Patent Description:
It has become commonplace for mailpieces to be mass generated and sent to designated recipients through the U. Postal Service. These mailpieces can contain a variety of printed insert materials (e.g., "inserts" or, taken together, an "insert stack"), which can include, for example, invoices, account statements, and/or marketing materials (e.g., pre-printed advertisement materials). According to the known solutions for creating these mailpieces, large and cumbersome systems are implemented to carry out a method of "stuffing" the printed insert materials within pre-assembled envelopes to create these mailpieces. In such known solutions, these pre-assembled envelopes generally are stopped at one or more specified positions so that they can be opened (e.g., by applying a vacuum or by other mechanical devices) for insertion of the printed insert materials therein. However, this approach requires that the envelopes be pre-assembled and delivered to the inserting machine in regular intervals to be manually loaded into the inserting machine by an operator. Because the envelopes must come to a stop within the inserting machine during processing, such conventional inserters suffer from relatively frequent paper jams and significant mailpiece damage. Furthermore, currently known solutions suffer from insufficient adhesive "hygiene" (e.g., unwanted glue transfer, accumulation, and/or build up, whereby glue is dispensed on an envelope sheet to form a mailpiece, yet the envelope sheet is misfed, causing glue to adhere to the machinery downstream, when it should be only on and within the envelope sheet.

Some have attempted to increase throughput of mailpieces by modifying such inserting machines to decrease the relative velocity between the printed insert materials and the envelope. This can be done by either slowing the envelope through the inserting machine or accelerating the printed insert materials along the assembly path, so that the envelope or the printed insert materials can overtake the other, resulting in an assembled envelope. However, even these attempts have been unable to overcome all of the known drawbacks associated with such inserting machines, such as using pre-assembled envelopes, which must be stored after their assembly, are subject to deterioration from potentially non-optimal environmental conditions, and require significant manual labor for their loading in the inserting machines. Furthermore, while these inserting machines may be capable of reaching higher processing speeds, the required motion controllers needed to control the precise location of the envelope for the insertion of the printed insert materials leads to an increased cost and size of such inserting machines, while the act of inserting the printed insert materials into a moving pre-assembled envelope requires a certain amount of travel (e.g., "runway") over which the inserting occurs, thus requiring a longer and larger footprint for the inserting machine.

<CIT> discloses a device configured to receive and dispense one or more insert sheets as an insert stack onto an envelope sheet. The envelope sheet is transported on an envelope sheet transporting path and the insert sheets are transported on a sheet conveying path. The device is further configured to hold the insert stack and to dispense the insert stack onto the envelope sheet while the envelope sheet abuts a butt member and remains stationary.

<CIT> discloses a device configured to receive and dispense one or more sheets as an insert stack onto an envelope sheet. The envelope sheet is transported along a conveyor using two pins. The insert stack is held in a tray and pushed out of the tray and onto the envelope sheet by two different pins which are part of the conveyor transporting the envelope sheet. The edges of the envelope sheet are provided with adhesive, whereupon the envelope sheet is wrapped around the inserts with a buckle folding system.

As such, devices, systems, and methods of creating a mailpiece containing printed insert materials without the need to use pre-assembled envelopes are disclosed herein.

The subject matter of the present invention is defined by the independent claims.

The subject matter described herein relates to creating mailpieces in an automated fashion from cut paper or a continuous web of paper to form the envelopes of each mailpiece around printed insert material that is positioned on the envelope during creation of the mailpiece.

In one example embodiment, a system is provided according to claim <NUM>.

In another such example embodiment, a method of folding an envelope sheet around one or more insert sheets to create a mailpiece is provided according to claim <NUM>.

In yet another non-claimed example embodiment, a device configured to sequentially receive and dispense one or more insert sheets as an insert stack onto an adjacent envelope sheet is provided. According to this embodiment, the device comprises: a holding slot for the insert stack; a stop gate disposed at an exit of the holding slot; and a mechanical linkage system configured to produce first and second motion profiles from a single input, the mechanical linkage system comprising: a motor configured to generate a locomotive force, wherein the locomotive force is the single input; a crank arm that is connected to the motor; a coupler linkage coupled, at a first end, to the crank arm via a coupler bearing and, at a second end, to a pivot bearing; a first linkage subassembly rotatably connected, at a first end, to the coupler linkage at the pivot bearing and comprising a stop gate arranged at a distal end of the first linkage subassembly, the single input being transmitted to the first linkage subassembly through the pivot bearing to generate the first motion profile, wherein the first motion profile is a rotary movement of the stop gate along a stop gate travel path; one or more insert drive rollers arranged so that one or more portions thereof protrude, at least partially, through a bottom side of the holding slot; one or more insert idler rollers arranged substantially vertically over the one or more insert drive rollers; a second linkage subassembly rotatably connected, at a first end, to the coupler linkage at the pivot bearing and comprising the one or more insert idler rollers, the single input being transmitted to the second linkage subassembly through the pivot bearing to generate the second motion profile, wherein the second motion profile is a substantially vertical movement of the one or more insert idler rollers about an idler pivot; wherein the mechanical linkage system is configured such that the single input simultaneously causes the first and second motion profiles of the stop gate and the one or more insert idler rollers, respectively, and wherein the first and second motion profiles are different from each other.

In still another non-claimed example embodiment, a system configured to create a mailpiece with an external envelope folded around one or more insert materials is provided. According to this embodiment, the system comprises: one or more insert feeders configured to dispense one or more insert sheets onto an insert transport plate, wherein the one or more insert sheets from each insert feeder are stacked sequentially on top of each other to form an insert stack; an insert assembly transport belt configured to transport the insert stack on top of the insert transport plate; an envelope sheet feeder configured to dispense an envelope sheet onto an envelope transport plate; an envelope conveyor configured to transport the envelope sheet along the envelope transport plate by an envelope conveyor belt, wherein a speed of the insert assembly transport belt is different from a speed of the envelope conveyor belt; an insert stager located adjacent to the envelope conveyor at a merge region, wherein the insert stager is configured to: receive the insert stack from the insert assembly transport belt; hold the insert stack until triggered by a merge optical sensor to dispense the insert stack; and dispense, at a same time as or after the merge optical sensor detects the envelope sheet at a dispensing position, the insert stack onto an insert area of the envelope sheet, wherein the envelope sheet is in continuous motion while the insert stack is dispensed thereon; one or more adhesive applicators that are configured to apply an adhesive proximate to lateral edges of the envelope sheet in at least a portion of the insert area thereof; a buckle folder comprising: a fold plate arranged out of a plane defined by a direction of travel of the envelope sheet; a fold diverter configured to divert a leading edge of the envelope sheet onto the fold plate when triggered from a rest position into an actuated position at a same time as or after a diverter optical sensor detects the leading edge of the envelope sheet; a fold plate stop bar configured to prevent the leading edge of the envelope sheet from moving beyond a position on the fold plate, the position corresponding to a size of the envelope sheet, the insert stack, and/or the mailpiece; wherein the fold diverter is configured to move back to the rest position before or at a same time as the leading edge of the envelope sheet contacts the fold plate stop bar; a first plurality of transport rollers that are configured to drive the envelope sheet past the one or more adhesive applicators, onto the fold plate until the leading edge of the envelope sheet contacts the fold plate stop bar, and, after the leading edge of the envelope sheet contacts the fold plate stop bar, underneath the fold plate; a second plurality of transport rollers located behind the fold plate which are configured to fold the envelope sheet at an envelope primary fold point; one or more adhesive sealing rollers that are substantially aligned with the edges of the envelope sheet along which the adhesive is dispensed by the one or more adhesive applicators, wherein the one or more adhesive sealing rollers are configured to apply a compressive force to seal a back region of the envelope sheet onto the insert region of the envelope sheet, thereby forming an unsealed envelope; one or more right angle turn (RAT) modules configured to turn the unsealed envelope by substantially <NUM> degrees; a pair of crease rollers configured to form an envelope flap crease line at a bottom edge of a flap region of the unsealed envelope;
an adhesive applicator configured to dispense an adhesive onto the flap region; a plow fold guide and plow folder configured to fold the flap region over to cover, at least partially, the back region of the unsealed envelope; a flap sealer configured to compressively seal the flap region onto the back region, thereby sealing the unsealed envelope to form the mailpiece; and an output receptacle configured to receive the mailpiece.

The subject matter described in this specification may be implemented in hardware, software, firmware, or combinations of hardware, software and/or firmware. In some examples, the subject matter described in this specification may be implemented using a non-transitory computer readable medium storing computer executable instructions that when executed by one or more processors of a computer cause the computer to perform operations. Computer readable media suitable for implementing the subject matter described in this specification include non-transitory computer-readable media, such as disk memory devices, chip memory devices, programmable logic devices, random access memory (RAM), read only memory (ROM), optical read/write memory, cache memory, magnetic read/write memory, flash memory, and application specific integrated circuits. In addition, a computer readable medium that implements the subject matter described in this specification may be located on a single device or computing platform or may be distributed across multiple devices or computing platforms.

Embodiments of the presently disclosed subject matter having been stated hereinabove, and which is achieved in whole or in part by the presently disclosed subject matter, other embodiments will become evident as the description proceeds when taken in connection with the accompanying Examples as best described hereinbelow.

The presently disclosed subject matter can be better understood by referring to the following figures. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the presently disclosed subject matter (often schematically). In the figures, like reference numerals designate corresponding parts throughout the different views. A further understanding of the presently disclosed subject matter can be obtained by reference to an embodiment set forth in the illustrations of the accompanying drawings. Although the illustrated embodiment is merely exemplary of systems for carrying out the presently disclosed subject matter, both the organization and method of operation of the presently disclosed subject matter, in general, together with further objectives and advantages thereof, may be more easily understood by reference to the drawings and the following description. The drawings are not intended to limit the scope of this presently disclosed subject matter, which is set forth with particularity in the claims as appended or as subsequently amended, but merely to clarify and exemplify the presently disclosed subject matter. Portions for subassemblies have been omitted from the drawings in order to make otherwise occluded components visible.

For a more complete understanding of the presently disclosed subject matter, reference is now made to the following figures ("FIGS. "), in which:.

The presently disclosed subject matter now will be described more fully hereinafter, in which some, but not all embodiments of the presently disclosed subject matter are described. Indeed, the presently disclosed subject matter can be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements.

The terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be interpreted as in any way limiting the presently disclosed subject matter.

All technical and scientific terms used herein, unless otherwise defined below, are intended to have the same meaning as commonly understood by one of ordinary skill in the art. References to techniques, structures, devices, and steps employed herein are intended to refer to such techniques, structures, devices, and steps as they are commonly understood in the art, including variations on those techniques, structures, devices, and steps or substitutions of equivalent techniques, structures, devices, and steps that would be apparent to one of skill in the art. While the following terms are believed to be well understood by one of ordinary skill in the art, the following definitions are set forth to facilitate explanation of the presently disclosed subject matter.

In describing the presently disclosed subject matter, it will be understood that a number of techniques, structures, devices, and steps are disclosed. Each of these has individual benefits associated therewith, and each can also be used in conjunction with one or more, including all, of the other disclosed techniques, structures, devices, and steps.

Accordingly, for the sake of clarity, this description will refrain from repeating every possible combination and permutation of the individual steps in an unnecessary fashion.

Following long-standing patent law convention, the terms "a", "an", and "the" refer to "one or more" when used in this application, including the claims. Thus, for example, reference to "a tool" includes not only a single tool, but also a plurality of such tools, and so forth.

Unless otherwise indicated, all numbers expressing quantities of structures, elements, devices, steps, reaction conditions, and so forth used in the specification and claims are to be understood as being modified in all instances by the term "about. " Accordingly, unless indicated to the contrary, the numerical parameters set forth in this specification and attached claims are approximations that can vary depending upon the desired characteristics, behaviors, etc., sought to be obtained by the presently disclosed subject matter.

As used herein, the terms "about," "substantially," "approximately," and any other such synonymous terminology, when referring to a value, a degree, or an amount of a composition, mass, weight, temperature, time, volume, concentration, percentage, etc., is meant to encompass variations of, for example, ±<NUM>% in some embodiments, ±<NUM>% in some embodiments, ±<NUM>% in some embodiments, ±<NUM>% in some embodiments, ±<NUM>% in some embodiments, ±<NUM>% in some embodiments, ±<NUM>% in some embodiments, and ±<NUM>% in some embodiments from the specified amount, degree, or amount, as such variations would be known by those having ordinary skill in the art as being appropriate to construct and/or operate the disclosed devices and/or systems, perform the disclosed methods, and/or employ the disclosed compositions.

The term "comprising", which is synonymous with "including," "containing," or "characterized by," is inclusive or open-ended and does not exclude additional, unrecited elements or method steps. "Comprising" is a term of art used in claim language which means that the named elements are essential, but other elements can be added and still form a construct within the scope of the claim.

As used herein, the phrase "consisting of" excludes any element, step, or ingredient not specified in the claim. When the phrase "consists of" appears in a clause of the body of a claim, rather than immediately following the preamble, it limits only the element set forth in that clause; other elements are not excluded from the claim as a whole.

As used herein, the phrase "consisting essentially of" limits the scope of a claim to the specified materials, devices, structures, behaviors, or steps, plus those that do not materially affect the basic and novel characteristic(s), behavior(s), etc., of the claimed subject matter.

With respect to the terms "comprising", "consisting of", and "consisting essentially of", where one of these three terms is used herein, the presently disclosed and claimed subject matter can include the use of either of the other two terms.

As used herein, the term "and/or" when used in the context of a listing of entities, refers to the entities being present singly or in combination. Thus, for example, the phrase "A, B, C, and/or D" includes A, B, C, and D individually, but also includes any and all combinations and subcombinations of A, B, C, and D.

<FIG> is a schematic diagram of a mailpiece inveloping system, generally designated <NUM>, which is configured to generate at least one (e.g., a plurality) sealed envelope from a sheet of paper (or any suitable fibrous material), using a buckle folder so that each envelope contains one or more insert (e.g., "printed insert material) therein. In forming the envelope, the envelope sheet moves through system <NUM> at a substantially constant speed, including when the one or more insert is positioned on a designated area of the envelope sheet.

As can be seen in <FIG>, three insert feeders 30A, 30B, and 30C are positioned in an insert transport path, generally designated <NUM>, which is parallel to and/or vertically above (e.g., higher than) a primary transport path, generally designated <NUM>, along which the envelope sheet and the inserts, after their merger with the envelope sheet, are transported. Primary transport path <NUM> is oriented along the direction of travel <NUM>, while insert transport path <NUM> is oriented to be substantially along the insert direction of travel <NUM>. In some embodiments, directions of travel <NUM> and <NUM> can be parallel to each other, substantially parallel to each other, or at an angle relative to each other (e.g., <NUM>°, <NUM>°, <NUM>°, <NUM>°, <NUM>°, or <NUM>° ± <NUM>°). It is contemplated that only a single insert feeder (e.g., 30C) is installed, that two insert feeders (e.g., two of 30A, 30B, and 30C are installed, or that more than three insert feeders (e.g., 30A, 30B, 30C,. , 30N) can be installed in or along insert transport path <NUM>. In embodiments where a plurality of insert feeders are installed in or along insert transport path <NUM>, one, some, or even all of such a plurality of insert feeders can be selectively disabled (e.g., electronically by computer <NUM> or manually by a human operator) so that less than all of the insert feeders will deposit (e.g., eject) an insert stored therein on top of inserts deposited on insert transport path <NUM> by "upstream" insert feeders (e.g., 30A is "upstream" of both 30B and 30C, while 30B is "upstream" of 30C but "downstream" of 30A).

In such embodiments where multiple inserts are being deposited onto insert transport path <NUM> by two or more (or all) of insert feeders 30A, 30B, and 30C, an insert stack is created, with the first insert in the stack being deposited by the furthest "upstream" insert feeder that is active (e.g., 30A) for the mailpiece being assembled, and the subsequent inserts to be included in the insert stack being deposited in a sequential manner on top of an insert deposited by an immediately "upstream" active insert feeder. For example, where the insert stack includes two inserts, the first, or primary, insert (e.g., the bottom insert of the insert stack) is deposited by insert feeder 30A onto insert transport path <NUM>, then the second, or secondary, insert (e.g., the top insert of the insert stack) is deposited by insert feeder 30B or 30C, whichever is active, on top of the first insert as the first insert is carried by active insert feeder 30B or 30C along insert transport path <NUM>. In another embodiment, where the insert stack has three inserts, insert feeder 30A deposits the first insert onto insert transport path <NUM>. The first insert then moves along insert transport path <NUM> to pass underneath, or otherwise adjacent to (e.g., beside), insert feeder 30B, which deposits a second insert on top of first insert, so as to at least partially cover the first insert. The first and second inserts then move along insert transport path <NUM> to pass underneath or otherwise adjacent to (e.g., beside), insert feeder 30C which deposits a third insert on top of first and second inserts, so as to at least partially cover the first insert, the second insert, or portions of both the first and second insert.

In embodiments where a plurality of inserts (e.g., an insert stack) is to be included in an assembled mailpiece, it is possible for the inserts to be arranged in the insert stack in any order, without regard for the dimensions of the respective inserts in the insert stack. However, in some such embodiments, the first insert at the bottom of the insert stack is the largest (e.g., in width, height, or thickness) insert, with each insert subsequently deposited in the insert stack having the same or smaller dimensions than the immediately adjacent insert. By this arrangement and in embodiments where each insert has a different shape and/or one or more dimension from the other inserts in the insert stack, the inserts can be arranged to provide a visually appealing "cascading" arrangement (e.g., where each insert is partially visible behind the insert which is arranged directly in front thereof) when the insert stack is front, rear, or side registered.

Regardless of the arrangement or the number of inserts included in the insert stack, the inserts are deposited one on top of each other along insert transport path <NUM>, and are held, at least temporarily, in an insert stager <NUM> until triggered to be deposited (e.g., ejected) out of insert stager <NUM> and onto a designated portion of a substantially flat envelope sheet being transported underneath, beside, or otherwise adjacent to insert stager <NUM> as the envelope sheet moves, along primary transport path <NUM>, from envelope sheet feeder <NUM> into merge region <NUM>, where the insert stack merges with the envelope sheet. The merged envelope sheet and insert stack move together in the direction of travel <NUM>, with substantially no relative movement therebetween, into adhesive applicator region <NUM>, where adhesive is applied along at least a portion of the sides of the envelope sheet. Next, the merged envelope sheet and insert stack enter a buckle folder system <NUM>, where the envelope is formed without any creasing or substantial bending of the insert stack. The merged envelope sheet and insert stack then enter the side adhesive sealer <NUM>, where the adhesive applied to the envelope sheet in adhesive applicator region <NUM> is activated (e.g., by pressure) to sealingly form the envelope. After the envelope is adhesively sealed on the lateral sides thereof, a right angle turn (RAT) module <NUM> changes the direction of travel <NUM> of the partially formed envelope, without actually rotating the envelope, so that the envelope is then bottom edge registered by a bottom edge justifier <NUM>. The use of RAT module <NUM> allows for system <NUM> to occupy a more compact footprint where an operator can access the majority of the components therein from a single position, rather than having to traverse the length of system <NUM>, thus allowing for faster error intervention and correction, reducing downtime of system <NUM>. In some embodiments, the envelope itself can be turned rather than having its direction of travel <NUM> changed. Once the envelope is bottom edge registered, a crease for folding the flap and sealing the envelope is formed passing the envelope through a flap creaser <NUM> at a position designated for the crease line. After the crease is formed, adhesive is applied, using a flap adhesive applicator <NUM>, to the flap and/or an adjacent part of the rear portion of the envelope, against which the flap will be sealed. With the adhesive applied to seal the flap to the rear portion of the envelope, the envelope passes through flap plow folder <NUM>, which bends the flap over, and then through a flap sealer <NUM> which activates the adhesive (e.g., by pressure) to seal the flap portion against the rear portion of the envelope. One or more of flap creaser <NUM>, flap adhesive applicator <NUM>, flap plow folder <NUM>, and/or flap sealer <NUM> can be collectively referred to as "envelope closing system" <NUM>. Finally, the sealed envelope is deposited into an output section <NUM>, such as a basket, tray, cart, conveyor, or any suitable mailpiece receptacle and/or transport device.

