Note: Descriptions are shown in the official language in which they were submitted.
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HIGH SPEED MACHINE FOR INSERTTNG SHEETS INTO ENVELOPES
BACKGROUND OF THE INVENTION
1. Field of the invention
This invention relates, generally, to machines that insert
sheets of paper or other items into envelopes. More
particularly, it relates to a feeder machine that operates at a
very high speed.
2. Description of the prior art
Machines for inserting items such as sheets of paper into
envelopes at a relatively high rate of speed have been known
since the 1980s. They can perform about 8000 insertions per hour
when properly maintained and adjusted. At least thirty six
patents cover the original machine and various improvements
thereto.
The known machine is mechanically complex. For example, it
employs a total of nine cams for performing various functions
such as opening and closing mechanical clamping devices, raising
and lowering suction cups,used for opening envelopes, and so on.
It includes a large number of gears, belts, drive shafts and the
like. There are so many mechanical complexities that the device
even includes a unique device for taking looseness or play out
of the mechanism. The mechanical complexity relies upon human
oversight for frequent adjustment purposes but even a well-
adjusted machine is subject to frequent paper jams and the
downtimes associated therewith.
Moreover, the envelope feeder of the known machine holds
only a short stack of envelopes. As a result, the machine
operator must frequently replenish the stack. A taller stack is
contraindicated because the mechanism must remove envelopes
sequentially from the bottom of the stack. The mechanism cannot
cope with the extra weight of a tall stack, or the changing
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weight of a stack that steadily decreases in height as the
machine operates.
The earlier machine also includes a reciprocating,
pivotally-mounted, pendulum-like arm that feeds each sheet of
paper or small stack of sheets into each envelope. It swings
forwardly to perform one insertion and then swings back to
prepare for the next insertion. This back-and-forth cycle takes
place eight thousand times an hour when the machine is operating
smoothly. Since the arm has non-negligible mass, the need to
change direction sixteen thousand times per hour places a strain
on the machine and prevents faster operation.
Another limitation of the known machine that restricts it
to 8000 insertions per hour is conveyor speed. If the conveyor
that delivers the sheets to the envelopes is run any faster than
its 8000 insertions per hour speed, the envelopes into which the
sheets are to be inserted cannot be delivered to the insertion
station quickly enough. Moreover, the increase in speed of the
conveyor belt causes the sheets to fly from it.
Another source of the known machine's relatively slow speed
of operation is the use of suction cups to open envelopes at the
sheet insertion station. Since suction cups cannot grasp a
moving envelope, each envelope must come to a full stop before
the suction cups can be lowered into engaging relation thereto.
After the sheets have been inserted, the suction cups must be
released and moved upwardly again so that the cycle can be
repeated for the next envelope.
The known machines are further limited because the
envelopes and sheets to be inserted thereinto follow a parallel
path of travel as they approach a sheet insertion station. This
requires that rectangular sheets be inserted in a "narrow edge
leading" position, i:e., the sheets are pushed into the envelope
in their long dimension. This requires a time delay for indexing
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to occur and an acceleration of the paper thereafter to make up
for the delay.
The known machines also incorporate flighted conveyor
belts, in their collator section, where longitudinally spaced
apart vertical walls divide the belt into bins of ten inches in
length. If bins of different lengths are needed for a particular
application, a different belt must be installed.
What is needed, then is a machine that can perform
insertions at a rate of speed much faster than eight thousand
insertions per hour.
There is a need as well for a machine with less mechanical
complexity. A more elegantly-designed machine could operate at
higher speeds with increased reliability and less downtime, and
would require less operator attention.
A need also exists for an envelope'feeder that does not
require frequent replenishment.
Another need exists for a machine that does not rely upon a
pivotally-mounted,~reciprocating arm to push paper sheets into
envelopes.
Moreover, there is a need for a machine that can deliver
more sheets per hour without increasing the speed of the
conveyor belt that delivers the sheets to an envelope insertion
station.
There is a need as well for an improved means for opening
envelopes prior to sheet insertion. The improved means should
not require the envelope to reach a full stop before the
insertion procedure begins and the improved means should not
rely upon suction cups.
A need exists as well for a machine that can feed sheets of
rectangular paper in a "wide edge~leading" format so that the
short side of a rectangular sheet is pushed into its envelope,
thereby reducing the length of each pusher stroke and
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eliminating a need to index, delay and accelerate the mechanisms
involved in the sheet insertion process.
