Patent Publication Number: US-6990789-B2

Title: Adjustable stripper blade/moistener system for a mailing system

Description:
FIELD OF THE INVENTION 
   The invention disclosed herein relates generally to mailing systems, and more particularly to an adjustable stripper blade/moistener system for stripping and moistening an envelope flap of an envelope being processed by the mailing machine. 
   BACKGROUND OF THE INVENTION 
   Mailing systems, such as, for example, a mailing machine, often include different modules that automate the processes of producing mail pieces. The typical mailing machine includes a variety of different modules or sub-systems each of which performs a different task on the mail piece. The mail piece is conveyed downstream utilizing a transport mechanism, such as rollers or a belt, to each of the modules. Such modules could include, for example, a singulating module, i.e., separating a stack of mail pieces such that the mail pieces are conveyed one at a time along the transport path, a stripping/moistening module, i.e., stripping open the flap of an envelope, wetting and sealing the glued flap of an envelope, a weighing module, and a metering/printing module, i.e., applying evidence of postage to the mail piece. The exact configuration of the mailing machine is, of course, particular to the needs of the user. 
   The stripping/moistening module includes a structure for deflecting a flap of a moving envelope away from the envelope&#39;s body to enable the moistening and sealing process to occur. The deflecting structure typically includes a stripper blade that becomes inserted between the flap of the envelope and the body of the envelope as the envelope traverses the transport deck of the mailing machine. Once the flap has been stripped, the moistening device moistens the glue line on the flap in preparation for sealing the envelope. One type of moistening system, known as a contact moistening system, generally deposits a moistening fluid, such as, for example, water or water with a biocide, onto the glue line on a flap of an envelope by contacting the glue line with a wetted applicator. 
   In contact systems, the wetted applicator typically consists of a contact media such as a brush, foam or felt. The applicator is in physical contact with a wick. The wick is generally a woven material, such as, for example, felt, or can also be a foam material. At least a portion of the wick is located in a reservoir containing the moistening fluid. The moistening fluid is transferred from the wick to the applicator by physical contact pressure between the wick and applicator, thereby wetting the applicator. A stripped envelope flap is guided between the wick and applicator, such that the applicator contacts the glue line on the flap of the envelope, thereby transferring the moistening fluid to the flap to activate the glue. The flap is then closed and sealed, such as, for example, by passing the closed envelope through a nip of a sealer roller to compress the envelope and flap together, and the envelope passed to the next module for continued processing. 
   There are problems, however, with conventional stripping/moistening modules as described above. For example, the position of the stripper blade/moistening device is generally fixed within the mailing machine. The position of the stripper blade/moistening device in relation to the flap of the envelope directly impacts the reliability of the functions performed. Envelopes are increasingly available in a variety of sizes, which makes it difficult to design into a mailing machine optimum interaction between an envelope and the stripper blade. For example, there are several sizes of commercial business envelopes and baronial envelopes available. For commercial business envelopes, a #10 envelope has dimensions of 4⅛ inches by 9½ inches, a #11 envelope has dimensions of 4½ inches by 10½ inches, a #7 envelope has dimensions of 3⅝ inches by 6½ inches, and a #6¼ envelope has dimensions of 3½ inches by 6 inches. For baronial envelopes, a #4 envelope has dimensions of 3⅝ inches by 5⅛ inches, and a #5 envelope has dimensions of 4⅛ inches by 5½ inches. Other types of envelopes, such as, for example, a square envelope, may have dimensions of 5 inches by 5 inches, 6 inches by 6 inches, or 8 inches by 8 inches. Multiple other sizes and dimensions of envelopes are also available. In addition, envelopes can have differently shaped flaps, such as commercial style, monarch style or square style, and the different shapes can each be provided in different sizes. 
