Patent ID: 8647040

Claim:
A method of transferring a plurality of substantially flat items, while maintaining an orientation alignment of the substantially flat items, the method comprising: receiving the substantially flat items in an open container; transferring the substantially flat items from the open container to an unloader box by placing the open container into the unloader box, rotating the unloader box to an at least partially inverted position and removing the open container from the unloader box with the unloader box in the inverted position; returning the unloader box to a non-inverted alignment, while retaining the substantially flat items in the unloader box; guiding the substantially flat items from the unloader box to a next work station using, as the open container, a tray having a bottom and sidewalls fixed to the bottom and an open top, and providing the plurality of items in the tray with the plurality of the items having an initial alignment; providing the unloader box with a top portion capable of opening with respect to a remaining portion of the unloader box; transferring the substantially flat items into the unloader box by receiving the tray holding the items in the unloader box with the top portion opened and with the plurality of items exposed within the unloader box at the open top portion of the unloader box; positioning the tray within the unloader box with the unloader box closed to cover the open top of the tray; rotating the unloader box, thereby positioning the open top of the tray in a generally downward facing orientation; opening the unloader box to expose the tray, with the open top of the tray facing in the generally downward facing orientation; removing the tray from the unloader box while retaining the plurality of items within the unloader box for subsequent discharge; providing at least one rest surface, whereby, subsequent to removing the tray from the unloader box, the plurality of flat items rest against the resting surface along one edge of each of the substantially flat items or of most of the substantially flat items; positioning a first comb comprising a plurality of fingers extending along a direction substantially parallel to a face alignment of the substantially flat items to position the substantially flat items on one side of the first comb, thereby confining the substantially flat items; moving the first comb, thereby moving the plurality of flat items along the resting surface, with the edges remaining against the resting surface; transferring the plurality of flat items to a second comb by passing the first comb by the second comb, thereby causing the second comb to engage the substantially flat items; causing the first comb to retract, thereby disengaging the plurality of flat items from the path of motion; and moving the second comb to move the plurality of flat items along the resting surface.