A need is extant, further, for a machine having a flighted
conveyor belt in its collator section that is not limited to ten
inch bins and which can be modified to have bins of differing
length without requiring changing of the belt.
However, it was not obvious to those of ordinary skill in
this art how the needed improvements could be provided, in view
of the art considered as a whole at the time the present
invention was made.
SUN~1ARY OF THE INVENTION
The long-standing but heretofore unfulfilled need for an
innovation that overcomes the limitations of the prior art is
now met by a new, useful, and nonobvious invention.
In a first embodiment, the novel machine for inserting
sheets into envelopes includes a first table means including an
elongate envelope feed conveyor means and a second table means
disposed in substantially parallel relation to the first table
means. The second table means includes an elongate sheet feed
conveyor means, at least one sheet feeder means and at least one
sheet pusher means.
The novel machine further includes a third table means or
envelope loading station disposed substantially transversely to
the first table means and the second table means. The envelope
loading station includes an envelope hopper. An elongate queue
of envelopes is formed on the elongate envelope feed conveyor
means of the first table so that keeping the envelope hopper
full of envelopes requires infrequent additions of envelopes to
the queue. The envelope hopper has a predetermined elevation
less than a predetermined elevation of the elongate envelope
feed conveyor means so that an envelope reaching the envelope
hopper follows a downward path of travel as it exits the
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elongate envelope feed conveyor means and enters into the
envelope hopper.
The envelope loading station includes a sheet insertion
station that is transversely spaced apart from the envelope
hopper.
An envelope displacement means is provided for displacing
an envelope from the envelope hopper to the sheet insertion
station. The envelope displacement means includes a clamp
adapted to selectively engage and release an envelope. The clamp
is mounted on a rotating chain means or belt means that follows
a predetermined path of travel in a substantially vertical
plane. The clamp is adapted to engage an envelope in the
envelope hopper, to displace the envelope to the sheet insertion
station, and to release the envelope at a predetermined location
after displacing it away from the sheet insertion station.
A first cam means forms a part of a mechanism for removing
an envelope from the envelope hopper. A second cam means opens
and closes the clamp when the clamp is positioned in
predetermined juxtaposition to the envelope hopper. The second
cam means opens the clamp to enable it to receive an envelope at
the envelope hopper and said second cam means then closes the
clamp to enable it to engage the envelope and displace it to the
sheet insertion station.
A third cam means at the sheet insertion station opens the
clamp to allow sheet insertion and then closes the clamp again.
A fourth cam operates an insert entering finger assembly. All
four cams are mounted on a common, transversely disposed, motor-
rotated shaft and are transversely spaced apart from one
another.
The at least one sheet pusher member is mounted on a
predetermined structure including a rotating chain means or belt
means that forms an endless loop so that the at least one sheet
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pusher member follows a predetermined path of travel that
alternately carries it towards the sheet insertion station and
away from the sheet insertion station in the absence of an
abrupt change of direction. The rotating chain or belt means
includes a pair of parallel, transversely spaced apart chain or
belt means and the at least one sheet pusher member is disposed
therebetween:
The at least one sheet pusher member includes at least one
set of sheet pusher members, and the at least one set includes a
plurality of sheet pusher members disposed in transversely
spaced apart relation to one another.
The at least one set of sheet pusher members may include a
plurality of sets of sheet pusher members that are
longitudinally spaced apart from one another at equidistantly
spaced intervals.
Significantly, only two sets of sheet pusher members are
employed for sheets having a length greater than six inches,
such as 9 X 12 envelopes, for example. Where the chain means
that carries the pusher members is forty inches in length, the
two sets of pusher members are spaced twenty inches from one
another. Moreover, the flighted conveyor that carries the sheets
to the sheet insertion station is divided by vertical walls that
are spaced 14~ inches from one another.
For sheets having a length greater than four inches but
less than six inches, the machine is reconfigured so that three
sets of pusher members are installed on the chain means. Since
the sets are equidistantly spaced apart from one another, on a
forty inch chain means the spacing between three sets of pusher
members is 13.33 inches. Moreover, the walls that divide the
flighted conveyor into sheet-receiving bins are spaced 76 inches
apart.