   The stripper blade/moistening module is fixedly set in one position within the mailing machine to reliably strip and moisten standard commercial business envelopes, and specifically #10 envelopes, as they are most commonly used. This creates problems, however, for other envelopes of different size or with different shaped flaps. For example, the stripper blade in this position may experience problems stripping square flaps, due to the width of the flap. In addition, even when the square flap is properly stripped open, the moistening device will moisten the entire width of the flap, and not just the glue line, since the entire flap must pass over the moistening device due to the position of the moistening device. Moistening the entire flap can cause moistening of the contents of the envelope as well, which could damage the contents. Excessive moistening can also negatively impact any printing performed on the envelope, such as, for example, a postage indicium. For example, if the printing is being done by an ink-jet printer, an excessive amount of moisture will cause the ink to run, thereby possibly rendering any printed information illegible. 
   Thus, there exists a need for a stripper blade/moistener system that can better accommodate envelopes of different sizes having different shaped and sized flaps. 
   SUMMARY OF THE INVENTION 
   The present invention alleviates the problems associated with the prior art and provides a stripper blade/moistening system that can reliably strip and seal envelopes of different sizes having flaps of different shapes and sizes. The present invention provides an adjustable stripper blade and moistening assembly that can be set based on the envelope size or flap size. The adjustable system of the present invention provides better control over the stripping of the envelope flap, as well as the placement of moistening fluid deposited on an envelope flap, thereby ensuring more consistent stripping and sealing, while also reducing the likelihood of an over-wetting condition. 
   In accordance with the present invention, a stripper blade and moistening assembly are adjustable in a direction transverse to the movement of a mail piece being passed through the mailing machine. By allowing the stripper blade to move with respect to the feed deck, the position of the stripper blade can be optimally set to reliably strip different size envelopes having flaps of different shapes and sizes. Additionally, by allowing the moistening assembly to move in conjunction with the stripper blade, there is better control of the amount and location of deposition of the moistening fluid on the envelope flap, thereby preventing possible damage to the envelope or its contents. In accordance with one embodiment of the present invention, the position of the stripper blade and moistening assembly are manually adjustable by an operator. In accordance with another embodiment, the position of the stripper blade and moistening assembly are automatically adjusted based on an input or, alternatively, sensed profile of the envelope flap. 
   Therefore, it should now be apparent that the invention substantially achieves all the above aspects and advantages. Additional aspects and advantages of the invention will be set forth in the description that follows, and in part will be obvious from the description, or may be learned by practice of the invention. Moreover, the aspects and advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out in the appended claims. 

   
     DESCRIPTION OF THE DRAWINGS 
     The accompanying drawings illustrate presently preferred embodiments of the invention, and together with the general description given above and the detailed description given below, serve to explain the principles of the invention. As shown throughout the drawings, like reference numerals designate like or corresponding parts. 
       FIG. 1  illustrates a mailing machine including an adjustable stripper/moistener system according to the present invention; 
       FIG. 2  illustrates a top view of the adjustable stripper/moistener system according to the present invention in a first position; 
       FIG. 3  illustrates a side view the adjustable stripper/moistener system according to the present invention; 
       FIG. 4  illustrates a top view of the adjustable stripper/moistener system according to the present invention in a second position; 
       FIG. 5  illustrates a top view of the adjustable stripper/moistener system according to the present invention in a third position; and 
       FIG. 6  illustrate in block diagram form an adjustable stripper/moistener system according to another embodiment of the present invention. 
   

   DETAILED DESCRIPTION OF THE PRESENT INVENTION 
   In describing the present invention, reference is made to the drawings, wherein there is seen in  FIG. 1  a mailing machine  10  that includes an adjustable stripper/moistener system according to the present invention. Mailing machine  10  comprises a base unit, designated generally by the reference numeral  14 , the base unit  14  having a mail piece input end, designated generally by the reference numeral  16  and a mail piece output end, designated generally by the reference numeral  18 . A control unit  20  is mounted on the base unit  14 , and includes one or more input/output devices, such as, for example, a keyboard  22  and a display device  24 . One or more cover members  26  are pivotally mounted on the base  14  so as to move from the closed position shown in  FIG. 1  to an open position (not shown) to expose various operating components and parts for service and/or repair as needed. 
