length to bind a collation  12  of a particular thickness dimension T. The processor  40  issues a first signal to a first input actuator  134 , i.e., a rotary actuator, which advances wire  120 W, through the nip of a pair of rollers  128 , and across a pair of spaced-apart bending beams  130   a ,  130   b  of the stitch head  122 . Furthermore, the wire  120  is disposed beneath a forming block  132  which cooperates with the bending beams  130   a ,  130   b  to form the prongs P about the squared edges of the forming block  132 . Wire to form the stitch  120  may be drawn from a conventional spool  138  mounted to the housing of the stitcher/stapler  10 . In addition to the thickness T of the collation  12 , which determines the minimum length of the prongs P required to penetrate the collation  12 , other dimensions needed to perform this operation include: (i) the width of the web W, i.e., the length of wire between the prongs, and (ii) the end length LE (see  FIG. 8   d ) of the prong end PE i.e., the portion protruding through, and securing the collation. 
     The processor  40  issues a second signal S 2  to a second input actuator  140  to center the wire  120 W across the bending beams  130   a ,  130   b . Additionally, the processor  40  issues a third signal S 3  to a third input actuator  142  to displace several components of the stitch head  122 , i.e., internal structure of the stitch head  122  which forms the stitch  120 , upwardly toward the underside of the collation  12 . That is, as third input actuator  142  strokes upwardly, portions of the upward displacement, denoted by lines D 1 , D 2  and D 3  actuate one or more connected elements. 
     A first portion of the stroke D 1  causes a shearing device  142  to cut the stitch wire  120 W. This motion can be conveyed directly to the shearing device  142  or via cams connected to one of the bending beams  130   a ,  130   b . In  FIG. 8   b , a second portion of the stroke D 2  displaces the bending beams  130   a ,  130   b  upwardly. In this portion of the displacement, the stitch wire  120 W falls, and is guided, within a pair of grooves  146   a ,  146   b  formed along the internal walls of the bending beams  130   a ,  103   b  to bend the stitch wire  120  about the squared ends of the forming block  132 . In addition to guiding the prongs P, the internal grooves  146   a ,  146   a  provide buckling stability as the prongs P penetrate the collation  12 . 
     In  FIGS. 8   b  and  8   c , the displacement D 2  also causes the forming block  132  (shown in  FIG. 8   b ) to move away, (into or out of the plane of  FIG. 8   c ) such that the web W is free to move upwardly in the subsequent portion of the stroke D 3 . The second portion of the stroke D 2  terminates when the bending beams  130   a ,  130   b  abut the lowermost sheet of the collation  12 . That is, the ends of each of the bending beams  130   a ,  130   b  define a reference surface which will be used by the processor  40  to position the anvil  124  relative to the stitch head  122 . In the final or third portion of the stroke D 3 , a striker or ram  148  (see  FIG. 8   c ) engages the web W of the stitch  120  to drive the prongs P though the collation  12 . At the same time, i.e., while the lower portion of the stitcher  122  moves into position below the collation  12 , the processor  40  issues a fourth signal S 4  to a fourth input actuator  150  to lower the anvil or clincher  124 , (a displacement denoted by line D 4  in  FIGS. 8   c  and  8   d ) against the uppermost sheet of the collation  12 . 
     In  FIG. 8   d , the motion of the striker  148  causes the prongs P to penetrate the collation  12  and crimp/clinch the ends PE of each prong P. In the described embodiment, the clincher  150  includes arcuate surfaces for securing the ends PE of the prongs, however, other clinching devices, including those which actively recurve the ends PE of the prong P, are contemplated. 
     System and Method for Preparing Multi-Sheet Collations 
     In  FIGS. 9-12   b , a mailpiece inserter system  200  according to another embodiment of the present invention is described. The embodiment described herein relates to an inserter system  200  which obviates the misalignment of a collation edge due to folding operations. More specifically, the mailpiece inserter system  200  according to the present invention performs various processing operations, prior to folding operations, such that edge alignment is effected subsequent to folding operations. This feature, and others, will become apparent in view of the following detailed description. 
     While many of the mailpiece inserter devices/modules discussed in the current embodiment have the same functionality to those described hereinbefore, certain devices/modules include additional functionality. Accordingly, such devices/modules of the mailpiece inserter system  200  may be assigned a new reference identifier to reflect differences in connection with the current embodiment of the invention. Yet others, to the extent that the functionality is essentially identical to that previously described, will retain the same reference identifier. 
     The mailpiece inserter system  200  according to the present invention employs a feeding module or device  202  ( FIG. 9 ) including a web or roll  202 W of sheet material  202 S. While the term “module” implies a device that is modular or capable of being independent and distinct from other systems, it will be appreciated that the term means any device capable of performing a particular function, whether modular or integrated with other systems. Accordingly, the terms “module”, “device” or “system” are used interchangeably herein. The web  202 W may include a series of pre-printed pages of content material such as bank statements, credit card invoices, marketing materials, etc., which are pre-addressed for mailpiece delivery. For example, the web  202 W may include a plurality of pre-printed pages of sheet material  202 S intended for delivery to a particular recipient. Each sheet of the mailpiece is printed in series, (i.e., in tandem) on the web  202 W and transported by a conveyance system  204  to one of a variety of downstream processing devices/modules. 
     A conveyance system  204  transports the sheet material  202 S to one or more downstream modules including: a scanning device  220 , a cutting device  230 , an accumulating device  240 , a registration/binding device  250 , and/or a folding device  270 . The conveyance system  204  is electronically coupled to, and controlled by, a system processor  280  which controls the transport of the sheet material  202 S along the feed path FP, i.e., the path taken by the sheet material as it moves from one processing device/module to another. While a single overall system processor  280  is depicted, it should be understood that multiple processors, i.e., processors associated with each of the individual processing devices/modules, may be employed and should be viewed as an equivalent for the purposes interpreting the scope of the appended claims. Furthermore, it should be appreciated that the system processor  280  controls the operation of the mailpiece inserter  200  and may acquire information from a variety of sensors/encoders to track the location, and monitor the operation being performed on the sheet material  202 S. 