System <NUM> is configured to be controlled by a computer <NUM>, using information obtained from a server <NUM>. Computer is configured for control, either remote or local, by an operator by a user terminal <NUM>. In some embodiments, server <NUM> has a list of "jobs" in a queue, with the "jobs" being orders for mailpieces that need to be created. In some such embodiments, one or more of the "jobs" may direct an operator to change one or more setting or component of system <NUM> for the particular mailpiece assembly job to be performed. For example, where a unique invoice is to be included in each mailpiece, the operator may be instructed to place such invoices into one of the insert feeders 30A, 30B, and 30C for insertion into each of the mailpieces. The operational throughput (e.g., volume of mailpieces), errors, warnings, envelope sheet size, insert stack size, and any other operational parameters can be input by and/or displayed to an operator through user terminal <NUM> and transmitted to and/or from computer <NUM>, so that when an error condition (e.g., a paper jam) is detected or an informational message (e.g., low paper) needs to be displayed, computer <NUM> can display such messages to the operator at user terminal <NUM>, thus directing the operator to the specific location of the error or the location to which the informational message pertains for corrective action. System <NUM> operation and control may be configured, in some embodiments, to use PLC (Programmable Logic Controller) components and a control panel (e.g., a user input device) for system operation. In some other embodiments, system <NUM> may be controlled by computer <NUM>. In still other embodiments, system <NUM> may be controlled by some combination of the components described above (e.g., PLC components, a control panel, and/or computer <NUM>). System <NUM> is configured to process and generate up to and including <NUM>,<NUM> mailpieces per hour. In some embodiments, system <NUM> can process and generate from as few as <NUM>,<NUM> and up to <NUM>,<NUM> mailpieces per hour. Regardless of the particular design aspects (e.g., throughput, size of envelope, etc.) of each design of such systems, these systems, are nevertheless simpler to build, maintain, and operate, as there are fewer moving parts to those known in the art, no suction is needed to open an envelope for insertion of the printed material(s), there is no flap opener needed to manipulate the envelope, etc..

Referring now to <FIG>, an envelope sheet feeder, generally designated <NUM>, is illustrated according to an example embodiment of system <NUM> of <FIG>. In the embodiment of <FIG>, envelope sheets <NUM> are contained within an envelope sheet hopper <NUM>. Envelope sheets <NUM> can be either plan paper stock or pre-printed with any suitable material (e.g., images and/or text). In some aspects, the plain paper stock can be advantageous in that there is no need to have pre-printed inventory, eliminating a common scenario where such pre-printed inventory becomes outdated (e.g., replaced with a new design) while in storage. Envelope sheets <NUM> are individually dispensed from envelope sheet hopper <NUM> by envelope sheet dispenser <NUM> and transported onto envelope conveyor <NUM>, which may be disposed on, or separate from, an envelope transport plate <NUM>, by one or more feeder rollers <NUM>. Once on envelope conveyor <NUM>, envelope sheets <NUM> are rear edge registered by one or more tabs <NUM> formed on or otherwise attached to one or more envelope conveyor belts <NUM>. These tabs <NUM> push envelope sheets <NUM> along envelope conveyer <NUM>. In the embodiment shown, envelope sheets <NUM> have an envelope window <NUM> formed therein. In some embodiments, envelope window <NUM> is covered by a glassine layer to protect the contents of the assembled mailpiece.

Envelope window <NUM> allows for unique printed information on an insert visible within an assembled mailpiece to be externally visible, such as would be necessary for address information to be visible for delivery. In some embodiments, a plurality of envelope windows <NUM> can be formed in envelope sheet <NUM>, enabling, for example, a return address to be visible. In such embodiments, envelope window <NUM> allows for unique mailings to be created based on insert contents and not based on unique printing on the outside of an assembled envelope. In some embodiments, envelope sheet hopper <NUM> and envelope sheet dispenser <NUM> can be replaced with a paper dispenser and cutter <NUM>, which is configured to form the envelope sheets <NUM> from a continuous web (e.g. roll) of paper that is cut to the proper size for a given assembled mailpiece. While envelope window <NUM> is shown already formed into envelope sheet <NUM>, it is possible in some embodiments for envelope window <NUM> to be formed in envelope sheet <NUM> "on demand" (e.g., during envelope assembly) by, for example, a laser cutting device or a die-cutting device. This can be especially useful where paper dispenser and cutter <NUM> is used, such that envelope sheets <NUM> are formed from a continuous web of paper, rather than from pre-cut paper stock, as is shown in <FIG>.

In <FIG>, an insert feeder, generally designated <NUM>, is shown located vertically above envelope conveyor <NUM>. While a single insert feeder <NUM> is shown, it is noted that a plurality of such insert feeders arranged sequentially is expressly contemplated (see, e.g., <FIG>) and, in fact, at least one such "upstream" insert feeder (e.g., 30A or 30B) is present and active in the example embodiment shown in <FIG>, as primary inserts <NUM> are moving underneath insert feeder <NUM> along insert transport path <NUM>, such that insert feeder <NUM> deposits secondary insert <NUM> on top of primary insert <NUM> as primary insert <NUM> moves adjacent to (e.g., underneath) insert feeder <NUM>. In this embodiment, all inserts, including primary insert <NUM> and secondary insert <NUM>, move at a constant speed along insert transport path <NUM> after being dispensed from a respective insert feeder <NUM> onto insert stack, generally designated <NUM>. Insert stack <NUM> moves along insert transport path <NUM>, being driven by insert assembly transport belt <NUM> and each of the inserts in insert stack <NUM> being rear edge registered by tabs <NUM> formed on or substantially fixedly attached to insert assembly transport belt <NUM>.

In some embodiments, a first insert assembly (e.g., 30A, see <FIG>) deposits a primary insert <NUM> (e.g., a control insert) onto insert assembly transport belt <NUM>, which is rear edge registered by tabs <NUM>. Next, as primary insert <NUM> moves into a second position (e.g., under or adjacent to a first insert assembly, such as 30B in <FIG>), a secondary insert <NUM> is inserted on top of primary insert <NUM>, thus creating insert stack <NUM>. In some embodiments, one or more further inserts (e.g., a tertiary insert, et seq. ) may be deposited onto insert stack. Each insert of insert stack <NUM> is rear edge registered by tabs <NUM>. Such rear edge registering can further be provided by precisely timed depositing of the secondary (and further) inserts onto insert stack <NUM>, as well as by normal operational vibration levels, which act to reduce relative friction between the inserts within insert stack <NUM>. Also, the inserts may be deposited from insert feeders <NUM> at a speed that is less than the speed at which insert assembly transport belt <NUM> is moving, such that the relative difference in speeds causes the upper insert of insert stack <NUM> to slide backwards, relative to the insert stack, towards and into contact with tabs <NUM> as the upper insert of insert stack <NUM> is accelerated to the same speed as insert stack <NUM> and insert assembly transport belt <NUM>. In some embodiments, a stationary upper belt (or portion thereof) can use friction to drag against the top surface of the upper insert of insert stack <NUM>, thereby rear-edge registering each insert in insert stack <NUM> against the tabs <NUM>.

The depositing of the inserts (e.g., <NUM> and <NUM>) onto insert stack <NUM> is precisely controlled. In some embodiments, the speed at which insert assembly transport belt <NUM> is moving along insert transport path <NUM> is known, such that a known spacing of insert assemblies (e.g., 30A, 30B, and 30C) along insert transport path <NUM> can be used to deposit an insert onto insert transport plate <NUM> at a calculated frequency and/or period. In some other embodiments, an optical sensor can be used to detect a leading edge of insert stack <NUM>, tabs <NUM>, and/or an optical marking on insert assembly transport belt <NUM>, which indicates a position of insert stack <NUM> relative to one or more (e.g., each) insert feeder <NUM>, such that, when the optical sensor is triggered, an electronic signal is sent for insert feeder <NUM> to deposit (e.g., eject) an insert (e.g., <NUM> or <NUM>) onto insert transport plate <NUM> to become part of insert stack <NUM> or, in the case where primary insert <NUM> is being deposited, to be a first insert of an insert stack <NUM> being created. In some embodiments, insert stack <NUM> may have only a single insert, such as primary insert <NUM>. In some other embodiments, one or more of the inserts of insert stack <NUM> (e.g., <NUM> and/or <NUM>) can be a pre-folded sheet of paper (e.g., bi-folded or tri-folded). In the embodiment shown, each insert added onto insert stack <NUM> is dimensionally smaller in at least one dimension than the preceding insert of insert stack <NUM>. In some embodiments, one or more of the inserts of insert stack <NUM> (e.g., <NUM>, <NUM>, et. ) can be a same size as, or even larger than, a previously deposited insert of insert stack <NUM>. Due to the dimensional differences between insert stack <NUM> and envelope sheet <NUM>, insert stack <NUM> moves along insert transport path <NUM> at substantially half the speed at which envelope sheet <NUM> moves along primary transport path <NUM>. Other speed ratios between the primary and insert transport paths <NUM> and <NUM> are possible, depending on the dimensions of insert stack <NUM>, envelope sheet <NUM>, and/or the spacing of tabs <NUM> formed on or attached to insert assembly transport belt <NUM>, which is configured to move insert stack <NUM> along insert transport path <NUM>. In the example embodiment shown and described herein, the nominal speed difference of envelope sheet <NUM> and insert stack <NUM> along the primary transport path <NUM> and the insert transport path <NUM>, respectively, is a two-to-one ratio, wherein the transport speed of envelope sheet <NUM> is double the transport speed of insert stack <NUM>. This speed ratio improves the reliability of the placement of insert stack <NUM> onto envelope sheet <NUM> relative to envelope fold point <NUM> (see, e.g., <FIG>). The speed ratio improves the probability of placement of insert stack <NUM> on, or slightly trailing, envelope fold point <NUM>. In such a manner, error tolerances will not accumulate to where insert stack <NUM> is placed in a leading position, relative to envelope fold point <NUM>, which would result in insert stack <NUM> entering buckle folder system <NUM>, causing a malfunction (e.g., a paper jam) that would require manual intervention by one or more operators.

