Sheet feeding or delivering – Feeding – With means to align sheet
Reexamination Certificate
2001-10-25
2003-11-11
Walsh, Donald P. (Department: 3651)
Sheet feeding or delivering
Feeding
With means to align sheet
C271S003010, C271S003030, C414S790700
Reexamination Certificate
active
06644657
ABSTRACT:
FIELD OF THE INVENTION
The instant invention generally relates to a document accumulating transport, (also known as a collator, sheet accumulator, document accumulator, accumulator or dual accumulator) which is part of a high-speed document feeding system. The accumulator is utilized in a document processing system for collating sets of documents (also known as collations or sub-sets of documents or sheets) being processed for delivery to a customer or client in groups, document packets, or collation assemblies all of which may be inserted into a waiting envelope in a document processing machine such as that described above. There may be one document or sheet-feeding path in the accumulator, or two such as that common in a dual accumulator where the document feeding paths are arranged in parallel relationship. Such an accumulator has utility in an inserting machine that typically processes sheets in the form of individual inserts or sets of inserts or collations to be inserted into an envelope. The documents are initially advanced towards the document accumulator by document feeding apparatus that shingles them prior to reaching the input side of the accumulating apparatus.
BACKGROUND OF THE INVENTION
It has been a common solution that sheet or document processing equipment such as inserting equipment have document accumulating systems such as dual accumulators or accumulators that have one or more accumulator bins in order to help maintain the highest possible throughput of the documents or sheets through the equipment. The additional accumulator bins are especially helpful in providing higher throughput or output of documents in collations or subsets of documents. It is also often a requirement that the document accumulating systems within such equipment must be able to provide subsets of document or sheet material within a collation that will eventually be inserted into an envelope.
While individual sheets are conveyed serially and processed serially in such document accumulating systems, provisions for accepting an entire subset or collation that is shingled while entering each collating bin has not been provided. Prior art such as that described in U.S. Pat. No. 5,083,769 to Young illustrates the handling of sheets in serial relationship, and for depositing single sheets in two accumulator bins of a dual accumulator.
It is now desirable to process sheets or documents that are shingled or overlapped in shingled relationship to form subsets or collations that are typically arranged with the lower sheet being the first document of the subset or collation. These collations of shingled documents are fed along a conveyor from an input source in spaced apart relationship that leads to an accumulator having one or more accumulator bins. The shingled relationship of individual sheets or documents has come about in an effort to process a greater quantity of such documents in equipment such as that described above. When this shingling process is used, the shingled document subset or collation must then be registered or justified at some point within the accumulator bin of the document accumulator for further processing as a completed document collation ready for further processing downstream in the equipment.
There are various schemes and apparatus known in the document-processing field that will ramp or lift individual documents to their desired position in an accumulator bin to an overlying position that may be on top of a previously deposited document. There currently are a number of problems that exist as to how this is accomplished with reliable mechanism and components to effect the final desired collation. The final collation may be one sheet or document, or many, depending on the job being processed. Using presently available document accumulator systems presents a problem because of the physical nature of part of the conveying systems and associated ramp devices leading into the accumulator bins. For example, presently available accumulators typically have an assembly of intermediate transport devices with “O” ring belt pulleys and accompanying “O” rings that are wrapped about the pulleys that have small diameters. These intermediate assemblies provided with small rollers and accompanying ramp members are used to propel a succeeding document over a waiting document in the accumulator bin in order to form a collation.
The use of ramps having a series of small rollers that “O” ring belts move over and under is a common way to effect the direction of the documents over the ramp. Within these accumulator designs, wear and tear on the “O” rings is a problem requiring a service call to replace the belts as they wear due to reverse flexing at high speed because the belts traverse the small support rollers in the area of the ramps. The other problem is that these types of ramps and conveyors will not properly bend a collation that is composed of multiple sheets or documents having greater thickness than a single sheet or document. The nature of bending the sheets or documents around small diameter rollers and pulleys in the intermediate conveying area of the accumulator is necessary in order to provide the desired accumulation of documents in either regular of reverse order. Subsets or collations of documents of thickness greater than a single sheet that traverse the intermediate conveying area of the accumulator conveying system leading to the accumulator bin often jam or become skewed in that area, thereby causing a machine malfunction requiring downtime for the processing equipment.
The processing speed of sheets or documents being conveyed through such equipment is increasing with the need for increased quantities of documents to more and more delivery points that meet customer needs. The material that the documents represent includes customer financial statements, credit card statements and the like. The documents as accumulated in sets, subsets or collations are delivered to the public in mailing envelopes through the USPS as they are supplied through the high-speed document processing equipment and inserting machines. The need for increased speed in order to process such material and documents only adds to the problem of wearing belts, and therefore reduced running time of the equipment due to service needs including replacement of damaged conveying belts. In addition, the increased speed of the sheets and documents means that careful attention must be paid to how the leading end of those sheets and documents arrive at the document accumulators and their respective accumulator bins. Another problem presented by the prior art is that the increased speed and velocity of the documents or sheets easily causes deflection of the sheets due to air resistance and obstructions including diverting mechanisms and ramps such as those described above having sharp bending points that can distort portions of the sheets. Improper guiding devices or conveying devices will extend the problem of sheet or document damage during their conveying motion through the intermediate diverting area of the sheet or document accumulator where the typical accumulator bin is located.
The other problem that may be present in the higher speed sheet processing equipment using sheet or document accumulators is that the sheets may be unintentionally overlapped so that they are uneven at their leading end. This may cause a jam for the reasons explained above. Once in the accumulator bin of the document accumulator, overlapped sheets or documents require justification at their leading edge in order to be subsequently released to the next stage of processing such as a folder module. If a sheet, a document or a collation is not properly squared off, justified or registered, an improper fold in the folder module typical of such processing equipment will occur. Improperly folded documents or collations will not enter envelopes waiting downstream in the document processing system. Therefore, it is desirable to have the sheets or documents justified after they enter the collating bin as much as possible to avoid having
Anderson Rebecca J.
Wright William J.
Chaclas Angelo N.
Cummings Michael J.
Malandra, Jr. Charles R.
Pitney Bowes Inc.
Schlak Daniel
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