Abstract:
An apparatus for transporting substrates. The apparatus being characterized by a removeable and positionally reversible control unit, to permit use of the apparatus as a bi-directional conveyor. The apparatus has a perforated transport belt, supported by a slotted deck, both of which allow passage of air downwardly through the belt. Dryer mounts on the apparatus are designed to allow tool-free adjustment of the dryer height for various types of sheet-like media. Further, an adjustable clip-on catch tray is easily changeable to accommodate the outfeed of various types of media.

Description:
RELATED APPLICATION 
       [0001]    This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/215,483, filed 6 May 2009. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    The present invention pertains to material handling, and more particularly to an apparatus for conveying flat media. Various types of equipment have been developed to convey flat pieces of media, such as paper, postcards and envelopes along a machine path. In general, these devices are adapted to propel the pieces in a single downstream direction. The present invention is directed to a multi-directional conveyor having several new features which will, among other advantages, reduce costs, simplify construction, reduce inventory costs, and reduce noise levels and power consumption. 
       SUMMARY OF THE INVENTION 
       [0003]    The present invention is directed to a conveyor apparatus that facilitates multi-directional transport of flat substrates, such as paper, envelopes or other similar media. This is accomplished through use of an electrical control unit that may be positioned on either side of the apparatus, and maneuvered without changing any wiring. The control unit is releasably mounted to the conveyor apparatus, and is detachable by removing releasable attachment means, such as conventional screws, snap connections, hooks, or other similar means of releasable attachment. The control unit is then available for re-mounting to the opposite side of the apparatus by the same means of releasable attachment. The reversibility of the control unit allows a single conveyor apparatus to operate with left-hand, right-hand, and straight-on feeding devices, such as, but not limited to, printers and addressing machines. A method of using a conveyor having a reversible control panel is also contemplated. 
         [0004]    The preferred embodiment also contains other key features to accommodate efficient transport of flat substrates. According to the present invention, a perforated transport belt and a slotted deck is provided. The conveyor belt is used to move the media and is preferably a single belt design having a plurality of laterally spaced apertures to allow air from fans, or other suction devices, to pass through and draw the media down securely on the belt. The slotted deck that supports the perforated belt is slotted to similarly allow fans, or other suction methods, to draw air in a downward direction through the perforated conveyor belt. 
         [0005]    The suction device intended to draw the media against the conveyor belt is preferably one or more small electric fans mounted internally within the conveyor frame. These fans, commonly known as “muffin fans”, draw air through the slotted frame and the perforated conveyor belt. This allows the media to move securely along the belt. 
         [0006]    The combination of the fans, perforated belt, and slotted deck are intended to eliminate the need for any type of vacuum pump, hoses, air ducts, funnels, or other similar items. 
         [0007]    The present invention may also employ a clip-on catch tray for receiving the media, such as paper, at the exit end of the conveyor apparatus, as well as an adjustable exit wheel. Both the catch tray and the exit wheel are preferably adjustable for use with different types of media being passed through the conveyor apparatus, and to aid in the stacking of the media at discharge. 
         [0008]    A unique dryer mounting allows for quick adjustment of the dryers for different thickness of media, and is designed such that no tools are required to position the dryers. A knock-down assembly may also be used to direct the media onto the conveyor belt. The optional knock-down assembly may be manipulated into various configurations to be used with any of the various directional and feeding configurations of the apparatus. 
         [0009]    The present invention may use a photo sensor that, when activated, directs the multi-directional conveyor to function as a sequence stacker. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]      FIG. 1  is a perspective view of an apparatus as disclosed in a preferred embodiment of the present invention. 
           [0011]      FIG. 2  is an exploded view of the cooperating components of the present invention. 
           [0012]      FIG. 2A  is an enlarged fragmentary view of the area called out as  2 A in  FIG. 2 . 
           [0013]      FIG. 2B  is an enlarged fragmentary view of the area called out as  2 B in  FIG. 2 . 
           [0014]      FIG. 3A  is a perspective view of conveyor apparatus according to the present invention and showing the reversible control panel being detached from the apparatus, where it was attached for use as a left to right conveyor apparatus. 
           [0015]      FIG. 3B  is a view similar to that of  FIG. 3A , but showing the reversible control panel being rotated 180 degrees. 
           [0016]      FIG. 3C  is a view similar to that of  FIGS. 3A and 3B  but showing the reversible control panel being attached to the opposite side of the conveyor apparatus, for use as a right-to-left conveyor apparatus. 
