Inserting Apparatus

Most businesses distribute a significant amount of material through either the United States Postal Service, private couriers or intraoffice distribution systems. The materials being distributed include, for example, written correspondence, invoices, payments, return postcards or envelopes, and laminated plastic identification cards or plastic credit cards. The material being distributed invariably is inserted into an envelope to insure confidentiality, to protect the item being shipped, to prevent the separation of several items or to conform with requirements of the carrier. The envelope may be printed with the address of the entity to which the material is being sent. Alternatively, the envelope may be provided with a window through which address indicia on the material being sent is displayed.

Many businesses distribute an extremely large volume of material, and thus are equipped with large, sophisticated and expensive equipment for use in this distribution process. However, many businesses distribute a volume of material that exceeds the practical limits for manual insertion into envelopes, but which does not reach a volume that would justify the substantial expenditure required to purchase one of the currently available inserters. For example, a business that distributes a few hundred pieces of mail each day almost certainly could not justify the large expenditure of money and the substantial allocation of office space for the available inserters. Typically, this smaller company would direct a few of their clerical employees to devote the last hour or two of each day to stuff envelopes with the invoices, laminated cards, or other material produced during the course of the day. This procedure, of course, is very labor intensive, requires employees to be periodically diverted from other more productive tasks, and inherently includes a substantial probability of error. The most likely type of error in this manual insertion involves the improper collation of inserts with envelopes such that one addressee receives material intended for another.

Even if a small or medium size business invested the substantial sums to purchase an available inserter, the resulting product would have several significant disadvantages. The most obvious such disadvantage is the inflexibility of most such machines. More particularly, a machine adapted to insert invoices into envelopes could not readily be readapted periodically to distribute plastic identification cards or credit cards. Similarly, the known prior art machines could not conveniently switch from distributing some items with return envelopes and others without. The prior art machines also could not readily switch from folding the insert once to folding it several times. Furthermore, the typical prior art inserting apparatus has been substantially independent of other office equipment. Thus, an office that already had a printer, a plastic card embosser and/or an insert folder, could not readily enhance those existing machines with a functionally flexible inserter. If an inserter was purchased, it would not only be large and expensive, but also unable to be functionally integrated with the existing equipment. In most instances, the only choice available to the office manager would be the replacement of the existing equipment with a single, very costly and functionally inflexible piece of equipment to perform several functions.

An example of a typical inserting and distributing problem encountered in many companies involves the production and distribution of plastic identification or credit cards. These cards are widely distributed by stores, mail-order houses, employers, unions, schools and government agencies. Typically, the plastic cards and an explanatory letter to the cardowner are printed separately. These cards and letters then may be collated manually such that the card and the letter may be inserted in an envelope. The card may be adhesively fixed to the accompanying letter or may be incorporated into an array of retaining slots cut into the letter. In either case, this manual collation takes considerable time and presents the possibility of human error. Alternatively, the collation may be carried out mechanically by available equipment that applies adhesive to the cover letter and then secures the card to the adhesive. This equipment requires frequent cleaning to prevent clogging by excess adhesive. Additionally, the machine must be stopped periodically to insure that the plastic cards are being applied to the proper corresponding cover letter. This is especially important since the address on the cover letter often shows through a window on the envelope, and thus identifies the person who will receive the card. However, even with frequent stops for spot checking, there is a significant possibility that two offsetting collating errors will occur between spot checks, thereby providing certain people with incorrect credit or identification cards.

Another problem with prior art inserting devices has been ensuring that the envelope is opened to accept the insert. Some prior art devices have employed complex suction mechanisms to grab one or opposed sides of the envelope and to urge the envelope into a slightly opened condition for receiving the insert. Other prior art inserting devices have employed arrangements of mechanical fingers which are slid into the envelope to urge the envelope into a partially opened condition for receiving the insert. Devices that employ mechanical air pumps or other such suction sources add to the complexity, cost and noise of the system. Similarly, devices that employ mechanical fingers to open the envelope can also add to the complexity of the system. Components which add to the complexity of the system typically also add to the size of the inserter and to the cost, thereby rendering these prior art inserters less desirable for many small or medium businesses.