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Where the sheet length is less than four inches, four sets
of pusher members are carried by the chain means, spaced ten
inches from one another. The walls are spaced 76 inches apart as
in the three pusher embodiment.
Thus, the flighted conveyor of the inventive machine may be
divided into bins of differing lengths, thereby eliminating the
need to change conveyor belts when a different bin size is
needed.
There are no gear ratio changes when the machine is
reconfigured from a four pusher member configuration to a two
pusher member configuration i.e., the only gear ratio change is
made when three pusher members are used. This allows the feed
conveyor to operate at the same speed for all pusher member
configurations.
A plurality of transversely spaced apart air jets are
formed in an insert plate that lies flush with the surface of
the second table means in juxtaposition with the envelope
insertion station. A sensor means detects the presence of an
envelope in the envelope insertion station and activates a
pneumatic means for causing a puff of air to flow from the air
jets to open an envelope positioned in the envelope insertion
station. The puff of air may be initiated before the envelope
comes to a complete stop. Moreover, the use of air to open the
envelopes eliminates the suction cups heretofore used and the
mechanical complexities associated therewith. An insert entering
finger or guide that is used in prior art machines to hold the
envelope open during sheet insertion may also be used in
conjunction with the novel air jets. This invention improves the
known entering finger by equipping it with air jets as well to
enhance its effectiveness.
In an alternative embodiment of the novel machine, the
first~table means is eliminated. Instead of an elongate envelope
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queque in a horizontal plane, a high capacity, generally
vertical demand envelope feeder is used. Such envelope
feeders are known and can be used as a substitute
structure for the elongate first table means.
According to one aspect of the invention there is
provided a machine for inserting preselected items such
as sheets of paper into envelopes, comprising:
a first table means including an elongate envelope
feed conveyor means;
a second table means disposed in substantially
parallel relation to said first table means, said second
table means including an elongate sheet feed conveyor
means, at least one sheet feeder means and at least one
sheet pusher means;
a third table means disposed substantially
transversely to said first table means and said second
table means;
said third table means including an envelope loading
station aligned with said elongate envelope feed conveyor
means and an envelope insertion station aligned with said
elongate sheet feed conveyor means, said envelope loading
station and said envelope insertion station being
transversely spaced apart with respect to one another;
said envelope loading station including an envelope
hopper; and
said elongate envelope feed conveyor means adapted
to hold an elongate queue of envelopes aligned with said
envelope hopper so that keeping said envelope hopper full
of envelopes requires infrequent additions of envelopes
to said queue.
Another important object is to provide a "wide edge
leading" insertion for rectangular sheets to reduce the
length of the pusher stroke and to eliminate the delay
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and acceleration required of prior art machines during
sheet insertion.
These and other important objects, features, and
advantages of the invention will become apparent as this
description proceeds.
The invention accordingly comprises the features of
construction, combination of elements and arrangement of
parts that will be exemplified in the construction
hereinafter set forth, and the scope of the invention
8a
«ill ha in~i~atP~ in the claimS_
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BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the nature and objects of the
invention, reference should be made to the following detailed
description, taken in connection with the accompanying drawings,
in which:
Fig. 1 is a top plan view of a first embodiment of the
machine where two sets of pusher members are employed;
Fig. 2A is a side elevational view of said first
r
embodiment;
Fig. 2B is a side elevational view of a second embodiment
where three sets of pusher members are employed;
Fig. 2C is a side elevational view of a third embodiment
where four sets of pusher members are employed;
Fig. 2D is an enlarged view of the encircled area in Fig.
2C that is denoted 2D;
Fig. 3 is a side elevational, diagrammatic view of the
novel envelope feed conveyor;
Fig. 4 is a front elevational view of the machine;
Fig. 4A is a detailed view of the encircled area denoted 4A
in Fig. 4;
Fig. 4B is a detailed view of the encircled area denoted 4B
in Fig. 4;
Fig. 5 is a diagrammatic representation of the control
means for the novel machine;
Fig. 6 is a diagrammatic side elevational view of the novel
envelope-opening means;
Fig. 6A is a diagrammatic front elevational view of the
novel insert plate, depicting the air jets formed therein; and
Fig. 7 is a diagrammatic front view of a high capacity
demand envelope feeder.
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DETAINED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to Fig. 1, it will there be seen that an
exemplary embodiment of the invention is denoted as a .whole by
the reference numeral 10.