Still referring to <FIG>, once insert stack <NUM> is transported to an end of insert transport plate <NUM>, insert stack <NUM> enters an insert stager <NUM>, where an insert stack <NUM> is held to be deposited onto envelope sheet <NUM>. Insert stager <NUM> is located within merge region <NUM>, where insert stack <NUM> merges with and is deposited on top of at least a portion of envelope sheet <NUM>. At the transition between insert transport plate <NUM> and stager transport plate <NUM>, the locomotion of insert stack <NUM> is transferred from being controlled by tabs <NUM> to one or more stager transport belts <NUM>, which is configured to be located over at least a portion of the length of stager transport plate <NUM>; at this transition point, stager transport belts <NUM> accelerate insert stack <NUM> away from tabs <NUM> to prevent "sniping" of the trail edge of insert stack <NUM> by the rotation of tabs <NUM> at the transition point. Stager transport belts <NUM> are configured to be inboard and/or outboard from tabs <NUM>. Stager transport belts <NUM> are disposed to be on top of and in contact with insert stack <NUM>, but in some embodiments, stager transport belts can be above and/or below insert stack <NUM>. Insert stack <NUM> passes by one or more (e.g., a plurality of) insert side jogger rollers <NUM>, which are set at a width corresponding to a width of a widest insert sheet (e.g., the first, or control, sheet, or any subsequently deposited sheet) in insert stack <NUM> and vibrate insert stack <NUM> to facilitate the front edge justification, and also to correct conditions where the inserts (e.g., <NUM> and <NUM>) in insert stack <NUM> may be skewed relative to one another. In some embodiments, stepper motors, servo actuators, and the like, are used to ensure that both side jogger rollers <NUM> are in/out at the same time such that the insert stack <NUM> is vibrated effectively, rather than merely being shifted side to side. Additionally, a photocell may be used to determine the relative positions of the side jogger rollers at startup to ensure that their positions are sufficiently synchronized during operation. In some embodiments, stager transport belt <NUM> is configured to accelerate insert stack <NUM> along stager transport plate <NUM>, such that the inserts of insert stack <NUM> become forward edge registered against the stop gate <NUM>, as shown in <FIG>, within the insert stager <NUM>. Once an insert stack <NUM> is held within insert stager <NUM>, insert stack <NUM> is held in a substantially fixed position to be deposited onto envelope sheet <NUM> when triggered.

Primary transport path <NUM> is arranged vertically beneath insert transport path <NUM>, such that primary transport path <NUM> is substantially parallel with insert transport path <NUM>. In some embodiments, insert transport path <NUM> may be disposed above, below, beside, adjacent to, and/or at an angle (or any combination thereof) relative to primary transport path <NUM>. As shown in the example embodiment of <FIG>, envelope sheet(s) <NUM> moves along envelope transport plate <NUM> of envelope conveyor <NUM>, in direction of travel <NUM>. Envelope sheet <NUM> is side edge registered (e.g., right or left side edge) by envelope edge justifier <NUM>, while also being rear edge registered by envelope conveyor belt tabs <NUM>; in some embodiments, the side edge registering occurs simultaneous with the rear edge registering in the form a push pins moving through an angled ball registration device. In some embodiments, envelope edge justifier <NUM> can be omitted. After being side and/or rear edge registered, envelope sheet <NUM> moves into merge region <NUM>, which will be discussed further in more detail for <FIG> and in <FIG>.

Insert stager <NUM> is a critical component of system <NUM>, as it collects and stages inserts <NUM>, <NUM> in a holding slot <NUM>, and releases (e.g., ejects) the insert stack <NUM> onto envelope sheet <NUM>, traveling adjacent to (e.g., underneath) insert stager <NUM> at the same speed as envelope sheet <NUM> moves along conveyor. This is a complex process that requires precise positioning of insert stack <NUM> on top of envelope sheet <NUM>.

In some embodiments, it is advantageous to control dispensing of insert stack <NUM> onto envelope sheet <NUM> so that a relative position of insert stack <NUM> and envelope sheet <NUM> is maintained within a range of several millimeters (e.g., within <NUM>, within <NUM>, within <NUM>, or within <NUM>). Those having skill in the art will understand that the degree of precision in dispensing insert stack <NUM> onto envelope sheet <NUM> will also vary depending on the physical dimensions (e.g., size) of insert stack <NUM> relative to the insert region of the envelope (see, e.g., <NUM>, <FIG>). For example, where insert stack <NUM> is substantially a same size (e.g., within <NUM>, within <NUM>, within <NUM>, or within <NUM>) as the insert region of the envelope, it is much more critical to ensure precise dispensing of insert stack <NUM> onto envelope sheet <NUM> so that no portion of insert stack <NUM> extends beyond the envelope primary fold point (see, e.g., <NUM>, <FIG>), such that no portion of insert stack <NUM> is folded during formation of the mailpiece. However, when insert stack <NUM> is significantly smaller (e.g., smaller by at least <NUM>, <NUM>, <NUM>, etc.) than the insert region of envelope sheet <NUM>, the positioning of insert stack <NUM> on envelope sheet <NUM> need not be as precise, allowing for wider variations in placement of insert stack <NUM> on envelope sheet <NUM>. The lateral placement of insert stack <NUM> on envelope sheet <NUM> is of similar importance to ensure that no portion of insert stack <NUM> is dispensed into a region where the adhesive will be dispensed, in which case, the mailpieces created will be defective.

Where necessary, this precise positioning can be achieved by controlling a timing of the operation of insert stager <NUM> to dispense insert stack <NUM> the movement of envelope sheet <NUM> along primary transport path <NUM> and the one or more insert feeders <NUM>. These functions are typically, according to the teachings of the prior art, accomplished using a variety of each of photocells, linear actuators, solenoids, motors, encoders, and complex control logic. According to the subject matter disclosed herein, system <NUM> achieves these functions in a cost effective manner, while still achieving a high throughput (e.g., as many as <NUM>,<NUM> mailpieces per hour) without mailpiece damage or high rates of malfunctions (e.g., from paper jams, misfires, misalignments, and the like). Here, however, insert stager <NUM> has a comparatively less complex control scheme, which employs a mechanical linkage system, generally designated <NUM> (see <FIG>) to achieve the functionality needed for the operation of insert stager <NUM>.

As can be seen in at least <FIG>, insert stager <NUM> includes a complex mechanical linkage system <NUM> to control an output of insert stager <NUM>. Mechanical linkage system <NUM> includes a motor <NUM>, a plurality of linkages, or bars, such as crank arm <NUM>, coupler linkage <NUM>, stop gate rocker arm <NUM>, idler rocker arm <NUM>, insert idler linkage arm <NUM>, stop gate connection bar <NUM>, and insert idler support spring <NUM>, and a plurality of pivot points, such as coupler bearing <NUM>, pivot bearing <NUM>, insert idler pivot bearing <NUM>, idler bearing <NUM>, and stop gate pivot bearing <NUM>, about which the respective linkages of mechanical linkage system <NUM> rotate. In the arrangement shown in <FIG>, motor <NUM>, crank arm <NUM>, and coupler linkages <NUM> are connected together to transfer a locomotive force from motor <NUM> to first and second linkage subassemblies <NUM> and <NUM>, respectively. First and second linkage subassemblies <NUM> and <NUM> generate first and second motion profiles using the single input from motor <NUM>, which is transmitted to the first and second linkage subassemblies <NUM> and <NUM> through pivot bearing <NUM>, via crank arm <NUM> and coupler linkage <NUM>.

First and second motion profiles are different from each other. In the embodiment shown, first motion profile is illustrated as stop gate travel path <NUM>, which has a curved profile. Second motion profile is illustrated as insert idler roller travel path <NUM>, which is substantially vertically oriented (e.g., having a radial component of motion as it rotates around statically fixed idler bearing <NUM>), relative to stager transport plate <NUM>. Depending on the travel paths desired for stop gate <NUM> and insert idler rollers <NUM>, respectively, the components of mechanical linkage system <NUM> can be designed in any suitable fashion to produce the desired first and second motion profiles. The functionality of this mechanical linkage system <NUM> will be discussed in greater detail with respect to <FIG>. The design is complex, yet yields the functionality needed for mailpiece inveloping at the cost point required. Maintenance also is reduced since all required movement is produced by a single motor <NUM>. The insert stager <NUM> is configured for operation without an encoder being needed for positional detection or operation of the stager, via the mechanical linkage system <NUM> described herein.

Referring now to <FIG>, detailed side and perspective views of insert stager <NUM> are shown. According to this embodiment and as shown in <FIG>, insert stack, generally designated <NUM>, has two inserts, primary insert <NUM> and secondary insert <NUM>. Insert stack <NUM> is held in place in holding slot, generally designated <NUM>, within insert stager <NUM> by stop gate <NUM> until insert stager <NUM> is triggered to deposit insert stack <NUM> out of insert stager <NUM>. Stop gate <NUM> can be one piece, two pieces (or more), and has, in some embodiments, a radiused portion 260R (e.g., having a radius of about <NUM> inches) at the front face of the stop gate <NUM> where the insert stack impacts the stop gate during accumulation of the inserts <NUM> and <NUM>. Insert stack <NUM> is now front registered within holding slot <NUM>, such that the leading edge of each insert sheet of insert stack <NUM> (e.g., both primary insert <NUM> and secondary insert <NUM>) are both adjacent to and/or in direct contact with stop gate <NUM>. As will be seen in <FIG>, insert stager <NUM> is actually inclined with respect to gravity, such that both primary insert <NUM> and secondary insert <NUM> are front edge registered against stop gate <NUM>. Insert stack <NUM> is also held between insert guide plate <NUM> and stager transport plate <NUM>.

In the illustrations of <FIG>, primary insert <NUM>, secondary insert <NUM>, stager transport plate <NUM>, and insert guide plate <NUM> are shown being physically separated from each other to provide added clarity of the view shown, but these elements will, at various points in time during normal operation, come into contact with one or more of these other structures. Cyclic movement of the components of the insert stager <NUM> are accomplished via translation of a single input (e.g., a rotary force output from motor <NUM>) to drive distinctly different motion profiles of stop gate <NUM> and insert idler roller <NUM>, respectively, via a complex mechanical linkage system <NUM> (see <FIG>). This arrangement allows for a repeatable cyclic motion profile (e.g., a smooth sinusoidal motion), with a controlled motion profile at impact to allow for quieter operation, less impact force, less wear on components, less damage to mailpieces, and increased reliability of insert stager <NUM>. The insert idler roller <NUM> moves sinusoidally over a controlled path, gradually increasing force (e.g., having an analog characteristic) on insert stack <NUM>, while stop gate <NUM> also moves over a defined path without sudden (e.g., impulsive) motion. An example motion path for the mechanical linkage system <NUM> is shown in <FIG>, which will be described in greater detail below.