           [0017]      FIG. 4  depicts a conveyor apparatus in use to transport media (shown in phantom) in a left-to-right direction, with a feeding device located at a 90-degree feed position. 
           [0018]      FIG. 5  is a view similar to  FIG. 4 , but showing a conveyor apparatus in use to transport media (shown in phantom) in a right-to-left direction, with a feeding device located at a 90-degree feed position. 
           [0019]      FIG. 6  is a view similar to  FIGS. 4 and 5 , but showing a conveyor apparatus in use to transport media (shown in phantom) in a right-to-left direction, with a feeding device located in a straight-on position. 
           [0020]      FIG. 7  is a view similar to  FIGS. 4-6 , but showing a conveyor apparatus in use to transport media (shown in phantom) in a left-to-right direction, with a feeding device located in a straight-on position. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0021]    Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention which may be embodied in other specific structures. While the preferred embodiment has been described, the details may be changed without departing from the invention. 
         [0022]    A preferred embodiment of the present invention is illustrated in  FIG. 1  which shows a conveyor apparatus  100  for transporting individual, sheet-like substrates such as paper or other thin media. As shown in  FIG. 1 , the apparatus  100  is free-standing, supported by two members  102 , each extending to the floor, although any number of supporting members  102  may be used. The exploded view of  FIG. 2  shows the supporting members  102  linked by a longitudinal support plank  94 , which is preferably positioned parallel to the floor. As may be further seen in  FIG. 2 , many components of the present invention are contained between two oppositely-disposed, parallel, stationary rail guides  92 A,  92 B. The rail guides  92 A,  92 B are preferably positioned perpendicular to and extending above the support plank  94 . 
         [0023]    As indicated generally by reference numeral  10 , the conveyor apparatus  100  preferably includes a convenient, reversibly positionable. control unit. The reversibly positionable control unit  10  supports an electrical control panel  11  to be used for manual operation by the user. As viewed particularly in  FIGS. 3A-3C , the control unit  10  is designed such that it may be easily manipulated from one side  15 A of the conveyor apparatus  100  to an opposite side  15 B. The alternative mounting capability may be accomplished without making any changes to the wiring of the panel  10  or the apparatus  100 . The control unit  10  is releasably attached to the apparatus by releasable attachment means such as the screws  12  shown, however, it is to be noted that other suitable releasable attachment means may be used, including but not limited to, snap connections, hooks or any other type of conventional releasable attachment. 
         [0024]    As shown in  FIGS. 3A ,  3 B, and  3 C, the control unit  10  may be removed from one side  15 A of the apparatus  100  by removing or releasing the screws  12  or other releasable attachment and re-mounting the control unit  10  to the opposite side  15 B of the apparatus  100  in the same manner, thereby reversing the direction of media transport, relative to the user-operator (not shown). The ability to easily mount the control unit  10  in alternative configurations allows a single conveyor apparatus  100  to work with left-hand, right-hand, and straight-on feeding devices, such as printers, addressing machines and many other devices, as shown in phantom in  FIGS. 4-7 , inclusive. 
         [0025]    Next, with particular reference to  FIG. 2 , the present invention  100  is seen to preferably include an endless, perforated transport belt  20 . The perforated belt  20  moves in a continuous, oblong motion. The belt  20  may be rotatably supported by at least two axially spaced rollers  24 . An upper portion  21  of the belt  20  moves directly adjacent to a stationary longitudinal slotted deck  30  that includes a plurality of longitudinally parallel elongated slots  32  (see  FIG. 2B ). The slotted deck  30 , located directly below the upper, transporting portion of the perforated belt  20 , is designed to permit the flow of air in a downward direction through the perforated conveyor belt  20 . The single belt design with many apertures  22 , and the corresponding slotted openings  32  in the slotted deck  30 , allows fans or other suction means  40  to draw the media  98  downwardly via suction, providing excellent media control. 
         [0026]    The present invention preferably includes uniquely configured electric fans  40  to provide the suction as mentioned above. As shown in  FIG. 2 , the electric fans, or conventionally known “muffin fans”  40 , are mounted between the upper and lower suspended surfaces of the perforated belt  20 , and between the parallel guide rails  92 A,  92 B to thereby draw air thru the slotted frame  30  and perforated conveyor belt  20  and immediately draw the media  98  down against the upper, exposed surface  21  of the perforated belt  20 . 