In a first embodiment, machine 10 includes a first elongate
table means or envelope feed conveyor means 12 having a very
large plurality of envelopes 14 disposed thereatop.
A second elongate table means, denoted 16 as a whole, is
disposed in parallel relation to first elongate table means 12,
in transversely spaced apart relation to first elongate table
means 12.
As depicted in Fig. 2A, a plurality of sheet feeders are
mounted in longitudinally spaced apart relation to one another.
In this particular embodiment, there are five sheet feeders,
denoted 18a-e, but a commercial embodiment of the invention
includes six of such feeders (see Fig. 5). The number of sheet
feeders is not critical to the operation of machine 10. As in
prior art machines, each sheet feeder carries a replenishable
stack of individual paper sheets 20a-a to be inserted into
envelopes as a set.
A flighted conveyor belt 22 carries the paper sheets to the
forward end of second table means 16, as indicated by arrow 23,
where the individual stacks are sequentially inserted into
envelopes 14. In Fig. 2A, belt 22 is divided into sections or
bins by longitudinally-spaced apart vertical walls 24. This
particular configuration is used for sheets having a
longitudinal extent in excess of six inches; walls 24 are 14~
inches apart. A sheet of paper that is to be positioned at the
bottom of a stack is deposited into a bin at position 26e by a
roller mechanism that is well-known. That sheet then advances to
position 26d and the sheet that will be the second from the
bottom in the stack is then deposited atop it and so on until
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the stack has been assembled for insertion into an envelope. In
this example, the top sheet in the stack is deposited atop said
stack at position 26a by sheet feeder 18a.
Note that only two sets of pusher members, denoted 28b and
28d, are used in this first~embodiment. Where the pusher members
are carried on an endless chain means or belt means 28 having a
length of forty inches, the two sets of pusher members are
spaced twenty inches from one another. Chain means 28 follows a
generally elliptical path of travel so that the pusher members
do not abruptly change direction as the chain means rotates in a
vertical plane. It should be understood from Fig. 1 that chain
means 28 includes two sets of parallel chain members disposed in
transversely spaced apart relation to one another, and that the
pusher members are disposed therebetween.
The configuration of Fig. 2A is employed when the sheets to
be inserted are greater than six inches in length.
In the configuration of Fig. 2B, walls 24 are spaced 7~
apart, and three pusher members, denoted 28a, 28c and 28d are
employed. On a forty inch chain means, they are equidistantly
spaced from one another at 13.33 inch intervals. This
configuration is used when the sheets to be inserted are less
than six inches in length but greater then four inches in
length.
In the configuration of Fig. 2C, walls 24 are spaced 7~
apart, and four pusher members, denoted 28a, 28b, 28c and 28d
are employed. They are spaced ten inches from one another on a
forty inch chain means. This configuration is used when the
sheets are four inches or less in length.
As indicated in Fig. 2D, each pusher member is pivotally
mounted to chain means 28.
As indicated in Fig. 1, machine 10 further includes third
elongate table means or envelope loading station 30 having a
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longitudinal axis disposed transversely to the longitudinal axis
of first table means 12 and second table means 16. Third table
means 30 includes an envelope hopper 32 at a first end thereof,
said first end being in longitudinal alignment with first table
means 12. Third table means 30 further includes an envelope
flap-opening station 34, a sheet insertion station 36, an
envelope closing station 38, and an envelope ejection station
40.
Sheet insertion station 36 is disposed in longitudinal
alignment with second table means 16.
The operation of machine 10 will now be described.
A conveyor belt, not shown, is rotatably mounted in first
table means 12 so that its forward-traveling section is
substantially flush with the top surface of said table means 12.
It carries a long queue of envelopes 14 in the direction
indicated by single-headed directional arrow 42, said arrow
indicating said direction of forward travel.
As best understood in connection with Fig. 3, when an
individual envelope 14 reaches the end of table 12, it follows a
downward path of travel having a rounded ninety degree bend.
This path of travel places it in envelope hopper 32 which has
substantially the same height or depth as an envelope hopper of
the prior art. However, the horizontal queue of the envelopes
atop the conveyor means of first table 12 enables a machine
operator to place thousands of envelopes atop said conveyor
means without adding to the pressure or weight bearing down on
the lowermost envelope in hopper 32. Moreover, the pressure
applied to the lowermost envelope does not change as the length
of the queue of envelopes grows shorter or longer.
