Abstract:
A method is provided for using a rotatable insertion horn to open an envelope prior to insertion of documents. A pair of insertion horns is positioned at the sides of an envelope inserting station. An envelope is fed into the envelope inserting station with its flap open. The collation of documents is pushed into the open end of the envelope. The insertion horns are positioned in an initial position that is fully outside the envelope, prior to arrival of the collation. The insertion horns are controlled to simultaneously rotate into the envelope as the collation passes between the insertion horns. Preferably, rotation of the insertion horns into the envelope does not begin until a lead edge of the collation is in a region between the insertion horns. This facilitates insertion of the collation without catching on an upstream edge of the insertion horns.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates generally to multi-station document inserting systems, which assemble batches of documents for insertion into envelopes. More particularly, the present invention is directed toward an envelope feeder-insert station having a rotatable insertion horn for opening an envelope prior to insertion of documents into the envelope. 
       BACKGROUND OF THE INVENTION 
       [0002]    Multi-station document inserting systems generally include a plurality of various stations that are configured for specific applications. Typically, such inserting systems, also known as console inserting machines, are manufactured to perform operations customized for a particular customer. Such machines are known in the art and are generally used by organizations, which produce a large volume of mailings where the content of each mail piece may vary. 
         [0003]    For instance, inserter systems are used by organizations such as banks, insurance companies and utility companies for producing a large volume of specific mailings where the contents of each mail item are directed to a particular addressee. Additionally, other organizations, such as direct mailers, use inserts for producing a large volume of generic mailings where the contents of each mall-item are substantially identical for each addressee. Examples of such inserter systems are the MPS and Epic™ inserter systems available from Pitney Bowes, Inc., Stamford, Conn. 
         [0004]    In many respects the typical inserter system resembles a manufacturing assembly line. Sheets and other raw materials (other sheets, enclosures, and envelopes) enter the inserter system as inputs. Then, a plurality of different modules or workstations in the inserter system work cooperatively to process the sheets until a finished mailpiece is produced. The exact configuration of each inserter system depends upon the needs of each particular customer or installation. For example, a typical inserter system includes a plurality of serially arranged stations including an envelope feeder, a plurality of insert feeder stations and a burster-folder station. There is a computer generated form or web feeder that feeds continuous form control documents having control coded marks printed thereon to the burster-folder station for separating and folding. A control scanner located in the burster-folder station senses the control marks on the control documents. Thereafter, the serially arranged insert feeder stations sequentially feed the necessary documents onto a transport deck at each station as the control document arrives at the respective station to form a precisely collated stack of documents which is transported to the envelope feeder-insert station where the stack is inserted into the envelope. The transport deck preferably includes a ramp feed so that the control documents always remain on top of the stack of advancing documents. A typical modern inserter system also includes a control system to synchronize the operation of the overall inserter system to ensure that the collations are properly assembled. 
         [0005]    In regards to the envelope feeder-insert station, they are critical to the operation of document inserting systems. Typically, such an envelope insert device inserts collated enclosures into a waiting envelope. Envelope inserting machines are used in a wide range of enclosure thickness&#39; and also with enclosures which are not significantly different in length than the length of the envelopes into which they are inserted. The difference between the length of the enclosures and the envelope should be minimized so that the addressing information printed on the enclosure which is intended to appear in the envelope window does not shift in position and become hidden. 
         [0006]    In Pitney Bowes high speed insertion machines, the mechanical paper guides herein called ‘horns’ are used form the entrance of the envelope so that an incoming collation is cleanly guides into the envelope. The horn extends approximately 50 mm into the envelope to further shield the collation from the inside edges of the envelope. The horns are mounts on servo motors, which retract the horns away from the envelope to allow suction cups to initially open the envelope. Afterwards, the servo motors will rotate the horns Into the partially opened envelope to complete the opening of the envelope. Typically these horns are angled inwards to create a tunneling effect so that the collation does not catch on entry to the horn. However, this angle reduces the maximum collation width that can be run. Once the horns are extended into the envelope, a collation of mail contents is inserted into the envelope. 