Damage to the leading edge of insert stack <NUM> is minimized, starting at the transition of inserts <NUM>, <NUM> from being driven by insert assembly belt tabs <NUM> onto stager transport plate <NUM>, which is inclined with respect to gravity (see, e.g., <FIG>). Inserts <NUM>, <NUM> are driven along stager transport plate <NUM> by stager transport belts <NUM>, which are, in some aspects, frictional drive belts. Stager transport belts accelerate inserts <NUM>, <NUM> away from tabs <NUM> to prevent sniping of the rear edges thereof by tabs <NUM>, then slows inserts <NUM>, <NUM> to maintain an effectively constant speed along insert transport path <NUM>, so that each insert stack <NUM> moves the same distance for every cycle of the machine. In some embodiments, programmable motors and/or one or more variable cam mechanisms can be used to produce a repeatable variability of the speed of insert stack <NUM>. Inserts <NUM> and <NUM> are released from the friction belts after having traversed approximately half of the length of stager transport plate <NUM>. Inserts <NUM>, <NUM> then traverse the remainder of the length of stager transport plate <NUM>, into holding slot <NUM>, by momentum and the vibration created by insert side jogger rollers <NUM>. This method results in a very gentle impact into the stop gate <NUM>, hence no damage to the leading edges of inserts <NUM>, <NUM> from striking stop gate <NUM>. In some embodiments, stop gate <NUM> has, at each end thereof (e.g., adjacent to the outer edges of insert stack <NUM>), a radiused portion 260R which prevents damage to the leading edges of inserts <NUM>, <NUM> from striking stop gate <NUM>. In some embodiments, where stop gate <NUM> comprises a plurality of separate portions, each end of each portion may have such a radiused portion 260R.

Damage is further reduced by having stop gate <NUM> move up and away from insert stack <NUM>, as illustrated in <FIG> and <FIG> by the motion profile of stop gate travel path <NUM>, instead of dragging stop gate <NUM> across the leading edge of insert stack <NUM>, as is commonly done by prior art designs, where stop gates are moved vertically, and are thus dragged across the leading edge of insert stack <NUM>. Stop gate travel path <NUM> facilitates the smooth ejection of insert stack <NUM> from holding slot <NUM> onto envelope conveyor <NUM> by moving away from insert stack <NUM> as insert idler roller <NUM> engages against insert stack <NUM> and compresses insert stack <NUM> against insert drive roller <NUM>. Variations in insert stack <NUM> ejection onto envelope conveyor <NUM> are a function of the frictional characteristics of the paper from which insert stack <NUM> is made, and the looseness of insert stack <NUM> within holding slot <NUM>. These variations in the ejection process, are accommodated by stop gate travel path <NUM>, further reducing the possibility of damage to the leading edges of inserts <NUM>, <NUM>.

In the embodiment shown, insert stager <NUM> operates through use of a complex mechanical linkage system, generally designated <NUM>, that is commonly driven by a single locomotive source. While the complex mechanical linkage system <NUM> of insert stager <NUM> is advantageous for the reasons noted hereinabove, in other embodiments, mechanical linkage system <NUM> can be replaced with any other suitable combination of mechanical linkage(s), as will be understood by those having ordinary skill in the art and, furthermore, may include two separately driven mechanical linkage systems. Non-limiting examples of such other possible mechanical linkages include pneumatic actuators, which suffer from a lack of feedback control, electromagnetic actuators, which generally require the use of mechanical snubbers/dampers to soften the impulsive nature of the impact (e.g., the driven motion), and a servo motor to control motion, e.g., a linear motion controlled servo-driven actuator, which suffers from excessive cost. A locomotive force is transmitted, here in a rotary fashion, from motor <NUM> into a crank arm <NUM>, which is fixedly connected to a first (e.g., proximal) end of a coupler linkage <NUM> via a coupler bearing <NUM>, which rotatably attaches coupler linkage <NUM> to crank arm <NUM>. Coupler linkage <NUM> simultaneously transmits the rotary movement of crank arm <NUM> to idler rocker arm <NUM> and stop gate rocker arm <NUM>, both of which are connected at their first (e.g., proximal) ends to the second (e.g., distal) end of coupler linkage <NUM> at pivot bearing <NUM>.

Idler rocker arm <NUM> is connected at its second (e.g., distal) end to one or more (e.g., two) insert idler rollers <NUM> to control the vertical movement thereof and is pivotably connected to idler pivot point <NUM> by an insert idler roller pivot arm <NUM>, which is fixed and and rotatable about idler pivot point <NUM>. Insert guide plate <NUM> is formed in the shape of a leaf spring, but is not driven by motor <NUM>. Instead, insert guide plate <NUM> is flexibly attached to the external housing of insert stager <NUM> and is configured to guide insert stack <NUM> into a staged position against stop gate <NUM>. A slot is formed through the thickness of insert guide plate <NUM> at least in a position vertically underneath insert idler rollers <NUM>, such that insert idler rollers <NUM> can move substantially vertically to press insert stack <NUM> against one or more (e.g., two) insert drive rollers <NUM> for ejection of insert stack <NUM> from insert stager <NUM>. These insert idler rollers are shown herein being disposed such that substantially all of insert drive rollers <NUM> are disposed beneath stager transport plate <NUM>, with only a portion of insert drive rollers <NUM> protruding beyond the upper surface of stager transport plate <NUM> and into holding slot <NUM>. In such embodiments, insert idler rollers <NUM> pass beyond the bottom surface of insert guide plate <NUM>, into holding slot <NUM>, to contact an upper surface of insert stack <NUM> (e.g., an upper surface of secondary insert <NUM>), thus compressively "sandwiching" insert stack <NUM> between insert idler rollers <NUM> and insert drive rollers <NUM> so that insert drive rollers <NUM> impart a driving ejection force to insert stack <NUM>.

In the embodiment shown in <FIG>, stop gate rocker arm <NUM> is connected, at its first (e.g., proximal) end, to coupler linkage <NUM> via pivot bearing <NUM> and, at its second (e.g., distal) end, to a stop gate pivot bearing <NUM>. Pivot bearing <NUM> is configured to move within insert stager <NUM>, whilst stop gate pivot bearing <NUM> is substantially rigidly fixed at a position within insert stager <NUM> (e.g., at or through a side housing of insert stager <NUM>), such that stop gate rocker arm <NUM> is not vertically displaceable, but instead is only rotatably movable around stop gate pivot bearing <NUM>. Stop gate connection bar <NUM> is rotatably movable around, at a first (e.g., proximal) end thereof, stop gate pivot bearing <NUM>, and is either fixedly attached to (e.g., by compression, such as a screw and nut arrangement) or integrally formed as part of (e.g., in a single piece with) stop gate rocker arm <NUM> at a second (e.g., distal) end thereof. Stop gate <NUM> is attached to and/or integrally formed as a single piece with stop gate connection bar <NUM>. In some embodiments, stop gate rocker arm <NUM>, stop gate connection bar <NUM>, and stop gate <NUM> form a single unitary structure (e.g., are integral, monolithic, and/or formed as a single piece). In some other embodiments, one or more of stop gate rocker arm <NUM>, stop gate connection bar <NUM>, and stop gate <NUM> are formed integrally with one or more of the other structures. In still other embodiments, each of stop gate rocker arm <NUM>, stop gate connection bar <NUM>, and stop gate <NUM> are formed discretely from each other and are substantially rigidly attached to each other in the manner described above.

Insert stager has a stop gate optical sensor <NUM>, which is configured to detect the presence of an insert stack <NUM> positioned within insert stager <NUM>, such that stop gate <NUM> will not be actuated from the first (e.g., closed) position to the second (e.g., open) position when no insert stack <NUM> is detected within insert stager <NUM>. A second set of drive and idler rollers, merge drive rollers <NUM> and merge idler rollers <NUM>, are arranged external to stop gate <NUM>. In some embodiments, merge drive rollers <NUM> and merge idler rollers <NUM> are configured to provide a secondary accelerative force to insert stack <NUM>, so that insert stack <NUM> merges onto a designated envelope sheet at substantially a same speed as the envelope sheet transport speed.

Referring now to <FIG>, an example embodiment of a mechanical linkage system, generally designated <NUM>, for an insert stager is shown at several positions of actuation thereof for the ejection of insert sheets. As seen in <FIG>, motor <NUM> provides (e.g., imparts) a locomotive rotary force to crank arm <NUM> in a direction indicated by motor direction <NUM> to drive the motion of stop gate <NUM>, through a first linkage subassembly, generally designated <NUM>, along a first motion profile defined by stop gate travel path <NUM> to control an ejection of insert stack (see, e.g., <NUM>, <FIG>) in a precisely timed and controlled manner onto an envelope sheet <NUM>. The movement of crank arm <NUM> along motor direction <NUM> also drives an oscillatory substantially vertically downward movement (e.g., having a radial component as it rotates around idler bearing <NUM>) of insert idler rollers <NUM>, through a second linkage subassembly, generally designated <NUM>, along a second motion profile defined by insert idler roller travel path <NUM>.