     In the described embodiment, the web  202 W of sheet material  202 S is transported across the scanning device  220  to acquire scan code data  32  (discussed previously in connection with the embodiment shown in  FIG. 3 ). As mentioned previously, at least one page of a mailpiece collation  210  will include scan code data  32  printed in a margin (right or left side) of a pre-printed sheet to provide processing information about the particular mailpiece collation  210 . For example, the scan code data  32  may provide information regarding: (i) the number of sheets which will be stacked to produce the collation  210 , (ii) the thickness of the collation, i.e., either the total thickness or the thickness of one or more sheets, (iii) whether the collation  210  is to be bound (i.e., stitched or stapled), (iv) whether the collation  210  is to be folded and, if so, (v) the fold configuration of the collation. 
     The processor  280  interprets that scan code data  32  to determine the anticipated fold configuration of the collation  210 . While the invention contemplates a variety of fold configurations, the invention is principally useful for preparing collations which will include a bi-fold and/or tri-fold configuration. In the described embodiment, a collation having a bi-fold configuration includes two panels folded about a fold axis. A collation having a tri-fold configuration includes a central panel and at least two outboard panels folded inwardly toward the central panel. The panels of a tri-fold configuration may be overlapping or abutting. With respect to the latter, a tri-fold configuration having panels which abut along an edge is also be referred to as a gate-fold configuration. 
     While, in the described embodiment, the processor  280  obtains information regarding the collation  210  using the scan code data  32  acquired from the scanner  220 , the processor  280  may, alternatively, acquire information in connection with the fold configuration from the mail run data file  36  (also discussed earlier in connection with the embodiment of  FIG. 3 ). From the fold configuration information, the processor  280  then determines a length dimension L 1 -L 7  (see  FIG. 10   a ) of each sheet of the collation  210 . Before describing the operations performed by the processor  280  to interpret the fold configuration data, i.e., to determine the length dimension L 1 -L 7  of each sheet, it will be useful to define the collation  210  in terms of an arrangement of sheets subsequent to a folding operation. 
     More specifically, the collation  210  comprises a plurality of sheets  211 - 217  (see  FIG. 11 ) which will, subsequent to a folding operation, be folded about a fold axis FA. Generally, any collation  210  useful as an insert for mailpiece creation includes an inner sheet  211  which folds about the fold axis FA, and at least one sheet, e.g., one of the outer sheets  212 - 217 , which fold about the fold axis FA of the inner sheet  211 . For example, collations  210  having a bi-fold configuration will have a single fold axis FA (i.e., the collation shown in  FIG. 11 ), collations having a C-fold configuration (not shown) will have only two fold axes, and collations having a Z-fold configuration will have at least two, and possibly several fold axes. Notwithstanding the fold configuration, each of the collations  210  described includes an inner sheet which folds upon itself relative to the fold axis and has outer sheets which fold about the same fold axis of the inner sheet. Furthermore, relative to one of the fold axes, the sheet which folds upon itself is the inner sheet, however, relative to another of the fold axes, the same sheet may be the outermost sheet. For example, in a Z-fold configuration, the sheet defined as the inner sheet with respect to one fold axis becomes the outer sheet with respect to an adjacent fold axis. 
     The processor  280  determines a length dimension L 1 -L 7  of each sheet of the collation  210  based upon the fold configuration and issues a length signal along line LS which is indicative of the length dimension L 1 -L 7  of each of the inner and outer sheets  211 - 217  of the collation  210 . As mentioned in the preceding paragraph, the inner sheet  211  is defined as the sheet which folds upon itself about the fold axis FA while the outer sheets  212 - 217  are defined as the sheets which fold about the fold axis FA of the inner sheet  211 . 
     In the broadest sense of the invention, the processor  280  issues a length signal along line LS in connection with each of the sheets  211 - 217  (see  FIGS. 10   a - 11 ) of the collation  210  to the cutting module  230  such that the length dimension L 1 -L 7  of at least one of the outer sheets, e.g.,  212 - 217 , is greater than the length dimension L 1  -L 7  of the inner sheet  211 . Based upon this teaching, the cutting module  230  is controlled by the processor  280  such that the length dimension L 1 -L 7  of the inner and outer sheets  211 - 217  vary, i.e., from one of the sheets  211  to another of the sheets  212 - 217 . In the preferred embodiment of the invention, the length dimension L 1 -L 7  increases by small increments from the inner sheet  211  to the outer sheets  212 - 217 . 
     The method for determining the length dimension L 1 -L 7  of any particular sheet of the collation  210  is described in greater detail hereinafter, however, suffice to say at this juncture, that the processor  280  uses information relating to: (i) the fold configuration in combination with: the thickness dimension of each individual sheet  211 - 217 , (ii) a summation of the sheet thickness from the inner sheet  211  to an outer sheet  217 , and/or (iii) the number of sheets in the collation  210  to arrive at a collation fold solution which effects edge alignment. Moreover, the information may be obtained, derived, or calculated from any one of a combination of: (i) a thickness measurement device/probe (not shown) to measure the thickness dimension of any one sheet  211 - 217 , or any group of sheets  211 - 217 , (ii) input data stored in the mail run data file  36  e.g., data relating to the length of the inner sheet in combination with a median thickness dimension of the sheet material  202 S dispensed from the web  202 W, (iii) relationships which calculate the length dimension of any particular sheet  211 - 217  and/or (iv) a look-up table of the sheet length dimension L 1 -L 7  based upon the fold configuration and type/thickness of each of the sheets  211 - 217 . 