   The base unit  14  further includes a horizontal feed deck  30  which extends substantially from the input end  16  to the output end  18 . A plurality of nudger rollers  12  are suitably mounted under the feed deck  30  and project upwardly through openings in the feed deck so that the periphery of the rollers  12  is slightly above the upper surface of the feed deck  30  and can exert a forward feeding force on a succession of mail pieces placed in the input end  16 . A registration wall  32  defines a mail piece registration surface substantially perpendicular to the feed deck  30  that extends substantially from the input end  16  to the output end  18 . Mail pieces placed in the input end  16  are fed by the nudger rollers  12  along the feed deck  30 , with the top edge of the mail piece being registered against the wall  32 . The mail pieces may be passed through one or more modules, such as, for example, a singulator module and an adjustable stripper/moistening module according to the present invention as described below. Each of these modules is located generally in the area indicated by reference numeral  36 . The mail pieces are then passed to a metering/printing module located generally in the area indicated by reference numeral  38 . 
   Referring now to  FIGS. 2 and 3 , there is illustrated a top view and a side view, respectively, of an adjustable stripping/moistening system  50  according to the present inventions. Stripping/moistening system  50  could be used, for example to process a mail piece being transported through the mailing machine  10  of  FIG. 1 , and would be located near the registration wall  32  along the feed deck  30  generally in the area designated  36 . System  50  may also be mounted in other types of mailing systems, such as, for example, an inserter. 
   System  50  includes a stripping blade  52  positioned to strip a flap  40  of an envelope  42  from the envelope  42  as the envelope  42  traverses the feed deck  30  in the direction indicated by arrow  44 . The envelope  42  is situated on the feed deck  30  face up, i.e., the back of the envelope, with the flap  40 , faces the feed deck  30 . Flap  40  includes a glue line  46 . As the envelope  42  is transported along the feed deck  30 , it is guided onto the stripper blade  52  such that the flap  40  will pass between a gap between the stripper blade  52  and feed deck  30  while the body of the envelope  42  will pass over the top of the stripper blade  52 . Thus, the flap  40  is stripped from the envelope  42  by the stripper blade  52 . 
   An applicator assembly  54  is coupled to the stripper blade  52 . Applicator assembly  54  includes a contact media, such as, for example, a brush, foam or felt. The applicator assembly  54  is located above a wick  56 . Wick  56  is preferably formed of a woven material, and has a first end portion  66  disposed in a reservoir  60  located beneath the feed deck  30  (FIG.  3 ). The reservoir  60  contains a moistening fluid  62 , such as, for example, water or water with a biocide, for moistening the glue line  46  on the flap  40  of envelope  42 . Wick  56  includes a second end portion  64  situated near an opening  58  in the feed deck  30  such that the applicator assembly  54  and the second end portion  64  of the wick  56  make contact with each other through the opening  58 . The wick  56  wicks moistening fluid  62  from the reservoir  60  from the first end  66  to the second end  64 . Moistening fluid  62  is then transferred from the second end portion  64  of the wick  56  to the applicator assembly  54 . As noted above, the body of the envelope  42  will pass over the top of the stripper blade, and hence the applicator assembly  54 , while the flap  40  will pass under the stripper blade  52  and thus between the applicator assembly  54  and portion  64  of the wick  56 . Moistening fluid  62  will thus be transferred from the applicator assembly  54  to the glue line  46  of flap  40 . The second end portion  64  of wick  56  is preferably located slightly below the level of the feed deck  30 , thereby minimizing any contact between the end portion  64  of wick  56  and the outside of the flap  40  of envelope  42 . 