         [0007]    Prior art inserting systems are described in the following patents, which are hereby incorporated by reference:
   5,992,132—Rotary Envelope Insertion Horn   8,978,583—High Speed Vacuum System for Inserters;   7,181,895—Jam Tolerant Mail Inserter;   7,600,756—System and Method for Preventing Envelope Distortion in a MailPiece Fabrication System;   8,281,918—System for Controlling Friction Forces Developed on an Envelope in a Mailpiece Insertion Module;   8,439,182—Mail Piece Inserter Including System for Controlling Friction forces Developed on an Envelope.   
 
         [0014]    Therefore it is an object of the present invention to overcome the difficulties associated with insertion horns that facilitate the insertion of documents into an envelope. 
       SUMMARY OF THE INVENTION 
       [0015]    Accordingly, the Instant invention provides a method for using a rotatable insertion horn tor opening an envelope prior during insertion of documents into the envelope. In this method, a pair of insertion horns are positioned at the sides of an envelope inserting station. The insertion horns rotate into the envelope to open the envelope&#39;s sides to form a clear channel for the collation to enter. An envelops is fed into the envelope inserting station with its flap open. The collation of documents Is pushed into the open end of the envelope. The Insertion horns are positioned in an initial position that is fully outside the envelope, prior to arrival of the collation. The insertion horns are controlled to simultaneously rotate into the envelope as the collation passes between the insertion horns. In the preferred embodiment, rotation of the insertion horns into the envelope does not begin until a lead edge of the collation is in a region between the insertion horns. This facilitates insertion of the collation without catching on an upstream edge of the insertion horns. 
         [0016]    In a further preferred embodiment, the insertion horns are controlled to rotate fully into the envelope such that side walls of the insertion horns are parallel with the sides of the envelope. This allows maximum space for the width of the collation. After insertion, the insertion horns can be relaxed from their full insertion position by rotating the insertion horns away from the sides of the envelope. This relaxation removes fractional contact between the sides of the envelope and the insertion horns, and allows subsequent feeding of the stuffed envelope from the envelope inserting station. After the stuffed envelope leaves the station, the insertion horns are moved back to the initial position and another empty envelope is fed into the insert station. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0017]    The above and other objects and advantages of the present invention will become more readily apparent upon consideration of the following detailed description, taken in conjunction with accompanying drawings, in which like reference characters refer to like parts throughout the drawings and in which: 
           [0018]      FIG. 1  is a block diagram schematic of a document inserting system in which the present invention input system is incorporated; 
           [0019]      FIG. 2  is a side, elevational view of an envelope inserting apparatus using the present invention insertion horns; 
           [0020]      FIG. 3  is a fop view showing the initial positioning of the horns prior to beginning an insertion operation. 
           [0021]      FIG. 4  is a top view showing the intermediate positioning of the horns as a collation is approaching insertion; 
           [0022]      FIG. 5  is a top view showing a final position of the horns as a collation is being inserted into the envelope. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0023]    Referring to  FIG. 1 , a schematic of a document inserting system according to one embodiment of the present application is shown. The document inserting system  10  includes an insertion station  100 . The document insertion system  10  is illustrative and many other configurations may be utilized. 
         [0024]    System  10  includes an Input system  12  that feeds paper sheets from a paper web to an accumulating station that accumulates the sheets of paper in collation packets. Preferably, only a single sheet of a collation is coded (the control document), which coded information enables the control system  14  of inserter system  10  to control the processing of documents in the various stations of the mass mailing inserter system. 
         [0025]    Input system  12  feeds sheets in a paper path, as indicated by arrow “a,” along what is known as the main deck of inserter system  10 . After sheets are accumulated into collations by input system  12 , the collations are folded in folding station  18  and the folded collations are then conveyed to a transport station  13 , preferably operative to perform buffering operations for maintaining a proper timing scheme for the processing of documents in insertion system  10 . 
         [0026]    Each sheet collation is fed from transport station  18  to Insert feeder station  20 . It is to be appreciated that an inserter system  10  may include a plurality of feeder stations, but for clarity, only a single insert feeder  20  is shown. Insert feeder station  20  is operational to convey an insert (e.g., an advertisement) from a supply tray to the main deck of inserter system  10  so as to be combined with the sheet collation conveying along the main deck. The sheet collation, along with the nested insert(s), are next conveyed into envelope insertion station  100  that is operative to first open the envelope and then insert the collation into the opening of the envelope. The envelope is then conveyed to postage station  22 . Finally, the envelope is conveyed to sorting station  24  that sorts the envelopes in accordance with postal discount requirements. 