     Returning to our discussion of the mailpiece inserter system  200 , the cutting module  230  receives the sheet material from the web  202 W, and is responsive to the length signal LS issued by the processor  280 . As mentioned above, the length dimension L 1 -L 7  of each sheet will vary depending upon the fold configuration and thickness, i.e., number of sheets, of the collation  210 . In the described embodiment, the collation  210  includes seven (7) sheets  211 - 217  of material. The cutting module  230  may include a rotary cutter  232  having an elongate blade  232 B disposed on a rotating shaft or cylinder  232 C. Therein, sheet material  202 S is driven, or pulled, onto the deck of the cutting module  230  by an upstream drive roller  234 R of the conveyance system  204 , and paused when a sufficient length of material  202 S has reached the cutting station, i.e., the portion of the cutting module  230  directly beneath the cutting blade  232 B. The blade  232 B is rotated into the sheet material  202 S by the rotating cylinder  232 C to sever the sheet material  202 S to the prescribed length while a downstream roller  234 R of the conveyance system  204  takes-away the individual cut sheets  211 - 217 , i.e., along the deck of the cutting module  230 . Inasmuch as the cutting module  230  is responsive to the length signal LS, the individual sheets of the collation  210  are cut such that the length dimension of at least one of the outer sheets  212 - 217  is greater than the inner sheet  211 . 
     Inasmuch as the upstream drive roller  234 R accelerates the sheet material  202 S with each cycle, i.e., starting and stopping the sheet material  202 S, the inserter  200  may include a take-up module  208  to reduce stresses induced in the web of sheet material  202 S. In the illustrated embodiment, the take-up module  208  includes a vacuum plenum  208 P operative to form a material loop  208 L which facilitates the pay-out and accumulation of sheet material  202 S within the plenum  208 P. More specifically, the loop  208 L allows the sheet material  202 S to be rapidly paid-out when the material is pulled past the rotary cutter  232 . As a consequence, stresses in the sheet material  202 S, downstream of the cutting module  230 , are reduced to mitigate the risk or opportunity for tearing. Moreover, additional sheet material  202 S accumulates within the plenum  208 P, i.e., the material loop  208 L elongates therein, when the drive roller  232 R is paused/stops. As a consequence, the feed module  202  may operate at constant velocity/speed, thereby avoiding the requirement to accelerate and decelerate the high inertial mass of sheet material web  202 W. 
     Following the cutting operation, each of the sheets  211 - 217  is conveyed to the accumulating module  240  which is operative to stack the individual sheets  211 - 217  associated with a particular collation  210 . In the described embodiment, the accumulating module  240  is a dual accumulator having upper and lower decks  240 U,  240 L which allow collations  210  to be buffered while downstream modules perform other processing operations, e.g., registration, binding and/or folding. 
     Once accumulated, the collation  210  is conveyed to the registration module/binding module  250  which performs the dual functions of aligning the edges of the collation  210  immediately prior to binding the collation  210 . While the described embodiment integrates the alignment/registration and binding operations, it will be appreciated that each operation may be performed by separate registration and binding devices  250 R,  260 B. That is, a registration device  250 R may be a module dedicated to registering the leading and trailing edges LE, TE of the collation  210  and a binding module  250 B may be dedicated to binding the collation at one of a variety of locations, i.e., proximal to, or distal from, the anticipated fold axis FA of the collation  210 . 
     In the described embodiment, and referring specifically to  FIGS. 9 ,  10   b - 11 , the registration/binding module  250  includes a registration device  250 R operative to engage the edges of the collation  210  such that at least one of the edges LE, TE thereof is misaligned, or defines an angle θ, relative to a vertical plane VP (as shown in  FIGS. 10   b  and  10   c ) prior to a folding operation. More specifically, the registration/binding module  250  includes at least one registration device  250 R (see  FIG. 9 ) wherein the collation  210  is disposed between opposed pairs of registration members  250 Rm ( FIGS. 10   b ,  10   c ). These registration members  250 Rm are similar to those discussed in connection with the alignment mechanisms  62   a ,  62   b  in the preceding section entitled “Transport and Alignment System For Producing Variable Thickness Collations”. Similarly, each of the registration members  250 Rm is supported by and connected to a displacement mechanism  250 Rd operative to oscillate the registration members into and out of engagement with the edges for alignment thereof. Further, the displacement mechanism  250 Rd operates to register the edges of thin and thick collations using the same algorithms and logic as discussed earlier in connection with the alignment mechanisms  62   a ,  62   b . Inasmuch as the displacement mechanism  250 Rd is essentially identical to the first displacement mechanism  70  described hereinbefore, no further description will be provided herein. 
     While the registration members  250 Rm may be moved from the idle to active positions in the same manner as discussed earlier in connection with the alignment mechanisms  62   a ,  62   b , at least one the registration members  250 Rm may include an inclined registration surface RS 1  (See  FIG. 10   b ) to effectively misalign one of the leading and trailing edges LE TE of the collation  210 . In the context used herein, the term “misalign” means that the resulting edge geometry, i.e., of either the leading of trailing edges LE, TE of the collation, is disposed at an angle θ relative to a vertical plane VP. As another point of reference, the vertical plane VP is orthogonal to another plane OP (see  FIG. 10   a ) along the length and/or width of the collation  210  in an unfolded condition. 
