Pitney Bowes Inc.

Newline Noosh, Inc.

Noosh, Inc.

Russell W Holbrook

Daniel J Williams

Edward M Ifkovits

Kevin J O'Dea

Karel J Janatka

Robert Marcinik

Robert J Allen

John W Sussmeier

William J Wright

Michael R Ifkovits

Joseph A Trudeau

James Morabito

Luciano P Dos Santos

Morton Silverberg

Steven A Supron

Walter J Kulpa

Thomas M Lyga

John R Masotta

Robert A St John

William D Toth

Dean H Foster

Douglas G Long

Nicholas R Antonelli

Thomas H Rosenkranz

Egbert E Most

Jeffrey L Chodack

Adrian S Ruck

Joseph C Brzozowski

Harvey Halperin

Peter Faucetta

Daniel Vetter J Williams

Scott A MacDonald

Derek S Scholefield

Valdimir V Pirc

Daniel J Willams

A system is provided for aligning multi-sheet collations including a conveyance system having a transport deck for supporting and conveying the multi-sheet collation along a feed path. The system includes a first pair of registration members disposed orthogonal to the feed path and defining a processing station along the feed path. The registration members further define registration surfaces which are repositionable from an active position above the transport deck to an idle position below the transport deck. A first displacement mechanism raises and lowers the registration members into and out of the active and idle positions, and oscillates at least one of the registration surfaces forward and aft in a direction parallel to the feed path when the registration member is in its active position. A processor controls the motion of the conveyance system relative to the registration members of the alignment station, and controls the first displacement mechanism to: (i) raise the registration surfaces into the active position, (ii) oscillate the registration surfaces to align the opposing edges of the multi-sheet collation, and (iii) lower the registration surfaces into the idle position to facilitate conveyance of the aligned multi-sheet collation along the feed path.

Transport and alignment system for producing variable thickness collations

A registration plate assembly for a compliant conveyance system and is adapted for use in combination with an array of print heads each having a print head nozzle. The registration plate assembly includes a mounting plate, a registration plate affixed to the mounting plate and at least one runner fastened to the mounting plate and disposed within an opening defined by the registration plate. The mounting plate has at least one aperture therein for accepting a print head nozzle associated with each of the print head and the registration plate includes and an opening for permitting the deposition of ink from each of the print head nozzles. The runner is aligned with the feed path of the conveyance system and has a blade portion disposed at a location between adjacent print head nozzles which is operative to maintain a stand-off distance from the face surface of each mailpiece to one of the print head nozzles.

Registration plate assembly for mailpiece conveyance system

A system and method for producing printed sheet material for use in a mailpiece inserter. The system comprises an input module for supplying the printed sheet material associated with a mailpiece fabrication job of the mailpiece inserter and a transfer module adapted to receive the printed sheet material from the input module and dispense the printed sheet material. An output module is adapted to receive the printed sheet material from the transfer module and convey the printed sheet material along the transport deck. A processor is operatively coupled to a mail run data file of the mailpiece fabrication job for controlling the input, transfer and output modules to stack the printed sheet material in accordance with the mail run data file. In the method, the output module includes at least two transport decks which may be repositioned such that one of the transport decks receives/stacks the printed sheet material in a manner which is best suited for subsequent use by the mailpiece inserter.

System and method for producing and arranging sheet material for use in a mailpiece inserter

A method for printing information on a print medium, such as a mailpiece, that includes determining a thickness of the medium while it is being transported toward a print head, such as an ink jet print head, causing the distance between the top surface of the medium the print head when the medium is located below the print head to be within a specified range based on the determined thickness, and printing the information on the print medium. Also, an apparatus includes a printing station having a print head, a transport mechanism for transporting the medium toward the printing station, and a thickness measuring mechanism. The apparatus is structured to cause the distance between the top surface of the medium and a portion of the print head when the medium is located below the print head to be within a specified distance range based on the thickness of the medium.