In view of the above, it is an object of the subject invention to provide an apparatus for inserting material into an envelope.

It is another object of the subject invention to provide an apparatus for collating materials to be inserted into an envelope.

It is an additional object of the subject invention to provide an apparatus for properly matching an identification or credit card to a proper cover letter.

It is a further object of the subject invention to provide an apparatus for securely enveloping a plastic card in a form addressed to the intended recipient of the card.

Another object of the subject invention is to provide a collating and inserting apparatus that can be readily adapted for use with existing office equipment.

Still another object of the subject invention is to provide a collating, folding and inserting apparatus that is small, lightweight and inexpensive.

An additional object of the subject invention is to provide a method for efficiently collating, folding and inserting materials into envelopes.

Still another object of the subject invention is to provide a form for securely enveloping a plastic card.

Yet another object of the subject invention is to provide an envelope for efficiently receiving materials to be inserted therein.

The subject invention is directed to a small, lightweight, versatile and inexpensive apparatus to be used with other office equipment for inserting materials into an envelope. In most embodiments, as explained further below, the subject apparatus and the related office equipment will be able to fit on an area no bigger than the standard desk top. Indeed, in many instances it is envisioned that the system into which the subject apparatus is incorporated will fit on an area substantially smaller than the standard desk top.

The apparatus of the subject invention comprises means for receiving sheets of material from a feeder of sheet material. The feeder may be part of a printing apparatus or computer which prints letters, forms or the like on sheets of paper. Alternatively, the feeder may merely be adapted to receive a plurality of previously printed sheets of material, and to sequentially feed these pre-printed sheets into the receiving means. The receiving means may comprise a pair of generally parallel and slightly spaced apart rollers which cooperate with one another.

The sheet of material may be guided by the receiving means toward a stop that may be adjustably located relative to the receiving means. On certain embodiments, this stop will be disposed to cause a controlled buckling of the insert sheet such that an area intermediate the opposed ends of the sheet will be urged into an inserting means, such as another pair of rollers at least one of which is driven. This inserting means will create a fold in the sheet of material. The relative location of the fold in the sheet of material can be precisely controlled by moving the stop relative to the receiving means and the inserting means.

The apparatus may be employed with a second feeder and a second receiving means. The second feeder may feed a plastic card, a postcard, a return envelope or a second sheet of material. The second feeder may be part of a printing means, such as a means for printing, forming or embossing a plastic card. The second feeder preferably is operative to feed the insert into the second receiving means.

If both the first and second feeders are part of printing means, it is desirable to provide control means for insuring synchronous printing actions by the two units. In this situation, it is preferred that the slower printing means be the control to which the faster printing means is coordinated.

In embodiments of the invention which include both first and second receiving means, the second receiving means may be operative to urge the insert from the second feeder into the sheet from the first feeder. This contact between the insert and the sheet may be operative to urge the insert and the sheet of material into the second receiving means.

In embodiments of the subject invention wherein the insert is a plastic card, the sheet of the material preferably will be a form adapted to securely engage the card. This form preferably will be dimensioned to have a single slightly off-center fold line, and the apparatus will be operative to fold the sheet along the fold line. The form preferably will include a pair of cut outs on the respective edges thereof opposite the fold. More particularly, the cut outs will lie at locations that will be in register and adjacent to the card being engaged by the sheet. These cut outs enable easy removal of the card from the sheet and also may provide a fail-safe check to insure that the card is properly mated with the sheet prior to insertion in the envelope. This check may be carried out by an appropriately located light source and a light sensor. If the card is properly enveloped, no light will be able to pass through the folded sheet. However, if the card is missing, light will pass through the location of the registered cut outs and will be sensed by the light sensor. The machine will then be stopped until the error is corrected. The apparatus may also include means for checking the thickness of the folded sheet and card enveloped therein. A thickness that is too great may signify two cards improperly being enveloped in the same sheet. This will also cause the apparatus to be stopped until proper collation is achieved. The sheet may be provided with appropriately located adhesive to securely engage the card therein. Alternatively the apparatus may include means for applying adhesive.