         [0027]    As further seen in  FIG. 2 , dryer mounts  74  are preferably located between parallel guide rails  92 A,  92 B. A media dryer  70  is supported by a plurality of longitudinally spaced spanning beams  72 . The spanning beams  72  are insertable into apertures  76  in the dryer mounts  74 . As shown in the Figures, the apertures  76  may be L-shaped openings within which the support beams  72  may be moved to adjust the height of the dryer  70  in relation to the media  98  on the transport belt  20 . While L-shaped apertures  76  are shown, these apertures  76  may be of any shape able to provide support for and positioning of the dryer spanning beams  72 . 
         [0028]    As further shown in the Figures, a preferred embodiment of the apparatus  100  may also include a clip-on catch tray  50 . A preferred clip-on catch tray  50  features a unique design which provides installation without need for external fasteners.  FIG. 2  illustrates a catch tray  50  including internally formed hooks  52 , or similar grasping devices, which may be inserted and slidably engaged with oppositely disposed, corresponding slots  54  on a supporting member  102  of the apparatus  100 . This simple clip-on configuration allows quick changing of the tray for many different media styles. 
         [0029]    The present invention may also include an adjustable exit wheel  60 , seen in  FIG. 2 . As shown, the exit wheel  60  is horizontally adjustable by way of slot  64 . In use, the axel  62  of exit wheel  60  rides in slot  64 . Movement of the axel  62  in slot  64  further positions the exit wheel  60  to locations along the belt  20 . Positioning of the exit wheel  60  provides control over the exit trajectory of handled media, and thereby improves the stacking process of different styles and sizes of media. Exit wheel  60  adjustment may be accomplished by an operator without the need of special tools or equipment. 
         [0030]    The present device  100  may include the use of a knock-down assembly  80 . A knock-down assembly  80  may direct substrates  98  onto the upper, exposed surface  21  of the perforated belt  20 . As viewed particularly in  FIG. 2 , various knock-down assembly  80  configurations  80   a ,  80   b ,  80   c ,  80   d , may be seen. Use of the various configurations,  80   a ,  80   b ,  80   c ,  80   d  may be seen in  FIGS. 4-7 , inclusive. The different configurations  80   a ,  80   b ,  80   c ,  80   d  are achieved through adjustment of the location and angle of infeed guide plate  82 . The infeed guide plate  82  may be angularly adjusted such that the open face of the plate  82  is facing the direction from which the media  98  is approaching the apparatus  100 . This is accomplished by laterally adjusting the location of support arm  84  between the parallel guide rails  92 A,  92 B and adjusting the location and angle-facing of the guide plate  82  on the guide plate arm  86 , for 90-degree feeding, as referenced by numerals  80   a  and  80   d  (see also  FIG. 4  and  FIG. 5 ). For straight-on feeding, as referenced by numerals  80   b  and  80   c , the knock-down assembly  80  further includes an additional arm  88  to which the guide plate arm  86  is attached such that the guide plate  82  may be turned to face the substrates entering the belt  20  from that straight-on direction (see also  FIG. 6  and  FIG. 7 ). 
         [0031]    As seen now in  FIG. 2 , an optional photo sensor  90  may be used to direct the conveyor  100  to function as a sequence stacker. This feature allows the apparatus  100  to stack the media either singulated or one on top of the previous one, and further allows for stacking with or without breaks in the stacks. 
         [0032]    A method of use is further contemplated, where the method includes the steps of:
       providing a free-standing instrumentation supported by at least one member extending to the floor and a first longitudinally extending support plank;   providing a continuous suction conveyor comprising an endless transport belt, said belt having an upper and a lower suspended surface movable in a continuous, oblong axial motion, said belt rotatably supported by at least two longitudinally spaced rollers;   providing a second longitudinal plank positioned immediately below said upper suspended surface of said transport belt; and   providing a control unit releasably joinable to said apparatus, and supporting a manually operable electrical control panel, wherein the position of said control unit is moveable from a first operating position to a second operating position for manipulating transport direction of said substrates on said apparatus;   transporting an individual substrate along a said transport belt;   creating suction capable of drawing a substrate to an upper exposed surface of said transport belt by use of a plurality of electrical fans drawing said evacuating air downwardly through perforations in the transport belt;   joining a reversibly positionable control unit said conveyor apparatus by means of releasable attachment.       
 
         [0040]    The foregoing is considered as illustrative only of the principles of the invention. Furthermore, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described. While the preferred embodiment has been described, the details may be changed without departing from the invention.