Method and apparatus for printing on variable thickness print media

A print module for printing mailpieces comprises a print head assembly operative to deposit ink on each mailpiece and a registration plate for registering a first surface of each of the mailpieces during print operations. The print module includes a conveyor belt opposing the registration plate and engaging a second surface of each of the mailpieces for conveyance along a feed path. Disposed beneath and supporting an underside surface of the conveyor belt, is a continuous compliant deck operative to urge the conveyor belt and mailpieces toward the registration plate during printing. The compliant deck is also operative to print consecutive mailpieces of variable thickness dimension. The print module also includes a pivotable support rack for mounting the print head assembly to a housing. A pair of gas springs produces a moment about a pivot axis to bias the support rack to an open position and a pair of locking mechanisms produces a biasing moment opposing the moment produced by the gas springs to retain the support rack in a closed position.

Print module having pivotable support/instrumentation rack for print head assembly

A compliant conveyance system for processing mailpieces along a feed path, e.g., printing on a first surface of a mailpiece, while being registered against a contact surface of a registration plate. The conveyance system comprises at least one conveyor belt opposing the contact surface of the registration plate, a continuous, uninterrupted, compliant deck disposed beneath and supporting an underside surface of the conveyor belt, and a spring biasing device operative to bias the compliant deck and the conveyor belt toward the contact surface of the registration plate. The conveyor belt includes a drive surface for engaging a second surface of each of the mailpieces for conveyance along the feed path. As each of the mailpieces pass the registration plate, the compliant deck and spring biasing device urge the second surface of each mailpiece into engagement with the contact surface during processing.

Mailpiece conveyance system

A system for binding variable thickness multi-sheet collations includes first and second processing stations including a stitcher and stapler, respectively and a means for determining the thickness of a multi-sheet collation. A processor is responsive to a thickness value signal and selects one of the first and second processing stations to bind the multi-sheet collation. A conveyance system then transports the multi-sheet collation to the selected one of the first and second processing stations. A method includes the steps of: stacking sheet material to produce a multi-sheet collation, determining the thickness of the multi-sheet collation, and selecting an apparatus to bind the multi-sheet collation from one of at least two binding apparatus based upon the thickness of the multi-sheet collation. The multi-sheet collation is then conveyed along a feed path to a selected one of the binding apparatus. The method further includes the steps of disposing the multi-sheet collation between a pair of opposed registration members and aligning opposed edges of the multi-sheet collation by oscillating at least one of the registration members into and out of engagement with at least one of the opposed edges based upon the thickness of the multi-sheet collation.

Stitcher/stapler for binding multi-sheet collations and method of operating the same

A system for processing nested/unnested content material in a mailpiece inserter includes a first accumulator, a second accumulator and a folding module disposed therebetween. The first accumulator is operative to feed individual sheets of content material, in one operating mode, and accumulate multiple sheets of content material in another operating mode. The second accumulator is operative to accumulate unnested, folded sheets of content material in one operating mode, and feed sheets of nested, folded sheets of content material in another operating mode. The folder interposes the first and second accumulators and is operative to (i) receive the individual sheets of content material from the first accumulator, fold the individual sheets, and feed the unnested, folded sheets to the second accumulator, in one of the operating modes, and (ii) receive the multiple sheets of content material from the first accumulator, fold the multiple sheets, and feed the nested folded sheets to the second accumulator, in the other of the operating modes. A system processor is operatively coupled to, and controls the operation of, the first accumulator, second accumulator and the folder in each of the operating modes.

System and method for processing nested/unnested mailpiece content material

An item handling system includes a vacuum source, a transport element defining a plurality of vacuum openings in fluid communication with the vacuum source to create a securing force on an item proximate to the transport element for holding the item in contact with the transport element, and a drive element for driving the transport element to transport the item. The transport element further defines a plurality of sensor openings arranged in two substantially parallel arrays along a longitudinal direction of the transport element. The system further includes a sensor associated with each array of sensor openings for sensing energy passing through the sensor openings to thereby sense the item on the transport element. Each sensor is disposed at a common longitudinal position relative to the transport element. Sensing the item corresponds to a condition where the sensor associated with each array is blocked.

Item handling system with tracking

An apparatus for registering sheet material while being conveyed along a feed path including: (i) a conveyance deck for conveying sheet material along a support surface, (ii) a registration member defining an abutment surface operative to align an edge of the sheet material as the sheet material is conveyed along the support surface of the conveyance deck, and (iii) a drive mechanism disposed adjacent to the registration member and along the conveyance deck. The drive mechanism includes a flexible belt disposed about and supported by at least two rolling elements, and a means for driving the flexible belt about the rolling elements. The flexible belt includes a twisted section defining a plurality of spiral edge segments operative to (i) frictionally engage a surface of the sheet material to urge the sheet material against the abutment surface and (ii) convey the sheet material along the conveyance deck.