In the embodiment shown in <FIG>, but specifically in <FIG>, first linkage subassembly <NUM> is configured, via its connection to coupler linkage <NUM> at pivot bearing <NUM>, to receive the single input from motor <NUM> through crank arm <NUM>, coupler bearing <NUM>, coupler linkage <NUM>. First linkage subassembly <NUM>, in the embodiment shown, includes stop gate rocker arm <NUM>, stop gate pivot bearing <NUM>, stop gate connection bar(s) <NUM>, and stop gate <NUM>. Components may be added, modified, and/or omitted to achieve any of a plurality of desired motion profile outputs, as will be understood by those having ordinary skill in the art. Stop gate rocker arm <NUM> is rotatably connected at a first end thereof to coupler linkage <NUM> at pivot bearing <NUM>; as such, stop gate rocker arm <NUM> is configured to be driven, via coupler linkage <NUM> and pivot bearing <NUM>, through the stop gate rocker arm travel paths <NUM>, which varies according to a stage of actuation of mechanical linkage system <NUM>, three positions respectively being illustrated in <FIG>, <FIG>, and <FIG>. Stop gate rocker arm <NUM> is rotatably (e.g., pivotably) connected at its second end to stop gate pivot bearing <NUM>, which is spatially fixed (e.g., incapable of translatory movement during operation). Thus, because stop gate pivot bearing <NUM> is statically fixed (e.g., allows only rotary motion thereabout), stop gate rocker arm travel path <NUM> has a shape of an arc, as stop gate rocker arm <NUM> is only capable of rotary motion about stop gate pivot bearing <NUM>. One or more stop gate connection bars <NUM> are each rigidly connected at the respective first ends thereof to stop gate rocker arm <NUM>, such that the rotary motion of stop gate rocker arm <NUM> around stop gate pivot bearing <NUM> causes a corresponding (e.g., identical) angular rotation of the one or more stop gate connection bars <NUM> around stop gate pivot bearing <NUM>. In some embodiments, the one or more stop gate connection bars <NUM> and/or the stop gate rocker arm <NUM> may be connected to an intermediate structure that itself is fixed to (e.g., allowing rotary motion about) stop gate pivot bearing <NUM>. Stop gate <NUM> is connected to (e.g., integrally or removably) a second end of the one or more stop gate connection bars <NUM> and is arranged at an angle relative to a main portion of the one or more stop gate connection bars <NUM>, so that stop gate <NUM> can be arranged substantially orthogonal to (e.g., within <NUM>°, within <NUM>°, within <NUM>°, within <NUM>°, or within <NUM>°) the plane defined by stager transport plate (see, e.g., <NUM>, <FIG>) while the one or more stop gate connection bars <NUM> are arranged at a second, non-orthogonal, angle.

In the embodiment shown in <FIG>, but specifically in <FIG>, second linkage subassembly <NUM> is configured, via its connection to coupler linkage <NUM> at pivot bearing <NUM>, to receive the single input from motor <NUM> through crank arm <NUM>, coupler bearing <NUM>, coupler linkage <NUM>. Second linkage subassembly <NUM>, in the embodiment shown, includes idler rocker arm <NUM>, insert idler pivot bearing <NUM>, insert idler linkage arm <NUM>, insert idler roller <NUM>, insert idler roller support spring <NUM>, and idler pivot <NUM>. Components may be added, modified, and/or omitted to achieve any of a plurality of desired motion profile outputs, as will be understood by those having ordinary skill in the art. Idler rocker arm <NUM> is rotatably connected at a first end thereof to coupler linkage <NUM> at pivot bearing <NUM>; as such, idler rocker arm <NUM> is configured to be driven, via coupler linkage <NUM> and pivot bearing <NUM>, through the idler rocker arm travel path <NUM>, which has rotary and translatory components and the particular directions of which vary according to a stage of actuation of mechanical linkage system <NUM>, three positions respectively being illustrated in <FIG>, <FIG>, and <FIG>. Idler rocker arm <NUM> is rotatably (e.g., pivotably) connected at its second end to insert idler linkage arm <NUM> at insert idler pivot bearing <NUM>. In this embodiment, insert idler linkage arm <NUM> is generally "L" shaped and is a rigid structure that will not deform (e.g., will only elastically deform, without yielding in plastic deformation) during normal use. Insert idler linkage arm <NUM> and idler rocker arm <NUM> are able to rotate relative to each other at insert idler pivot bearing <NUM>. As coupler linkage <NUM> drives idler rocker arm <NUM> downwards and in a counterclockwise direction, insert idler linkage arm <NUM> rotates in the same counterclockwise direction around idler pivot <NUM>, which is rigidly fixed to the insert stager (e.g., at a housing thereof). Insert idler roller <NUM> is rotatably connected to insert idler linkage arm <NUM> and is positioned such that, as insert idler linkage arm <NUM> rotates in the counterclockwise direction about idler pivot <NUM>, insert idler roller(s) <NUM> will be substantially vertically aligned on top of (e.g., sufficiently to impart the compressive force to reliably dispense the insert stack from the insert stager, as those having ordinary skill in the art will appreciate) insert drive roller(s) <NUM>. Insert idler roller support spring <NUM> provides a spring force to insert idler linkage arm <NUM> that is in the same counterclockwise direction with respect to idler pivot <NUM>, in order to prevent bounding or stuttering of insert idler roller(s) <NUM> vertically away from insert drive roller(s) <NUM> as insert idler roller(s) <NUM> is driven downwards to apply the compressive force to the insert stack be engaging with insert drive roller(s) <NUM>.

Accordingly, through mechanical linkage system <NUM> described herein, a single input is used to produce two distinct motion profiles that are synchronized (e.g., simultaneous) with each other, each of the single input, the first motion profile, and the second motion profile having different aspects of motion.

As such, in the position illustrated in <FIG>, insert idler rollers <NUM> and stop gate <NUM> are in their respective first positions. When insert stager <NUM> is triggered to eject an insert stack <NUM>, crank arm <NUM> rotates along motor direction <NUM> to a second position, which is substantially diametrically opposite to the position shown in <FIG>. An intermediate position between the first and second positions is shown in <FIG>. While motor direction <NUM> is shown in a counter-clockwise direction, crank arm <NUM> can be rotated in either clockwise or counterclockwise directions by motor <NUM>.

As crank arm <NUM> moves from the first position in <FIG> towards the second position, passing through the intermediate position shown in <FIG>, the mechanical linkage system is driven to produce a movement of idler rocker arm <NUM>, which has both rotational and linear aspects along idler rocker arm travel path <NUM>, as shown in <FIG>. As idler insert idler rollers <NUM> along idler rocker arm travel path <NUM> to a second position of the one or more insert idler rollers <NUM>, which has both radial and vertical components of motion, and insert idler roller travel path <NUM>, respectively. Simultaneously, stop gate rocker arm <NUM> pivots radially about stop gate pivot bearing <NUM>, causing a corresponding (e.g., proportional) rotational movement of stop gate connection bar <NUM> and stop gate <NUM>, generally along stop gate travel path <NUM>, to the second position of stop gate <NUM>. As such, stop gate <NUM> is actuated to the second (e.g., open) position while insert stack <NUM> is compressively engaged between insert drive rollers <NUM> and insert idler rollers <NUM>, resulting in imparting the rotary drive force of insert drive roller <NUM> to insert stack <NUM>, causing the ejection of insert stack <NUM> out of insert stager <NUM> while stop gate <NUM> is in the second (e.g., open) position. Insert idler rollers <NUM> move in an approximately vertical direction (e.g., relative to the plane defined by holding slot <NUM>) downward from the up position, distinguished by the closed stop gate <NUM>. Insert idler linkage arm <NUM> is connected at a first end to idler rocker arm <NUM> and at a second end to idler pivot <NUM>. Insert idler linkage arm <NUM> also has a substantially rigid construction to limit flexure thereof as idler rocker arm <NUM> is driven vertically and rotationally by the connection thereof to coupler linkage <NUM> at pivot bearing <NUM>. Insert idler roller support spring <NUM> connects insert idler linkage arm <NUM> to idler pivot <NUM>. Idler rocker arm <NUM> is connected to insert idler linkage arm <NUM> at insert idler pivot bearing <NUM>. Insert idler roller support spring <NUM> design parameters are selected to prevent the insert idler <NUM> from bouncing upon impact with the top side of insert stack <NUM>. Selecting too weak of a spring force will result in the insert idler roller <NUM> bouncing upon contact, which can prevent the continuous ejection of insert stack <NUM> from insert stager <NUM>, as the ejection force transmitted to insert stack <NUM> by insert drive roller <NUM> will be intermittently decoupled from insert stack <NUM> when insert idler roller <NUM> bounces away from insert drive roller <NUM>. Selecting an insert idler roller support spring <NUM> that is too strong can cause a binding action, which can prevent the continuous ejection of insert stack <NUM> from insert stager <NUM>. In either case, when an insert idler roller support spring is selected which has an incorrect spring force, insert stack <NUM> may not be positioned correctly on envelope sheet <NUM> after ejection of insert stack <NUM> from insert stager <NUM>, resulting in a system malfunction (e.g., a paper jam) or defective mailpiece.

<FIG> shows a first position of the components of the mechanical linkage system, such that insert idler roller <NUM> is spaced apart from insert drive roller <NUM> and stop gate <NUM> is in a closed position. In the example embodiment shown, motor <NUM> drives the crank arm <NUM> in the direction of motor direction <NUM> to the position shown in <FIG>. As shown in <FIG>, insert idler roller <NUM> is in contact with insert drive roller <NUM> to impart the rotational driven motion of insert drive roller <NUM> to an insert stack, while stop gate <NUM> is in an open position to allow the dispensing of an insert stack from insert stager.

Continuing on to the second intermediate position of <FIG>, motor <NUM> is driven in the direction of motor direction <NUM>, as indicated in <FIG>. This further motion moves through the second (e.g., fully extended) positions of the mechanical linkage system, such that, as the mechanical linkage system is driven from the position shown in <FIG> to the position shown in <FIG>, stop gate rocker arm <NUM> initially moves in the direction indicated by stop gate rocker arm path 217A, before reversing the direction of travel along stop gate rocker arm path 217B. This movement is also reflected in the movement of stop gate <NUM>, which initially is driven in the direction of stop gate travel path 262A, before reversing the direction of travel of stop gate <NUM>, as indicated by stop gate travel path 262B. However, because insert idler roller <NUM> is already in contact with insert drive roller <NUM>, the movement of coupler linkage does not cause any substantial further movement of insert idler roller <NUM>, but instead this motion is accommodated by additional bending of insert idler support spring <NUM> relative to idler rocker arm <NUM> and insert idler linkage arm <NUM> at insert idler pivot bearing <NUM>.