         [0027]    Referring now to  FIG. 2 . an insertion device  100  according to an illustrative embodiment of the present application is shown. For clarity,  FIG. 2  depicts an insertion station  100  without illustrating any enclosure collations or envelopes, in operation, an envelope enters the insertion station  100  along a guide path  114  and is transported into the insertion station  100  by a set of transport rollers  116  and  118  and continuously running transport belts  121 ,  123  and  125 . Each transport belt  121 ,  123  and  125  respectively wraps around rollers  127 ,  129  and  131 , each roller being connected to a common shaft  133   a.  Each transport belt  121 ,  123  and  125  is juxtaposed between deck strips that form transport deck  141  of insertion station  100 . 
         [0028]    The motion of each transport belt  121 ,  123  and  125  is continuous for maintaining registration of an envelope  112  against a backstop  180 . Continuous vacuum from each of the deck strips via their respective vacuum plenums prevents any jiggling. Of the envelope even though the transport belts  121 ,  123  and  125  are continuously running beneath. 
         [0029]    Rotating backstop members  180  are preferably located outside the vacuum deck strips in an elongate slot. Each backstop member  180  is concentrically mounted about a common shaft  182  for effecting rotation thereof. Each stopping portion  184  is configured to stop an envelope when it is above the deck  141  of insertion station  100 . A servo motor (not shown) causes rotation of the backstops members  180  about axle  182 . 
         [0030]    Insertion station  100  Includes envelope flap retainers  124  and rotating insertion horns  126  and  128  each having an underside that assists in helping an envelope conform to each transport belt  121 ,  123  and  125  while not presenting any catch points for the leading edge of the enclosure collation  130  to be inserted in a waiting open envelope  112 . The horns  126  and  128  are supported from above the envelope path and are eccentrically mounted on pivot shafts  103 . They are positioned perpendicular to the path of the envelope travel as the envelope is conveyed to backstop members  180 . Once the vacuum assembly  70  has begun to open the envelope, the insertion horns  128  and  128  can be pivoted into the envelope in a manner that will be further discussed in connection with  FIGS. 3-5 . Insertion horns  126  and  128  will move Into the envelope so that the outer edges of the envelope have been shaped and supported. Rotating insertion horns  126  and  128  perform the additional function of centering envelope  112  in the path of the oncoming enclosure collation  130 . The pivot shafts of each insertion horn  128  and  128  are driven by a servo motors  104  end  106  (see  FIGS. 3-5 ). 
         [0031]    Insertion station  100  further includes an envelope opening vacuum assembly  70  for separating the back panel of an envelope from its front panel. Vacuum assembly  70  is perpendicular to the transport deck  141  of insertion station  100 . Vacuum assembly  70  includes a reciprocating vacuum cup  72  that translates vertically downward toward the surface of the transport deck  141  and then upward away from the transport deck  141  to a height sufficient to allow a stuffed envelope to pass under. The vacuum cup  72  adheres to the back panel of an envelope, through a vacuum force present in vacuum cup  72  so as to separate the envelopes back panel away from its front panel during upward travel of the vacuum cup  72 . 
         [0032]    The enclosure collations  130  are fed Into the Insertion station  100  by means of a pair of overhead pusher fingers  132  extending from a pair of overhead belts  134  relative to the deck of inserter system  10 . As with the envelope  112 , the top side of the envelope flap retainers  124  and the associated interior of me insertion horns  126 ,  128  must not present any catch points for the leading edge of the enclosure collation  130 . 