Returning now to Fig. 1, it should be noted that flap 44 of
each envelope 14 is closed when it is in hopper 32. A stationary
flap opener means 46 in the form of a curved rod has a proximal
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end 46a positioned below the plane of third table means 30 and a
distal free end 46b disposed in the path of travel of each flap
44 as the envelopes are sequentially pulled from the bottom of
hopper 32. Thus, rod 46 mechanically displaces each flap 44 into
a fully open position; as indicated in Fig. 4, each flap 44 is
rotated more than one hundred eighty degrees when it is fully
open.
The lowermost envelope in hopper 32 is engaged at its
inboard end by a clamp 48 (see Figs. 1 and 4) having a pair of
opposed jaws that open and shut. When open, clamp 48 receives or
releases an inboard end of the lowermost envelope and when
closed, said clamp engages said inboard envelope.
As perhaps best understood in connection with Fig. 4, the
clamp at position 48a is open and ready to receive between its
opposed jaws the inboard end of an envelope 14 that is being
removed from envelope hopper 32.
The clamp at position 48b is closed and has pulled a
lowermost envelope out of hopper 32 and past curved rod 46 and
thus flap 44 has been fully opened so that it lies in a plane
more than one hundred eighty degrees from its initial, closed
position.
The clamp at position 48c has pulled an envelope to sheet
insertion station 36 where at least one sheet of paper or
similar item is inserted into an opened envelope.
Water in elevated reservoir 50 is conveyed under gravity
feed to brush 52 by hose 54; the clamp in position 48d has
pulled an envelope, with flap 44 still open, under said brush to
moisten the adhesive on the inside of the flap. A second curved
rod 56 has an inboard end 56a disposed below the plane of the
envelopes on table 30 and an outboard end 56b (Fig. 1) disposed
above said plane so that the flap is closed as soon as the
moisture is applied. Roller 58 turns in the direction indicated
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by arcuate arrow 59 in Fig. 4 and presses on the closed flap to
seal the envelope.
The clamp in position 48d opens to release the envelope
when an actuator 49 that depends therefrom (see Fig. 4A)
encounters roller 64 and the envelope is propelled to a
collection table, not shown, that would be positioned at the
left side of Fig. 4. The clamp at position 48d is approaching
the position of the clamp at position 48e when the envelope is
propelled to the collection table, because the clamps follow a
path of travel defined by sprocket chain 60 (or other suitable
belt means). The direction of travel of sprocket chain 60 is
denoted by directional arrows 61 and 62. Gear 64 is a driving
gear and gears 65, 66 and 67 are idler gears.
A first cam, not shown, forms a part of a well-known
mechanism that takes envelopes out of envelope hopper 32. A
second cam 69 selectively opens and closes the clamp at position
48a either directly or by means of bell crank 71 or other
suitable linkage means as depicted in this particular
embodiment. A third cam, not shown, selectively opens and closes
the clamp at position 48c so that the envelope can be opened for
the sheet insertion process and immediately closed thereafter. A
fourth cam is also employed to operate the insert entering
finger assembly, disclosed hereinafter. Thus, there are only
four cams in the inventive machine, whereas the known machines
have about twenty cams.
As indicated in the detailed drawings denoted Figs. 4A and
4B, each clamp is maintained in a normally closed configuration
by a bias means such as spring 47, and each clamp has an
actuator 49 that opens the opposed jaws of the clamp when
displaced.
Motor 68 drives belt 73 that in turn rotates shaft 72 of
indexing box 74. The first one hundred eighty degree rotation of
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shaft 72 results in a one hundred twenty degree rotation of
wheel 76. The second one hundred eighty degree rotation of shaft
72 results in no rotation of wheel 76, i.e., there is a dwell of
wheel 76 during said rotation of shaft 72. The arrow denoted T1
in Fig. 4 indicates the linear travel of a clamp 48 for each
rotation of wheel 76.
This rotate and dwell pattern is a three stop, three
position output, i.e., for each 360.degrees of input there is
120 degrees of output; 180 degrees of the input is dwell.
Indexing box 74 eliminates any need for a stepper motor,
i.e., the output shaft of motor 68 rotates continuously, in the
absence of starting and stopping.
Fig. 5 diagrammatically depicts the control means for novel
machine 10. In this example, there are six sheet feeders 18a-f,
as distinguished from the five sheet feeders depicted in Fig. 2.