<FIG> shows a second intermediate position of the components of mechanical linkage system, such that insert idler roller <NUM> is separated from insert drive roller <NUM> and, as crank arm <NUM> is rotated in the direction of motor direction <NUM>, insert idler roller <NUM> moves substantially vertically away from (e.g., having a radial component as it rotates around idler bearing <NUM>) insert drive roller <NUM>, this substantially vertical movement being indicated by insert idler roller travel path <NUM>, while idler rocker arm <NUM> moves and/or rotates in the directions indicated by idler rocker arm travel path <NUM>. As crank arm <NUM> and coupler linkage <NUM> are driven along the direction of motor direction, stop gate rocker arm <NUM> rotates in the direction of stop gate rocker arm path <NUM>, which causes a corresponding (e.g., proportional) rotation of stop gate <NUM> in the direction indicated by stop gate travel path <NUM>. As such, after the motion path indicated in <FIG> occurs, the mechanical linkage system will be in (e.g., pass through) substantially the first position illustrated in <FIG>.

Stop gate optical sensor <NUM> is configured to detect when insert stack <NUM> is no longer present and to send an electronic signal that initiates a rotary movement of crank arm <NUM> to the first position, as shown in <FIG>, such that one or more (e.g., two) insert idler rollers <NUM> vertically move away from one or more (e.g., two) insert drive rollers <NUM>, and stop gate <NUM> rotates back to the first (e.g., closed) position shown in <FIG>. Crank arm <NUM> can be configured to rotate about a full <NUM>° or can be configured to rotate only over substantially half (e.g., approximately <NUM>°) of a circular revolution in moving between the first and second positions.

As is shown in <FIG>, stop gate <NUM> moves radially along stop gate travel path <NUM>, as is controlled by the rotary movement of crank arm <NUM>, via a travel of stop gate rocker arm <NUM> along stop gate rocker arm path <NUM>, which is shown as pivoting radially around stop gate pivot bearing <NUM>. Stop gate <NUM> is shown in its first position in <FIG>, while the second position of stop gate lies at the opposite end of stop gate travel path <NUM> (see, e.g., other end of double arrow in <FIG> and <FIG>). Since stop gate rocker arm <NUM> is pivotably fixed at a distal end at stop gate pivot bearing <NUM>, as crank arm <NUM> rotates about motor <NUM>, the movement of stop gate rocker arm <NUM> along stop gate rocker arm travel path <NUM> drives stop gate <NUM> to radially pivot around stop gate pivot bearing <NUM> through the connection of stop gate <NUM> and stop gate connection bar <NUM> to stop gate pivot bearing <NUM>. Similarly, because both idler rocker arm <NUM> and stop gate rocker arm <NUM> are connected to coupler linkage <NUM> at a single pivotable connection point (e.g., pivot bearing <NUM>), idler rocker arm <NUM> moves at substantially a same frequency as the stop gate rocker arm <NUM>, such that idler rollers <NUM> are not engaged against drive rollers <NUM> (e.g., are in their first position) when stop gate <NUM> is in the position (e.g., the first position) shown in <FIG>. The complex motion described hereinabove can be, in some embodiments, accomplished by a single revolution e.g., around substantially <NUM>°) of motor <NUM>, thus reducing the control complexity needed for motor <NUM>. In some other embodiments, motor <NUM> can be controlled to rotate reciprocally (e.g., back-and-forth) through less than a full revolution, such as, for example, approximately <NUM>°.

Referring now to <FIG>, an insert stack <NUM> is disposed within insert stager <NUM>, prepared for ejection onto envelope sheet <NUM>, which is moving in direction of travel <NUM> along envelope transport plate <NUM>. In the respective positions of the elements in the embodiment shown, envelope sheet <NUM> is in the dispensing position, generally designated <NUM>, and, in this position, envelope sheet <NUM> is detected by merge optical sensor <NUM>, which triggers insert stager <NUM> to eject insert stack <NUM> from insert stager <NUM>, as described above in the description of <FIG>. Merge drive roller <NUM> is omitted from this view for clarity. Envelope sheet <NUM> is continuously moved at a substantially constant speed as insert stack <NUM> is ejected from insert stager <NUM> and deposited on top of envelope sheet <NUM>. In some embodiments, a computer (e.g., <NUM>, <FIG>) is configured to use the operational parameters, such as, for example, envelope sheet transport speed, signal latency of merge optical sensor <NUM>, the dimensions (e.g., length and/or width) of envelope sheet <NUM>, and/or the dimensions (e.g., length and/or width) of insert stack <NUM> to determine a precise timing setting for ejection of insert stack <NUM>, measured from the moment that merge optical sensor detects the leading edge <NUM> of envelope sheet <NUM>, such that insert stacks <NUM> are precisely and accurately deposited onto a designated area of envelope sheets <NUM>. In some embodiments, the timing for the delay between detection of the leading edge <NUM> of envelope sheet <NUM> and the ejection of insert stack <NUM> from insert stager <NUM> can be manually controlled, at least partially, by an operator. In some such instances, a computer sets an initial timing delay value based on one or more of the operational parameters noted above, and an operator is capable of fine-tuning (e.g., changing) this initial timing delay value based on performance of system <NUM>.

Referring now to <FIG>, envelope sheet <NUM> and insert stack <NUM> have been merged and the leading edge <NUM> of envelope sheet <NUM> is continuing to move at a substantially constant speed along envelope transport plate <NUM>, entering adhesive application region <NUM>. For clarity, insert stager <NUM> has been omitted from this view. While in adhesive application region <NUM>, an adhesive (e.g., a pressure-sensitive bonding glue) will be applied, using adhesive applicators <NUM>, over at least portions of the lateral sides of envelope sheet <NUM>, outside of insert stack <NUM>. Waste adhesive reservoirs <NUM> are disposed underneath each adhesive applicator <NUM>, to catch any excess adhesive that might otherwise be transferred to other portions of system <NUM>, causing defective mailpieces.

In this view, insert stack <NUM> is positioned on envelope sheet <NUM> so as to define, on one side of insert stack <NUM>, a flap region <NUM>, and, on a second side of insert stack <NUM>, a back region <NUM>. While it is contemplated that actual lines or creases may be formed on envelope sheet <NUM> along the broken lines defining flap region <NUM> and back region <NUM>, in the embodiment shown, the broken lines are phantom lines that are not in any way physically represented on envelope sheet <NUM>. As will be discussed further regarding other figures, the back of a finished mailpiece will be formed from the portion of envelope sheet <NUM> within back region <NUM>, while the flap of a finished mailpiece will be formed from the portion of envelope sheet <NUM> within flap region <NUM>. While the regions shown correspond to a "traditional" envelope shape, with back region <NUM> being significantly larger (e.g., <NUM>% or more) than the area assigned to flap region <NUM>, the sizes for the regions can be selected to have any size of back region <NUM> and flap region <NUM> by, for example, adjusting the position of insert stack <NUM> relative to the length of envelope sheet, adjusting a position (e.g., a height) of fold plate stop bar <NUM>, and/or adjusting or changing a configuration of the plow folder guide, the plow folder, and/or the flap sealer. (see, e.g., <NUM>, <NUM>, and <NUM>, respectively, in <FIG>.

Once transitioned into adhesive application region <NUM>, envelope sheet <NUM> will be engaged by and/or between a plurality of transport rollers <NUM>. The plurality of transport rollers <NUM> are configured to move envelope sheet <NUM> and insert sheet <NUM> at the same speed at which envelope sheet <NUM> moves in, for example, merge region (e.g., <NUM>, <FIG>). In some embodiments, the transport rollers <NUM> may be configured to move envelope sheet <NUM> at a slower or faster speed (e.g., to decelerate and/or accelerate envelope sheet <NUM>) than an entry speed of envelope sheet <NUM> into transport rollers <NUM>. In the embodiment of <FIG>, envelope sheet <NUM> and insert stack <NUM> are compressively engaged between opposing transport rollers <NUM> on top and bottom sides of envelope sheet <NUM> and insert stack <NUM>. Because leading edge <NUM> of envelope sheet <NUM> enters transport rollers <NUM> first, insert stack <NUM> enters transport rollers <NUM> after and on top of envelope sheet <NUM>. In some embodiments, a single set of transport rollers <NUM> may be disposed above envelope sheet <NUM>. Referring back to <FIG>, each of the plurality of transport rollers <NUM> is driven by transport roller drive motor <NUM>.

In the embodiments shown in <FIG>, three successive sets of transport rollers <NUM>, each set of transport rollers having a plurality of transport rollers <NUM>, are located serially along primary transport path <NUM>, such that leading edge <NUM> of envelope sheet <NUM> enters a first set of a plurality of transport rollers, generally designated 121A, then enters a second set of a plurality of transport rollers, generally designated 121B, and is then vertically diverted into a buckle folder system, generally designated <NUM>. Envelope sheet <NUM> is then pushed and/or drawn into a third set of a plurality of transport rollers, generally designated 121C in order to create the bottom edge of the mailpiece being formed (see, e.g., <FIG>). In some embodiments, one or more of the sets of a plurality of rollers 121A, 121B, 121C may have only a single transport roller <NUM> and/or may be omitted entirely. Each of the sets of a plurality of transport rollers 121A, 121B, 121C may be controlled independently or by a single motor. In the embodiment shown, each transport roller <NUM> rotates at substantially the same speed as each other transport roller <NUM>. In the embodiment shown, each of the plurality of transport rollers <NUM> and each of the plurality of adhesive sealing rollers <NUM> are drive by a roller drive belt <NUM>. In some embodiments, a plurality of such roller drive belts <NUM> may be provided.