       FIGS. 10   b  and  10   c  each depict a registration station adapted to receive a collation which will be folded based upon the selected/determined fold configuration.  FIG. 10   b  depicts a registration device  250 R adapted to prepare a collation which will be bi-folded at, or near, a centerline location, and possibly bound proximal to the fold axis.  FIG. 10C  depicts a registration device  250 R adapted to prepare collations which will be tri-folded and possibly bound proximal to an aligned edge of the collation. The utility of such arrangement will be discussed below when discussing the subsequent folding operation. Furthermore, additional structure and functionality will be discussed in another embodiment of the invention in the section entitled “System and Apparatus for Adaptively Registering/Binding a Collation” 
     More specifically, in  FIG. 10   b  each of the registration members  250 Rm includes a registration surface RS which causes the edge geometry (i.e., the “locus of points” defined by an edge of each sheet  211 - 217 ), to slope inwardly at an angle θ from one of the outer sheets  212 - 217  to the inner sheet  211 . It will be recalled that the inner sheet  211  is defined as the sheet which folds upon itself about a fold axis FA and the outer sheets  212 - 217  are defined as the sheets which fold about the fold axis FA of the inner sheet  211 . As will be discussed in greater detail hereinafter, this edge geometry, (i.e., wherein both registration surfaces RS are inclined so as to cause the leading and trailing edges to be misaligned), is preferably employed when the collation  210  is to be bound, i.e., by the binding device  250 B, at a location proximal to a centerline CL of the collation. In the context used herein, “proximal to the centerline” means a location between about 0.4 LM to 0.6 LM of the median length dimension LM (see  FIG. 10   a ), as measured from an edge of the collation  210 . 
     In  FIG. 10   c , only one of the registration members  250 Rm defines a registration surface RS 1  which causes an edge, i.e., the trailing edge TE, to be misaligned, or slope inwardly at an angle θ relative to a vertical plane VP. In this embodiment, the other of the registration members  250 Rm defines a registration surface RS 2  which causes the opposite edge, i.e., the leading edge LE, to remain aligned, or substantially parallel to the vertical plane VP. While this too will be addressed in the subsequent discussion, this configuration (i.e., wherein only one of the registration surfaces RS 1  effects an edge geometry which is misaligned), is preferably employed when the collation  210  is to be bound at a location proximal to an aligned edge of the collation  210 . In the context used herein, “proximal to an aligned edge” means a location between about 0.0 LM to 0.2 LM from the aligned edge measured in terms of the median length LM. 
     Once the leading and trailing edges LE, TE of the collation  210  are registered, i.e., misaligned or aligned relative to a vertical plane VP, the collation  210  may be bound. Alternatively, the collation  210  may be conveyed directly along the feed path FP to the folding device  270 , i.e., without being bound. While any suitable binding device may be employed,  FIG. 10   b  depicts a stitcher  250 B- 1  to perform a binding operation while  FIG. 10   c  depicts a stapler  250 B- 2  to perform the binding operation. The stitcher  250 B- 1  and stapler  250 B- 2  are structurally similar to the stitcher  20  and stapler  22 , respectively, described in connection with the previous embodiment entitled “Stitcher/Stapler For Binding Multi-sheet Collation and Method of Operation” (depicted in  FIG. 5  of the drawings). Accordingly, to facilitate the description, no further discussion of these binding devices  250 B- 1 ,  250 B- 2  are necessary at this juncture. Suffice it to say that the stitcher  250 - 1  may be used when the thickness of the collation  210  is less than a threshold value, while the stapler  250 - 2  may be used when the thickness of the collation  210  is greater than the threshold value. In the described embodiment the threshold value is about forty-five thousands inches (0.45″). 
     While the selection of the binding device, i.e., stitcher or stapler  250 B- 1 ,  250 B- 2 , can be important when binding thin or thick collations, of greater importance is the location of the stitch or staple relative to the fold axis FA, or relative to an edge of the collation. More specifically, when a collation  210  is to be bi-folded and bound at a centerline CL of the collation (i.e., proximal to the fold axis FA), it will be desirable to effect an edge geometry wherein both leading and trailing edges LE and TE are misaligned (i.e., wherein the angle of inclination θ slopes inwardly toward the inner sheet  211 ) such as the registration members  250 Rm shown in  FIG. 10   b ). Once again, this combination of registration and binding is required inasmuch as the binding operation prevents relative movement between the sheets  211 - 217  at the location of the stitch or staple  218 -L 1  (see  FIGS. 10   b  and  11 ). It will be appreciated, therefore, that when binding the collation  210  proximal to the fold axis FA, it will be necessary to effect an edge geometry which is inclined, at both the leading and trailing edges LE, TE of the collation  210  such that, following a folding operation, the sheets  211 - 217  will slip or move relative to one another. Due to this relative movement, both the leading and trailing edges LE, TE become aligned following a folding operation. 
     On the other hand, when a collation  210  is to be bi-folded and bound proximal to an edge of the collation, it will be desirable to effect an edge geometry wherein only one of the leading and trailing edges LE and TE is misaligned. More specifically, when binding the collation  210  at a location proximal to a first edge, e.g. the leading edge LE, it will be desirable to effect an edge geometry wherein a second or opposite edge, e.g., the trailing edge TE, is misaligned such as the arrangement depicted in  FIG. 10   c . Further, it will also be appreciated that, inasmuch as the collation  210  is bound proximal to one edge (e.g., the leading edge LE), it will generally be desirable to effect edge alignment along this edge. That is, since the binding operation inhibits movement, or slippage between sheets, at this edge location, it will be necessary to effect edge alignment (i.e., an edge geometry which is parallel to the vertical plane VP) by the registration device, rather than on a subsequent folding operation to effect edge alignment. Of course, inasmuch as the bound edge LE is aligned by the registration member  250 Rm, the opposite edge TE must be misaligned to allow for a subsequent folding operation to effect edge alignment. It will be appreciated that the angle of inclination is substantially larger, e.g., twice the degree of inclination) to effect the necessary edge alignment subsequent to a folding operation. Also, and as an aside, the rollers  204  of the conveyance system which transport the collation  210  along the feed path, are best adapted to handle a collation  210  having a leading edge LE which is aligned rather than shingled (or misaligned). As a result, it may be desirable to employ a registration/binding arrangement wherein the leading edge LE is aligned and the trailing edge is misaligned to minimize difficulties associated with conveyance. 