   Referring again to  FIG. 2 , the stripper blade  52  is mounted to a chassis  70 .  FIG. 2  illustrates the chassis  70  in a first position, in which the top edge  78  of the stripper blade  52  is located a distance d 1  from the registration wall  32 . The stripping action is most reliable when the bottom edge of the envelope flap  40  is close to the top edge  78  of the stripper blade  52 . While this position may be suitable for reliably stripping and moistening certain sizes of envelopes, such as, for example, #10 envelopes, it may not be as reliable for other size envelopes or envelopes with different flap styles. For example, a large square flap, which extends much further toward the chassis  70 , may be difficult to strip open, due to the location of the top edge  78  of the stripping blade  52  with respect to the bottom edge of the flap. To overcome these deficiencies, according to the present invention, chassis  70  is movable in a direction transverse to the direction in which the envelope  42  travels as indicated by arrow  72 . In accordance with one embodiment of the present invention, movement of chassis  70  is facilitated by a pair of channels  74   a,    74   b  in the feed deck  30 . Support rods  76   a,    76   b,  coupled to the chassis  70 , extend through the channels  74   a,    74   b  such that the rods  76   a,    76   b  can move from one end to the other of the channels  74   a,    74   b.  It should be understood, of course, that movement of the chassis  70  can be facilitated in any manner, such as, for example, tracks in which the chassis  70  slides, a single channel, or any other type of mechanism that allows the chassis  70  to move back and forth. A tab  100 , coupled to the chassis  70 , may be provided to allow an operator to manually slide the chassis  70  back and forth in the direction of arrow  72 . A position indicator, such as for example, a line graph  102 , can optionally be provided to indicate the position of the stripper/moistener system  50 . 
     FIG. 4  illustrates a top view of the adjustable stripper/moistener system  50  according to the present invention in a second position in which the top edge  78  of the stripper blade  52  is located a distance d 2  from the registration wall  32 . With the top edge  78  of the stripper blade  52  located a distance d 2  from the registration wall  32 , an envelope with a large flap, such as the flap  80  of envelope  82 , can be reliably stripped, since the top edge  78  of the stripper blade  52  is positioned near the bottom edge of the flap  80 . Additionally, the adjustable stripper/moistening system  50  of the present invention provides better control of the application of the moistening fluid  62 . This is accomplished by reducing the area of the flap  80  that will be moistened by the applicator assembly  54 . Since the applicator assembly  54  is coupled to the stripper blade  52 , it will also move when the chassis  70  is moved. Thus, only the portion of the flap  80  that contains the glue line  86  will pass beneath the applicator assembly  54 , and not the entire flap  80  as would occur if the stripper blade/moistener system  50  were left in the first position as illustrated in FIG.  2 . This prevents excessive moistening of the flap  80 , thereby preventing possible damage to the contents of envelope  82  or any negative impact on any printing performed on the envelope  82 . 
   Better control of the application of the moistening fluid  62 , according to the present invention, also has other advantages. For example, the amount of moistening fluid is also better controlled by reducing the area of the flap  80  that contacts the applicator assembly  54 . This prevents the applicator assembly  54  from being depleted of moistening fluid  62  by not wasting the moistening fluid  62  on portions of the flap  80  where it is not desired or needed. The recovery time for the applicator assembly  54 , i.e., the time required between mail pieces for the applicator assembly  54  to have sufficient amount of moistening fluid  62  transferred to it from the wick  56 , is significantly decreased, as only the tip of the applicator assembly  54  (near blade edge  78 ) is being used. It is especially important to have a short recovery period for mailing machines that process mail pieces at a fast rate, such as, for example, 150 letters per minute. 
     FIG. 5  illustrates a top view of the adjustable stripper/moistener system  50  according to the present invention in a third position in which the top edge  78  of the stripper blade  52  is located a distance d 3  from the registration wall  32 . With the top edge  78  of the stripper blade  52  located a distance d 3  from the registration wall  32 , a large envelope with a square flap, such as the flap  90  of envelope  92 , can be reliably stripped, since the top edge  78  of the stripper blade  52  is positioned near the bottom edge of the flap  90 . Additionally, the area of the flap  90  that will be moistened by the applicator assembly  54  is reduced to a minimal amount that contains the glue line  96  similarly as described above. This prevents excessive moistening of the flap  90 , thereby preventing possible damage to the contents of envelope  92  or any negative impact on any printing performed on the envelope  92 . 