As is shown in <FIG>, a first adhesive optical sensor <NUM> is disposed vertically above primary transport path <NUM> such that leading edge <NUM> of envelope sheet <NUM> is detected by first adhesive optical sensor <NUM> before being detected by a diverter optical sensor <NUM>. The behavior of first adhesive optical sensor <NUM> will be described in greater detail with respect to <FIG>. In this embodiment, when leading edge <NUM> is detected by diverted optical sensor <NUM>, fold diverter <NUM> is actuated to a diverted position, so that leading edge <NUM> is vertically diverted to run along fold plate <NUM>. Fold diverter <NUM> is actuated by fold diverter motor (see, e.g., <NUM>, <FIG>) based on an electrical signal received from diverter optical sensor <NUM>. In some embodiments, the signal from diverter optical sensor <NUM> is transmitted directly to the fold diverter motor. In other embodiments, the signal from diverter optical sensor <NUM> is transmitted to computer <NUM>, which can apply further operational parameters (e.g., a delay, a duration of actuation, a height of actuation, etc.) to the signal, and then transmit the signal to the fold diverter motor. In some embodiments, when diverter optical sensor <NUM> does not detect an envelope sheet <NUM> within an anticipated time period window (e.g., a time period window based on an operational throughput of system <NUM>), computer <NUM> or PLC components can instruct adhesive applicators <NUM> to not dispense any adhesive (or withhold instructions to apply the adhesive) and, furthermore, keep the fold diverter <NUM> in the rest (e.g., non-actuated) position so that any envelope sheet <NUM> that arrives outside of the anticipated time period window will not be diverted onto fold plate <NUM>, but will instead be minimally processed and output, either to be discarded to fed through system <NUM> again. In some embodiments, system <NUM> may include a divert bin for such defective envelope sheets, so that they will be diverted upstream of any further processing steps after buckle folder system <NUM>, or at some other point between buckle folder system <NUM> and output section <NUM>.

Referring now to <FIG>, envelope sheet <NUM> is in a position where fold diverter <NUM> is triggered by diverter optical sensor <NUM> sensing leading edge <NUM> of envelope sheet <NUM>. When triggered, fold diverter <NUM> is actuated from a first position that is substantially parallel to and/or in line with envelope transport plate <NUM> into a second, actuated position, in which fold diverter <NUM> is positioned relative to envelope transport plate <NUM>, such that leading edge <NUM> contacts fold plate <NUM> and moves vertically upwards towards fold plate stop bar <NUM>. Envelope sheet <NUM> is driven vertically up fold plate <NUM> at the constant speed at which envelope sheet <NUM> is propelled by transport rollers <NUM>. The transport speed at which envelope sheet <NUM> is moved by transport rollers <NUM> is used, such that an actuation time for fold diverter <NUM> is set, fold diverter <NUM> returning to the first position after the actuation time elapses. In some embodiments, an optical sensor is used to detect envelope sheet moving vertically up fold plate <NUM> in order to move fold diverter <NUM> back to the first position; in some embodiments, this optical sensor can be used to disable adhesive applicators <NUM> when the lead edge of envelope sheet <NUM> is not detected. A vertical position of fold plate stop bar <NUM> is selected based on the dimensions of envelope sheet and the size of the mailpiece to be created. The position of fold plate stop bar <NUM> is set by fold plate stop bar adjuster <NUM>, which can include a knurled knob threadably engaged on a rod captively passing through a fold plate stop bar slot <NUM>. In some embodiments, detents can be formed in fold plate stop bar slot <NUM> in order to define preset vertical positions of fold plate stop bar <NUM>, these preset vertical positions corresponding to preset sizes of envelope sheets <NUM> to be processed.

Referring now to <FIG>, envelope sheet <NUM> and insert stack <NUM> are both shown being engaged (e.g., compressively) between transport rollers <NUM> as envelope sheet <NUM> and insert stack <NUM> are driven by transport rollers at constant velocity. In this view, fold diverter <NUM> has returned to the first, unactuated, position, such that, after leading edge <NUM> of envelope sheet <NUM> contacts fold plate stop bar <NUM>, preventing any further vertical movement along this vertical buckle path, envelope sheet <NUM> is driven underneath fold plate <NUM>. Because the vertical movement of envelope sheet <NUM> is stopped by fold plate stop bar <NUM>, but envelope sheet <NUM> is still being driven at constant velocity by transport rollers <NUM>, envelope sheet <NUM> is folded over itself at envelope primary fold point <NUM>, defining back region <NUM> above this point. As is shown in <FIG>, first and second sets of transport rollers 121A and 121B continue to drive envelope sheet underneath fold plate <NUM>, thus driving envelope primary fold point <NUM> to be engaged between third set of transport rollers 121C. The speed of envelope sheet <NUM> and insert sheet <NUM> are substantially unchanged as envelope primary fold point <NUM> is defined and insert region of the envelope (see, e.g., <NUM>, <FIG>) is substantially coplanar with the inserts within insert stack <NUM>.

In <FIG>, the dispensing of the adhesive, which was omitted in <FIG> for clarity, is shown. After first adhesive optical sensor <NUM> is triggered by leading edge <NUM> of envelope sheet <NUM>, adhesive is applied by adhesive applicators <NUM> adjacent to and/or substantially at the lateral edges of envelope sheet <NUM>. The adhesive is, in some embodiments, a pressure-sensitive liquid dispensed glue. In some other embodiments, the adhesive may be dispensed as a gel or as a film, rather than a liquid. Adhesive is applied to envelope sheet <NUM> at adhesive application point <NUM>, starting at adhesive start point <NUM> along adhesive line <NUM>. A delay time value may be programmed in order for envelope sheet <NUM> to move beyond the detection point at which leading edge <NUM> is detected by first adhesive optical sensor <NUM>, such that the adhesive is not applied prematurely. The duration of adhesive application is set by a timer value based, for example, on the size of envelope sheet <NUM> and the speed at which transport rollers <NUM> are operated.

Referring now to <FIG>, envelope sheet enters side adhesive sealer, generally designated <NUM>. In side adhesive sealer, portions of envelope sheet are sealed to each other, such that a partially assembled envelope, generally designated <NUM>, is formed by pressure sealing of back of envelope <NUM> to front of envelope <NUM> between adhesive sealing rollers <NUM>. In some embodiments the adhesive can be applied in a pattern comprising a solid line, dots, and/or dashes, the latter of which can be beneficial in minimizing adhesive consumption. In this view, envelope <NUM> is pushed along by transport rollers <NUM> into adhesive sealing rollers <NUM>. In some embodiments, adhesive sealing rollers <NUM> may be driven at the same speed as transport rollers <NUM>. In some other embodiments, adhesive sealing rollers <NUM> are configured as idler rollers. In some other embodiments, adhesive sealing rollers <NUM> and transport rollers <NUM> are made of an elastomeric material, such as silicone, rubber, or latex. In some other embodiments, adhesive sealing rollers <NUM> are made from a material having a higher or lower durometer than transport rollers <NUM>, thus providing for an enhanced seal formed by the adhesive. In some embodiments, adhesive sealing rollers <NUM> and the axles associated therewith are separate from (e.g., physically isolated from) the axles of transport rollers <NUM>, so that the thickness of insert stack <NUM> does not affect the pressure applied by adhesive sealing rollers <NUM>. This can be accomplished, for example, by adhesive sealing rollers <NUM> being arranged laterally outside of the width of the widest insert within insert stack <NUM>, such that transport rollers <NUM> will be vertically displaced by the thickness of insert stack <NUM> as it moves therethrough, without any accompanying vertical displacement of adhesive sealing rollers <NUM> associated therewith. In some embodiments, adhesive sealing rollers <NUM> are arranged laterally outside of transport rollers <NUM>, so that only envelope sheet <NUM> and the adhesive are compressed between adhesive sealing rollers <NUM>, so that a constant pressure is applied to seal the adhesive, independent of a thickness of insert stack <NUM>.

Next, as is shown in <FIG>, partially assembled envelope <NUM> exits side adhesive sealer <NUM>, continuing into right angle turn (RAT) module, generally designated <NUM>. RAT module <NUM> includes one or more (e.g., two) right angle turn assemblies <NUM>, which include a plurality of rollers that alter a directional path of envelope <NUM> by such that, after envelope <NUM> moves underneath right angle turn assemblies <NUM>, the direction of travel <NUM> of envelope <NUM> is substantially orthogonal compared to the direction of travel <NUM> before envelope <NUM> entered the right angle turn assemblies <NUM>. Any suitable RAT module <NUM> may be used, including those that will physically rotate envelope <NUM> without altering a travel direction thereof. Next, envelope <NUM> is bottom edge registered by one or more bottom edge justifier assemblies <NUM> and the movement of envelope <NUM> is aided by one or more envelope guides <NUM>. An envelope side adjuster <NUM> can be used to adjust a behavior of the bottom edge justifier assemblies <NUM> and/or a position of one or more of the envelope guides <NUM>.

Claim 1:
A system (<NUM>) configured to fold an envelope sheet (<NUM>) around one or more insert sheets (<NUM>, <NUM>) to create a mailpiece, the system (<NUM>) comprising:
an insert transport path (<NUM>) configured to transport the one or more insert sheets (<NUM>, <NUM>) to a merge region (<NUM>);
a primary transport path (<NUM>) configured to transport the envelope sheet (<NUM>) to the merge region (<NUM>), wherein the insert transport path (<NUM>) is parallel to and/or vertically above the primary transport path (<NUM>);
an insert stager (<NUM>) that is connected to the insert transport path (<NUM>) and arranged proximate to the primary transport path (<NUM>) at the merge region (<NUM>), wherein the insert stager (<NUM>) is configured to receive the one or more insert sheets (<NUM>, <NUM>) from the insert transport path (<NUM>) in a form of an insert stack (<NUM>), hold the insert stack (<NUM>), and to dispense the insert stack (<NUM>) onto the envelope sheet (<NUM>) when the envelope sheet (<NUM>) is at a first position on the primary transport path (<NUM>), wherein the insert stack (<NUM>) is dispensed from the insert stager (<NUM>) at substantially a same speed as a speed of the envelope sheet (<NUM>) along the primary transport path (<NUM>);
one or more adhesive applicators (<NUM>) configured to apply an adhesive along lateral edges of a back side portion of the envelope sheet (<NUM>) as the envelope sheet (<NUM>) is fed into a buckle folder;
a buckle folder system (<NUM>) configured to form an unsealed envelope (<NUM>) for the mailpiece by folding the envelope sheet (<NUM>) around the insert stack (<NUM>), wherein folding the envelope sheet (<NUM>) around the insert stack (<NUM>) forms, on a first side of the insert stack (<NUM>), a back of the envelope (<NUM>) and, on a second side of the insert stack (<NUM>) opposite the first side, a flap of the envelope (<NUM>) and a front of the envelope (<NUM>); and
an envelope closing system (<NUM>) configured to close and seal the unsealed envelope (<NUM>) by folding the flap of the envelope (<NUM>) over the back of the envelope (<NUM>) and adhesively sealing the flap of the envelope (<NUM>) to the back of the envelope (<NUM>).