     In  FIGS. 9 and 11 , once the collation  210  is registered and bound in accordance with the anticipated fold configuration, the collation  210  is folded along one or more folding axes FA by a folding device  270 . In  FIG. 9 , the collation  270  is conveyed upwardly into at least one fold plate  272  having a stop surface  272 S for engaging the leading edge of the collation  210 . With the leading edge LE restrained, a roller  273  continues to drive the trailing edge TE causing the collation  210  to buckle at a midsection MS thereof. As the collation  210  continues to buckle, the midsection M is driven into the nip of folding rollers  274  such that the collation  210  is folded along the fold axis FA. Thereafter, the folded collation  210  is conveyed to a lower stop plate  275  and driven outwardly to conveyance rollers  277 ,  278  by an ejection roller  276 . 
     In  FIG. 11 , the collation  210  has been bound and folded such that the leading and trailing edges LE, TE are aligned relative to the vertical plane VP. The collation is shown with a stitch  218 -L 1  disposed through the sheets  211 - 217  along a centerline CL or, alternatively, with a staple  218 -L 2  disposed through the sheets  211 - 217  and proximal to the edge. Inasmuch as the sheets  202 S are fed from a web  202 W of sheets, each of the sheets  211 - 217  can be cut incrementally longer or shorter depending upon the length dimension L 1 -L 7  determined by the processor  280 . When cutting pre-printed sheets from a web  202 W, the incremental increase/decrease will be added to, or to taken from, the margins of each sheet. Furthermore, inasmuch as the conveyance device  204  includes numerous photo-sensors and encoders (not shown) to precisely pay-out and control the position of the sheet material  202 S, a rotary cutting device  230  may be used to precisely cutting each of the sheets to a desired length dimension. Cutting devices of the type described are capable of cutting sheets to within a tolerance of about 0.004 inches, and can readily cut sheets which may vary incrementally in length dimension by as little as 0.008 inches. 
     Returning to our discussion concerning the operation of the processor  280  and the method of determining the length dimension, it will be recalled that the processor  280  uses information relating to: (i) the fold configuration in combination with: the thickness dimension, i.e., the median thickness dimension T m  (see  FIG. 10   a ) of each individual sheet  211 - 217 , (ii) a summation of the sheet thickness from the inner sheet  211  to an outer sheet  217 , and/or (iii) the number of sheets in the collation  210  to arrive at a collation fold solution which effects edge alignment. Moreover, the information may be obtained, derived, or calculated from any one of a combination of: (i) a thickness measurement device/probe (not shown) to measure the thickness dimension of any one sheet  211 - 217 , or any group of sheets  211 - 217 , (ii) input data stored in the mail run data file  36  e.g., data relating to the length of the inner sheet in combination with a median thickness dimension of the sheet material  202 S dispensed from the web  202 W, (iii) relationships which calculate the length dimension of any particular sheet  211 - 217  and/or (iv) a look-up table of the sheet length dimension L 1 -L 7  based upon the fold configuration and type/thickness of each of the sheets  211 - 217 . 
     This information, in combination with information concerning the thickness of each individual sheet, or the median thickness T m  of the sheets  211 - 217 , can then be used to determine a thickness dimension from an innermost sheet of the collation  210  to any outer sheet  212 - 217  of the collation  210  (hereinafter referred to as the “relevant thickness dimension”). With respect to the median thickness T m  of an individual sheet  211 - 217 , such thickness data can be measured using a thickness probe (not shown), or obtained from predetermined input data such as from the mail run data file  36 . 
     In the described embodiment, the relevant thickness dimension effecting the length dimension of any particular sheet may be determined by the product of the median sheet thickness T m  in combination with the number of inboard sheets of the collation, i.e., the number of sheets over which a particular sheet will fold. In addition to determining the relevant thickness dimension of the collation  210 , the processor  280  identifies the anticipated fold configuration by reading the scan code data  32  from the scanner  220  which, in turn, correlates the scan code data  32  with predefined collation information in the mailpiece data run file  36  ( FIG. 3 ). The anticipated fold configuration may include any of a variety of conventional folds such as a bi-fold, C-fold, Gate fold or Z-fold configuration. The described embodiment also contemplates the use of the scan code data  32  to determine a thickness dimension T of the collation  210 , which can then be used, along with other information, to determine a length dimension L 1 -L 7  of each sheet. 
     From the anticipated fold configuration and, information regarding the thickness dimension T of each sheets, or the median thickness T m  of the sheets, the processor  280  determines the length dimension L 1 -L 7  of each of the sheets  211 - 217  of the collation  210 . Generally, the processor  280  obtains the length dimension of the innermost sheet L 1  from the mail run data file, e.g., eleven (11) inches in length. From the baseline length dimension of the innermost sheet  211 , the length dimension of each outer sheet  212 - 217 , i.e., sheet outboard of the innermost sheet  211  in the direction of radial arrow R, is determined by adding an incremental length dimension required for each outer sheet  212 - 217  to traverse the fold axis FA of the innermost sheet  211 , i.e., the sheet which folds upon itself. The incremental increase in length, from one of the sheets  212 - 217  to another of the sheets  212 - 217 , allows each sheet to traverse or extend around the fold axis FA while maintaining edge alignment of each of the sheets  211 - 217  relative to a vertical plane VP (see  FIG. 10   b ). For example, in a bi-fold configuration, the length dimension of any particular sheet L(n) outboard  212 - 217  of the innermost sheet  211 , can be determined by the following relationships (1) and (2):
 