Prior art sheet feeders, as mentioned earlier, are
controlled as a group by a single motor means. Thus, each sheet
feeder deposits one sheet on flighted conveyor 22 for each cycle
of operation. However, if a customer wants sheet feeder 18a to
deposit two sheets for every sheet deposited by sheet feeder
18b, the single motor assembly of the prior art cannot be used.
This invention provides a single motor means such as motor
means 82 (Fig. 5) for use when each sheet feeder 18a-f is
operating at the same speed as the other sheet feeders. It also
includes a plurality of motors such as motors 82 and 84 and
others so that a motor is dedicated to each sheet feeder 18a-f
whereby each sheet feeder is independently controlled and run at
a preselected speed. Thus, if it is desired to operate one or
more of the sheet feeders at two times, three times, or more
times the speed of the other sheet feeders, such differing
speeds of operation can be accomplished.
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In a six sheet feeder machine, there could be four regular
motors, one stepper motor and one high speed motor. Any
combination of motors is available; the motors depicted in
Figure 5 are merely exemplary.
All motors in machine 10 are under the control of novel
control means or programmable logic controller (PLC) 86 which is
electrically connected to monitor 88 and control panel 90. Push-
button safety switch actuator 92 is electrically connected in
series to push-button switch actuators 94 and 98 so that said
switch actuators do not work unless switch actuator 92 is
activated simultaneously. Depressing switch actuators 92 and 98
at the same time starts the novel machine. Depressing switch
actuators 92 and 94 at the same time jogs the machine, i.e., the
machine runs only for so long as the depression of said switches
is maintained. Depressing switch actuator 96 re-sets the
controls of the machine but does not result in operation of any
moving parts. Accordingly, it is not in series with safety
switch 92. Push-button switch actuator 100 is the stop switch
and is also not in series with safety switch actuator 92. The
physical spacing of safety switch actuator 92 from switch
actuators 94 and 98 is a well-known safety feature that ensures
that the machine operator's hands are safely away from moving
parts when the machine is operated.
PZC 86 is programmable so that sheet feeders 18a-f are
individually controllable.
Referring now to Fig. 6, when an envelope 14 arrives at
sheet insertion station 36, air is blown thereinto to open said
envelope so that insert entering finger 85 may be inserted
thereinto to hold the envelope open during the sheet insertion
process. The air, denoted 83a, flows out of a plurality of
parallel, horizontally disposed air jets 80 (Fig. 6A) that are
formed in insert plate 83, said insert plate being flush with
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the top surface of table means 16. The jets have a longitudinal
axis parallel with the longitudinal axis of table means 16 and
they are transversely spaced apart from one another as indicated
in Fig. 6A so that said jets supply air along the entire extent
of the envelope to be opened. A sensor means 37 (Fig. 5) detects
the presence of an envelope at sheet insertion station 36 and
actuates a pneumatic means, not shown, that delivers the brief
puff of air, from said jets, into said envelope so that it is
momentarily opened. An item such as a sheet of paper or a small
stack of papers 26 in inserted, by pusher member 28a, into the
envelope during the brief time it is open.
Thus, each envelope 14 is already open by the time it
arrives at sheet insertion station 36. This enhances the
productivity of machine 10 because prior art machines deliver
closed envelopes to a sheet insertion station as mentioned
earlier. In the prior art machine, envelope-opening suction cups
are brought down to grab each closed envelope as it arrives at
the sheet insertion station. Significantly, the envelope must be
at a complete stop before it can be engaged by the suction cups.
After the sheet insertion, the suction cups must then be
disengaged before the envelope can resume movement. By
eliminating the suction cups and the mechanical means for
lowering them into engagement with each envelope and for '
thereafter lifting them out of said engagement, the mechanical
complexity of the machine is reduced and the cycle time for
performing a sheet insertion is substantially reduced.
Element 85 in Fig. 6 is known in the industry as an insert
entering finger; it holds an open envelope in its open position
during the insertion process. It also serves as a guide means
for guiding the sheets into the envelope and for holding said
sheets down. This invention improves a conventional insert
entering finger by adding air jets formed in the leading edge of
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said insert entering finger 85 to enhance its effectiveness. A
blast of air from said jets is denoted 85a; note the downward
direction of the air blast which serves to hold the sheets down.