Alignment/registration and conveyance apparatus

A stitcher for binding variable thickness collations including a means for determining the thickness of a multi-sheet collation, a stitch head operative to drive a stitch through the multi-sheet collation, an anvil operative to clinch the stitch to bind the sheets of the collation and a plurality of actuators operative to displace forming elements of the stitch head to form the stitch, position the stitch head and anvil against opposite surfaces of the multi-sheet collation, drive the stitch through the collation and clinch the ends of the stitch. A processor, responsive to the thickness value signal, controls the actuators to form the stitch and bind the collation.

Reconfigurable stitcher for binding consecutive variable thickness collations

A vacuum conveyance/manifold system is provided for processing mailpieces. The vacuum conveyance/manifold system includes at least one conveyor belt and a compliant deck disposed beneath and supporting an underside surface of the conveyor belt. The conveyor belt has rows of aligned apertures disposed therein and a drive surface for engaging a face surface of each of the mailpieces. The compliant deck defines a neutral axis in bending and has a high elongation, low modulus material in a portion of the deck which is distal from the bending neutral axis, and a high yield strength, high modulus material in a portion of the deck which lies coincident with the bending neutral axis. Furthermore, the compliant deck has a plurality of elongate slots formed in the high elongation, low modulus material, which elongate slots are aligned, and in fluid communication, with the rows of apertures in the conveyor belt. A flexible manifold system, having a plurality of flexible tubes, is in fluid communication with the elongate slots of the compliant deck and the vacuum source for developing a pressure differential across each of the mailpieces when in contact with the drive surface of the conveyor belt.

Flexible vacuum conveyance/manifold system

An apparatus is provided for altering the spatial orientation and/or direction of sheet material. The apparatus includes an input deck for receiving sheet material along an input feed path, an output deck for forwarding sheet material along an output feed path, and an orbit nip roller assembly disposed adjacent to and aligned with the input and output decks. The orbit nip roller assembly includes a primary and secondary roller defining a roller nip which lies substantially parallel to the input and output feed paths. The secondary roller is adapted to be bi-directionally displaced in an arc about the periphery of the primary roller such that the roller nip orbits the primary roller from a first radial position to a second radial position. In the first radial position, the roller nip is adapted to accept sheet material from the input deck at a substantially right angle relative to the input feed path and, in the second radial position, the roller nip is adapted to dispense sheet material to the output deck at a substantially right angle relative to the output feed path.

Apparatus for altering the orientation and/or direction of sheet material in mailpiece fabrication systems

An apparatus includes a frame, a rotatable first shaft, wherein the first shaft includes a first cam, a rotatable second shaft, an item gripper connected to the second shaft by a connection including a link and an offset shaft rotatably connected to the link, and a linkage. The link is adapted to rotate with the second shaft for pivoting the offset shaft about the second shaft. The item gripper includes jaws adapted to open and close when the offset shaft is axially rotated relative to the link. The linkage connects the first cam on the first shaft to a rider on the offset shaft. The linkage includes a second having a stepped surface for a stepped movement of the rider along the stepped surface to open the jaws during a predetermined angular movement of the offset shaft about the center axis of the second shaft.

Cam driven insert gripper

An item transport system includes a first transport element rotating around a plurality of first transport rollers in a first direction, a second transport element in opposing relation to the first transport element, the second transport element rotating around a plurality of second transport rollers in a second direction opposite to the first direction, a guide plate proximate to the first transport element for engaging the items during processing by an item processing element, and an item registration device configured to maintain the items in registration with the guide plate. The item registration device includes a plurality of independently articulating pivot assemblies biased to engage the second transport element with the first transport element and a plate associated with each pivot assembly. Each plate is fixedly constrained with respect to the pivot assembly at one end and slidably constrained with respect to the pivot assembly at another end.

Growing community of inventors

Southbury, CT, United States of America

Russell W Holbrook