 L ( n )= L 1+(π)( T   r )  (1)
 
 T   r =( T   m )( N )  (2)
 
     where L 1  is the length dimension of the innermost sheet  211 , i.e., the sheet which folds upon itself, T r  is the relevant thickness dimension of the sheets inboard of the instant sheet L(n), (i.e., the sheets interposing the instant sheet L(n) and the fold axis FA of the collation, including the innermost sheet  211 ), T m  is the median thickness dimension of each sheet, and N is the number of inboard sheets. Hence, the collective thickness dimension T r  is determined by equation (2) to calculate the length dimension L(n) of equation (1). 
     Alternatively, for collations having C-fold and Gate-fold configurations, i.e., collations having a pair of fold axes and edges folded inwardly on the same side of a central fold panel, the length dimension of any particular sheet L(n), can be determined by the following relationships (3) and (4):
 
 L ( n )= L 1+2(π)( T   r )  (3)
 
 T   r =( T   m )( N )  (4)
 
     Alternatively, for Z-fold configurations having an odd number (1, 3, 5, 7 . . . etc.) of alternating folds, i.e., folds which alternate in direction about a plurality of fold axes, the length dimension of any particular sheet L(n), can be determined by the following relationships (5) and (6):
 
 L ( n )= L 1+(π)( T   r )  (5)
 
 T   r =( T   m )( N )  (6)
 
