System and method for singulating a stack of sheet-like materials

Abstract

An improved hopper and singulating/feed assembly for a utilization device, such as an inserter, that feeds sheet-like materials from a hopper feed stack that reduces the various geometrical and physical problems that lead to jams, misfeeds and failures to properly singulate the stack is provided. A hopper reduces the pressure on the bottom sheets of the stack by providing a parallel wedge structure at the stack base. This wedge structure also helps to drive bottom sheets successively forward toward a front face so as to further break frictional and adhesive contact between sheets at the bottom of the stack. Hopper side guides with integral angled shelves engage front side edges of the stack and allow easier singulation of respective bottom sheets. Likewise a fixed sucker block assembly, which seats a suction cup in a rotating base with a surrounding planar block face and an integral fulcrum edge improves the separation of the bottom sheet from the overlying stack. The block face is adjusted to lift the stack upon engagement for further aid in singulation. This block is also fixed in rotation and vertical position with respect to the stack, requiring no continual adjustment. There are also lower shelves upon which the sheet is driven as the sucker rotates away from the stack that have non-parallel sides to avoid binding, and more accurately locate the sheets for subsequent draw into a raceway by a gripper/plucker assembly.