         [0033]    Referring to  FIG. 2 , a method of operation according to an illustrative embodiment, of the present application is described. An envelope  112  is conveyed to the transport deck  141  of insertion station  100  via guide path  114  (which is in connection with an envelope supply (not shown)). Once a portion of the envelope  112  contacts the continuous running transport belts  121 ,  123  and  125 , these transport belts convey envelope  112  downstream as indicated by arrow B, in insertion station  100 . Concurrently, each deck strip of transport deck  141  provides a continuous vacuum force upon envelope  112  (via vacuum plenums) so as to force envelope  112  against the continuous running transport bets  121 ,  123  and  125 . Next, an elongate stopping portion  184  of backstop member  180  is caused to extend above the transport deck  141  at a height sufficient to stop travel of the envelope  112  in insertion station  100 . The leading edge of the envelope  112  then abuts against the stopping portion  184  of backstop member  180  so as to prevent further travel of the envelope  112 . 
         [0034]    While the envelope  112  is abutting against the stopping portion  184  of backstop member  180 , the transport belts  121 ,  123  and  125  are continuously running beneath the envelope  112 . To prevent jiggling of the envelope  112  (as could be caused by the friction of continuous running transport belts  121 ,  123  and  125 ) the continuous vacuum force applied to the envelope  112  by the deck stops functions to stabilize the envelope  112  on the transport deck  141  while if is abutting against backstop member  180 . 
         [0035]    When envelope  112  is disposed in insertion station  100 , the vacuum cap  72  of vacuum assembly  70  Is caused to reciprocate downward toward the back panel of envelope  112 . The vacuum cup  72  adheres to the back panel and then reciprocates upwards so as to separate the back panel from the envelope front panel to create an open channel in the envelope  112 . Enclosure collation  130  is then conveyed toward the envelope  112  by pusher fingers  132 . At first, as shown in  FIG. 3 , the insertion horns  126 ,  128  are positioned in a first position wherein their respective stripper blade portions  170  are positioned outside of the open end of the closed envelope  112 . Then as the collation  130  is advanced toward the open channel of envelope  112 , and the lead edge of the collation  130  is between the horns  126  and  128 , each Insertion horn  126  and  128  is gradually pivoted towards its second position, When the lead edge is between the horns they will be at approximately  46  degrees (see  FIG. 4 ). Finally, as seen in  FIG. 5 , the insertion horns  126  and  128  are pivoted fully into the envelope as the collation  130  begins to enter the envelope. At this point, the horns  128  and  128  are preferably at ninety degrees. In this manner, the pivoting Insertion horns  126  and  128  provide a guide path into the open channel of the envelope  112  into which an enclosure collation  130  travels through and into the envelope  112 . This method avoids catching on the upstream edge of the horns  128 , and the edges of the envelope  112 . 
         [0036]    The method of operation will now be discussed in conjunction with reference to  FIGS. 3-5 . Referring to  FIG. 3 , with an envelope  112  disposed in insertion station  100 , an enclosure collation  130  is conveyed by pusher fingers  132  ( FIG. 2 ) toward envelope  112 . At first, the insertion horns  128 ,  128  are positioned in a first position wherein their respective stripper blade portions  170  are positioned outside of the open end of the closed envelope  112 . Referring now to  FIG. 4  as the collation  130  is advanced to a position between the horns  128  and  128  into the open end of envelope  112 , each insertion horn  126  and  128  is pivoted in synchronized motion with the collation  180 . Thus when the lead edge of the collation  130  is between the horns  126  and  128 , the horns are positioned at approximately 45 degrees. Finally, as shown in  FIG. 8 , the horns  126  and  128  are moved to a full insertion position, approximately 90°, preferably at about the time the collation is just starling to enter the opening to the envelope  112 . 
         [0037]    After the enclosure collation  130  is inserted into the envelope  112 , the insertion horns  126  and  128  are caused to relax by to an angled position, about 5 degrees, so that they are no longer pressing on the outer edges of the envelope  112 . The will reduce friction so that the envelope  112  can be more easily withdrawn from the insert station  100 . The above process for inserting another collation into another envelope is then repeated. 
         [0038]    Thus, an advantage of the present invention pivoting insertion horns  126  and  128  are that they can be used to open an envelope to the fullest extent while guarding against a collation hitting an edge of the envelope  112  or an edge of the horns  126  and  128  themselves. 
         [0039]    Although the invention has been described with respect to preferred embodiments thereof it will be understood by those skilled in the art that the foregoing and various other changes, omissions and deviations in the form and detail thereof may be made without departing from the spirit and scope of this invention.