     In contrast to Z-fold configurations having an odd number of folds, those having an even number (2, 4, 6, 8 . . . etc.) of alternating folds do not require that the sheets vary in length dimension from sheet to sheet. This is principally due to the geometry of the Z-fold configuration which results in the innermost sheet associated with one of the folds to become the outer sheet of a subsequent fold. Accordingly, L(n)=L 1  for Z-folded collations having an even number of folds. 
     From each of the foregoing relationships, (1) &amp; (2), (3) &amp; (4), (5) &amp; (6), it will be appreciated that, to produce a folded collation having aligned edges (aligned relative to a vertical plane VP) at least at least one of the outer sheets  212 - 217  is greater in length dimension than the inner sheet  211 . Furthermore, the incremental increase required to effect aligned edges, is a function of the thickness of the inboard sheets and/or, the product of the thickness of each inboard sheet in combination with the number of inboard sheets. 
     Table I below is a summary of the sheet length dimensions which may be suitable for preparing a seven (7) sheet collation which is bi-folded, i.e., have a bi-fold configuration such as that shown in  FIG. 11 . The length dimension of the innermost sheet  211  is eleven (11) inches and the median thickness T m  of each sheet is approximately 0.004 inches. 
     
       
         
           
               
               
               
               
             
               
                 TABLE I 
               
               
                   
               
               
                   
                   
                 Relevant 
                 Length 
               
               
                   
                 Thickness 
                 Thickness 
                 Dimension L(n) 
               
               
                 SHEET # 
                 Dimension (in) 
                 Dimension T r  (in) 
                 (in) 
               
               
                   
               
             
            
               
                 211 (Inner) 
                 0.004 
                 0.004 
                 11.000 
               
               
                 212 (inboard) 
                 0.004 
                 0.008 
                 11.013 
               
               
                 213 (inboard) 
                 0.004 
                 0.012 
                 11.038 
               
               
                 214 (inboard) 
                 0.004 
                 0.016 
                 11.050 
               
               
                 215 (inboard) 
                 0.004 
                 0.020 
                 11.063 
               
               
                 216 (inboard) 
                 0.004 
                 0.024 
                 11.075 
               
               
                 217 (outer) 
                 0.004 
                 0.028 
                 11.089 
               
               
                   
               
            
           
         
       
     
     Table II below is a summary of the sheet length dimensions which may be suitable for preparing a seven (7) sheet collation which is tri-folded, i.e., have a tri-fold configuration. The length dimension of the innermost sheet  211  is eleven (11) inches and the median thickness T m  of each sheet is approximately 0.004 inches. 
                                 TABLE II                       Relevant   Length           Thickness   Thickness   Dimension L(n)       SHEET #   Dimension (in)   Dimension T r  (in)   (in)                  211 (Inner)   0.004   0.004   11.000       212 (inboard)   0.004   0.008   11.026       213 (inboard)   0.004   0.012   11.076       214 (inboard)   0.004   0.016   11.100       215 (inboard)   0.004   0.020   11.126       216 (inboard)   0.004   0.024   11.150       217 (outer)   0.004   0.028   11.178                    
Adaptive Registration/Binding Apparatus for Preparing Collations
 