If an envelope is not delivered to sheet insertion station
36, or if an incomplete set of sheets is delivered to said
station, as sensed by sensor means 39 (Fig. 5), a burst of air
delivered by upwardly pointing air jets, centered in openings
81, 81, ejects the set of sheets or incomplete set of sheets out
of said station 36. The air is supplied by a pneumatic means,
not shown, that is actuated by said sensor means 39. This
ejection means allows machine 10 to continue operating when the
above-mentioned events occur. Prior art machines must be stopped
when such events occur. The provision of an ejection means at
the point of sheet insertion was heretofore unknown.
Sensor means 41, also depicted in Fig. 5, senses the level
of envelopes in envelope hopper 32 and re-starts the conveyor
belt carried by the first table means to replenish said hopper
with additional envelopes in the absence of operator
intervention. Sensors are also provided for each sheet feeder to
start and stop said feeders to stage the pieces of paper.
Unlike the pivotally-mounted, reciprocating pusher means of
the prior art, novel pusher assembly 28 is provided in the form
of a plurality of pusher members that follow a path of travel
that forms a closed loop. As mentioned above, there are two,
three or four sets of pusher members, depending upon the length
of the sheets being inserted, and each set of pusher members may
include one or more push arms disposed in transversely spaced
apart relation to one another, as best indicated in Fig. 1. The
number of push arms within each set may be varied because the
number of push arms in a set is not critical.
A top view of the pusher member sets is provided in Fig. 1
and a side view thereof is provided in Fig. 2. Arcuate arrow 29
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in Fig. 2 indicates that the pusher member sets retreat from
sheet insertion station 36 for the first half of their path of
travel and advance toward said station 36 during the second half
of said path of travel. It is during the second half of said
path of travel that a set of pusher members such as pusher set
28c (Fig. 2B) engage a sheet of paper or a short stack of papers
and push said sheet or stack towards the envelope insertion
station 36. Pusher members 28d are depicted in said Fig. 2B
pushing a sheet or stack of sheets into opened envelope 14
during the release of the above-mentioned puff of air.
Note that the sets of pusher members in the retreat section
of the path of travel are disengaged from said sheets but are
rotating into position to sequentially perform the functions
being performed by the advancing pusher members.
Parallel, longitudinally extending grooves, not shown, are
formed in insert plate 83 (see Fig. 6) and the respective
lowermost ends of pusher members 28a-d are slideably received
within said grooves when the pusher members move toward envelope
insertion station 36. This enables the pusher members to extend
slightly below said top surface to ensure substantially problem-
free insertion of the sheets into the envelopes. There is one
groove for each pusher member.
Fig. 7 discloses an alternative means for delivering
envelopes to envelope hopper 32. This means does not include
elongate first table 12. Instead, a high capacity demand feeder
90 delivers envelopes to hopper 32 to ensure that said hopper
does not run out of envelopes. Feeder 90 is canted from a
vertical axis as depicted and may be provided with other means
as well to ensure that the lowermost envelope in the stack of
envelopes does not carry the weight of all envelopes above it.
The novel high capacity demand feeder of Fig. 7 delivers
envelopes to hopper 32 in a direction normal to the direction of
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arrow 42 in Fig. 1, i.e., the envelopes are displaced in a
transverse direction, entering edgewise into said hopper. The
high capacity demand feeders heretofore known feed envelopes in
the direction of said arrow 42. Note that Fig. 7 shows two
feeders 90 in flanking relation to envelope hopper 32; this is
intended merely to indicate that a single feeder 90 may be
placed in either side of said hopper 32.
This invention represents a major breakthrough in the art
of machines that insert sheets into envelopes. Being drawn to a
pioneering invention, the claims that follow are entitled, as a
matter of law, to broad interpretation to protect the heart or
essence of the invention from piracy.
It will thus be seen that the objects set forth above, and
those made apparent from the foregoing description, are
efficiently attained. Since certain changes may be made in the
foregoing construction without~departing from the scope of the
invention, it is intended that all matters contained in the
foregoing construction or shown in the accompanying drawings
shall be interpreted as illustrative and not in a limiting
sense.
It is also to be understood that the following claims are
intended to cover all of the generic and specific features of
the invention herein described, and all statements of the scope
of the invention which, as a matter of language, might be said
to fall therebetween.
Now that the invention has been described,