   Thus, according to the present invention, an adjustable stripper blade/moistening system  50  is provided that provides more reliable stripping of different sized envelopes and envelope flaps, as well as better control of the placement of moistening fluid on an envelope flap. It should be understood that while the above description included three different positions for the stripper/moistener system  50 , the invention is not so limited and can be provided with any number of positions according to the intended application of the mailing machine  10 . The position of the stripper/moistener system  50  can be manually adjusted by the operator based on the size of the envelope or flap style. Optionally, a reference guide or measurement guide could be printed on the feed deck  30  that provides an index of different flap styles and the optimal position setting of the stripper/moistener system  50  for the envelope flap style the operator is utilizing. Alternatively, the reference guide could be provided in a user&#39;s manual or the like. 
   Referring now to  FIG. 6 , there is illustrated in block diagram form an adjustable stripper/moistener system  150  according to another embodiment of the present invention. System  150  includes a stripper/moistener  152  that has similar mechanical features to stripper/moistener  50  as described with respect to  FIGS. 2 and 3 . Stripper/moistener  152  is coupled to a drive  154 , such as, for example, a motor, that moves the stripper/moistener  152  in a direction transverse to the feed deck  30 . Drive  154  can utilize a belt, screw, gears or any other type of system to move the stripper/moistener  152  back and forth perpendicular to the feed deck  30  to different positions similarly as described in  FIGS. 2-5 . The drive  154  is controlled by a processor  156 . Processor  156  is coupled to the control unit  20  of the mailing machine  10 . Thus, an operator can input the flap style and/or envelope size, utilizing the keyboard  22  and/or display  24  of control unit  20 , that the operator will be feeding through the mailing machine  10 . The processor  156 , in response to the input from the operator, will determine to optimal position for the stripper/moistener  152  and activate the drive  154  to move the stripper/moistener  152  to the determined optimal position for reliably stripping the envelopes being processed, and preventing any over-wetting conditions from occurring as described above. 
   Optionally, a flap profile sensor  160  could be provided along the feed deck  30  upstream from the stripper/moistener  152 . The flap profile sensor  160  could be similar to the apparatus as described in U.S. Pat. No. 4,924,106, which is hereby incorporated by reference. As an envelope moves in the direction indicated by arrow  44 , it will pass the envelope profile sensor  160  which provides information to the processor with respect to the profile of the flap of the envelope. The processor  156  can then automatically determine the optimal position for reliably stripping the envelope based on the profile as sensed by the sensor  160 , and will automatically activate the drive  154  to move the stripper/moistener  152  to the determined optimal position for reliably stripping the envelope being processed and preventing any over-wetting conditions from occurring as described above. Thus, the processing of mixed mail, i.e., mail pieces of varying sizes, can be automatically accomplished without the need for the operator to have to change the position of the stripper/moistener system for each separate mail piece. 
   Thus, according to the present invention, an adjustable stripper blade/moistening system is provided that provides more reliable stripping of different sized envelopes and envelope flaps, as well as better control of the placement of moistening fluid on an envelope flap. Those skilled in the art will also recognize that various modifications can be made without departing from the spirit of the present invention. For example, the construction of applicator assembly  54  can vary. A traditional “wick to contact medium” style, as described above, can be used. Alternatively, a wick could be attached to the stripper blade and hang into a supply of moistening fluid. The wick then also acts as the contact medium to transfer the moistening fluid to the glue line of the envelope flap. As another example, the stripper blade and reservoir could be one integral piece, with the wick being part of the stripper blade and moistening fluid being supplied from within the stripper blade. The supply of moistening fluid within the stripper blade could be maintained by pumping moistening fluid from a remote tank. 
   While preferred embodiments of the invention have been described and illustrated above, it should be understood that these are exemplary of the invention and are not to be considered as limiting. Additions, deletions, substitutions, and other modifications can be made without departing from the spirit or scope of the present invention. Accordingly, the invention is not to be considered as limited by the foregoing description but is only limited by the scope of the appended claims.