     While the invention contemplates dedicated registration and binding modules, the described embodiment depicts an integrated registration/binding module  250  wherein the registration and binding of a collation occurs at the same station, i.e., without transporting the collation from one station to another. More specifically, the registration/binding module  250  includes multiple registration/binding stations  250 R- 1 ,  250 R- 2 ,  250 R- 3  adapted to provide processing flexibility in terms of fabricating a variety of folded mailpiece collations, i.e., whether the collations are thin or thick, stapled or stitched, bi-folded or tri-fold, or some combination thereof. The selection of a registration/binding station  250 R- 1 ,  250 R- 2 ,  250 R- 3  will be dependant upon a variety of factors including information obtained from the scan code, mail run data file, and data interpreted/processed by the system processor  280 . While multiple registration/binding stations  250 R- 1 ,  250 R- 2 ,  250 R- 3  are depicted, it should be appreciated that a greater or lesser number of registration/binding stations may be employed which may be adaptive or reconfigurable to process multiple edge/binding configurations. 
     In  FIG. 9 , the registration stations  250 R- 1 ,  250 R- 2 ,  250 R- 3  may include a first station  250 R- 1  which registers the edges of the collation  210  in a conventional manner. That is, registration station  250 - 1  may include registration members which do not perform a pre-fold operation, i.e., does not misalign the edges in advance of a folding operation. A second registration station  250 R- 2  includes a first pair of registration surfaces RS (see  FIG. 10   b ) which are adapted to register the edges of the collation based upon a desired edge geometry, e.g., an edge geometry defined by a first fold configuration such as a bi-fold configuration. A third registration station  250 R- 3  includes a pair of registration surfaces RS 1 , RS 2  wherein only one of the registration members  250 Rm is adapted to misalign the edge, i.e., the trailing edge TE, of the collation  210 . As mentioned earlier, this configuration may be employed when the collation  210  is to be bound proximal to an edge, e.g., the leading edge LE of the collation  210 . Accordingly, it will be appreciated that a variety of registration stations may be pre-configured based upon (i) the anticipated fold configuration of the collation, (ii) the thickness of the collation and/or the (iii) the desired binding location for a stitch or staple. It will also be appreciated that the thickness of the collation  210  may determine whether the collation  210  is to be stitched or stapled. This was described earlier in the section entitled “Stitcher/Stapler For Binding Multi-sheet Collation and Method of Operation.” 
     To select/determine which of the registration stations  250 R- 1 ,  250 R- 2 ,  250 R- 3  will be used to register the edges TE, LE of the collation  210 , the processor  280  determines the fold configuration, i.e., from either the scan code  32  or mail run data file  36  (see  FIG. 3 ). To determine how the displacement mechanism  70  will jog the edges for alignment of the collation, the processor  280  will determine the thickness using the thickness data  30  as discussed in the embodiment described in the section entitled “Transport and Alignment System For Producing Variable Thickness Collations”. To select/determine whether the collation  280  will be stitched or stapled, the processor  280  uses the thickness data  30  in combination with the fold configuration to determine where the collation will be bound. That is, if a thin collation  210  is to be bi-folded, then the registration station  250 R- 2  shown in  FIG. 10   b  may be selected inasmuch as this station  250 R- 2  is integrated with a stitcher  250 B- 1  which is best suited for binding thin collations  210 . 
     Having determined the processing variables, i.e., the fold configuration, edge geometry, thickness, etc., the processor  280  issues a command signal to the conveyance device  204  to transport the collation to the selected registration station  250 R- 1 ,  250 R- 2 ,  250 - 3 . Once, registration of the collation  210  is complete, the collation  210  is bound by either a stitcher or stapler  250 B- 1 ,  250 B- 2 . Once again, the described embodiment depicts an integrated registration/binding module  250 , i.e., a module which does not require transport of the collation  210  from a registration station to a separate downstream binding station. It should be appreciated, however, that the invention contemplates both integrated and separate registration and binding stations. 
     Inasmuch as the number of variables, i.e., the fold configuration, thickness, type of bind (stitcher/staple), and location of bind, can result in a variety of edge/binding configurations,  FIGS. 12 ,  13  and  14  depict yet other embodiments of the adaptive registration/binding apparatus. In  FIGS. 12 and 13 , the adaptive registration/binding apparatus  250  includes a means  290  for variably displacing the position of the registration surfaces RSV based upon the fold configuration. More specifically, an actuation device RMS is operative to displace at least one of the registration surfaces RSV such that the angle of inclination θ is variable with respect to the vertical plane to change the edge geometry of the collation  210 . 
     In  FIG. 12 , the means  290  for variably displacing the registration surfaces RSV includes a linear actuator RMA 1  disposed in-line with a leg  286  of the displacement mechanism  70  (see  FIG. 6   d ), i.e., one of the legs  286  which comprised the four-bar linkage arrangement discussed earlier. The linear actuator RMA 1  is operative to increase or decrease the length of the leg  286 , thereby rotating the registration surfaces RVS of the registration members  250 Rm to a desired angle of inclination θ. In operation, the processor  280  determines the fold configuration to calculate the angle of inclination necessary to effect a desired edge geometry. The processor  280  issues a signal to the linear actuator RMA 1  to rotate the registration members  250 Rm and the registration surfaces RVS about a virtual hinge VH. Upon reaching the desired angle θ, the displacement mechanism  70  jogs the registration members  250 Rm to effect the desired edge geometry of the collation  210 . 
     In  FIG. 13 , the means  290  for variably displacing the registration surfaces RSV includes a linear actuator RMA 2  disposed in combination with a registration element  292  of the registration member  250 Rm. The registration element  292  is pivotally mounted to the registration member  250 Rm such that extension or retraction of the actuator RMA 2  moves the registration surface RSV to the desired angle of inclination θ. In operation, the processor  280  determines the fold configuration to calculate the angle of inclination necessary to effect a desired edge geometry. The processor  280  issues a signal to the linear actuator RMA 2  to rotate the registration element  292  and the registration surfaces RVS about a pivot axis PA. Upon reaching the desired angle θ, the displacement mechanism  70  jogs the registration members  250 Rm to effect the desired edge geometry of the collation  210 . 
     In  FIG. 14 , a means  294  is provided to variably displace the binding device  250 B such that the collation  210  may be bound at various locations along the length of the collation  210 . The means  295  includes a rack of linear gear teeth  296  mounted to a fixed housing structure (not shown) of the binding device  250 B, a pinion gear  298  engaging the rack of gear teeth  296 , and a rotary actuator BA disposed in combination with the binding device  250 B. In operation, the processor  280  determines the fold configuration to determine the desired location for binding the collation  210 . For example, a bi-fold collation may be bound proximal to the fold axis FA along the centerline CL of the collation  210 . Alternatively, a tri-fold collation may be bound proximal to an edge LE of the collation  210 . The processor  280  issues a signal to the rotary actuator BA to drive the pinion gear  296  relative to the linear gear teeth of the rack  298 . Rotation of the actuator BA drives the binding device  250 B along the length of the collation  210  such that it may be bound at any desired location. 
     It is to be understood that the present invention is not to be considered as limited to the specific embodiments described above and shown in the accompanying drawings. The illustrations merely show the best mode presently contemplated for carrying out the invention, and which is susceptible to such changes as may be obvious to one skilled in the art. The invention is intended to cover all such variations, modifications and equivalents thereof as may be deemed to be within the scope of the claims appended hereto.