The apparatus may also be adapted to insert the materials into an envelope. More particularly, the apparatus will include an envelope feeder that intermittently feeds envelopes at a speed which reflects the speed of the inserter. The envelopes will be fed in an opened condition with the open side substantially adjacent and in line with the second receiving means. As each envelope is advanced into alignment with the second receiving means, it will move past stationary guide means which urge opposed faces of the envelopes slightly apart to facilitate the reception of the insert. To further facilitate this opening of the envelope, an envelop with a pair of slits adjacent or on its rear face is provided. These slits may be disposed to be covered by the flap of the envelope such that security of the materials to be inserted therein will not be compromised. After the slightly opened envelope is in proper alignment with the second receiving means, the envelope will be retained in a stationary position until the insert is disposed therein. The stopping and starting of the envelope immediately before and immediately after the insertion may be controlled by sensing means. For example, the envelope may be printed with a metallic ink. The sensed presence of the metallic ink will cause the envelope to stop in position to receive the insert. A properly inserted card and/or sheet of material may block the the metallic ink thus causing the envelope and insert to move. The envelope and insert may be ejected and sent on their way to the addressee.

Another sensing means may be one or more photoelectric devices which will sense the presence of the envelope in a position to receive an insert, thereby stopping the envelope feeding means until the insert has been inserted into the envelope. The same photoelectric means or a second photoelectric means may be provided to sense the presence of the insert in the envelope. For example, a light source may be disposed on one side of the envelope, while a light sensor may be disposed on the opposite side. The light sensor may have a sensitivity to detect light from the source when the envelope is empty, but will not detect the light once the insert has been placed in the envelope. Thus, once the light sensor stops receiving its signal, the fully inserted envelope may be ejected, and a second empty envelope may be fed into a position to receive the next insert.

To facilitate and positively ensure that the envelope is in a partially open condition to receive an insert, the apparatus may comprise a rotatable fan means for delivering a stream of air toward the flap and adjacent opening to the envelope. The fan means may comprise a roller with at least one appropriately dimensioned and configured slot to generate a flow of air toward the envelope. The slotted roller or other such fan means may be operatively driven by the same power source that drives the rollers for delivering the inserts. The fan means, slotted roller or the like may be provided with a cowl to channelize the flow of air toward the open side of the envelope.

In certain embodiments, the above described apparatus may be incorporated for use with a postage meter which will properly stamp and seal the envelopes. In other embodiments, the envelope feeder may be part of a third printing means which prints the appropriate address indicia thereon. In this latter embodiment, the actions and relative speeds of each printing should be controlled by a common control means.

The apparatus preferably is provided with a means for detecting jams. This means comprises a pair of hinged plates disposed such that the hinge defines the above described stop. The sheet of material will advance between the two plates and into contact with the hinge. If for some reason too many sheets are advanced, one of the plates will rotate about the hinge and the spacing between the plates will increase. The apparatus will include switch means for detecting this movement and for signaling the jam.

The apparatus also may be adapted to create two folds in the sheet of material. In this embodiment, the first receiving means is adapted to initially direct the sheet of material toward a first adjustably located stop. The stop will cause the sheet to buckle into the nip between a pair of rollers which then direct the sheet toward a second stop. The sheet will then be urged into the second receiving means, as explained above, such that a second fold is formed in the sheet.

FIG. 1 is a side view of the inserting apparatus of the subject invention employed with two feeders.

FIG. 2 is a top plan view of the insert support shown in FIG. 1.

FIG. 3 is a front elevational view of the hinged guide assembly shown in FIG. 1.

FIG. 4 is a front view of the inserting apparatus shown in FIG. 1

FIG. 5 is a plan view of the top of a form used with the inserter of the subject invention.

FIG. 6 is a plan view of the bottom side of the form shown in FIG. 5.

FIG. 7 is a top plan view of the form shown in FIGS. 3 and 4 folded and sealed and engaging a plastic card.

FIG. 8 is a top plan view of an envelope for use with the inserter of the subject invention.

FIG. 9 is a side elevational view of the inserter of the subject invention in an alternate operating mode.

FIG. 10 is a side view of an alternate inserting apparatus in accordance with the subject invention.

A preferred embodiment of the inserter of the subject invention is illustrated in FIG. 1 and is identified generally by the numeral 10. The inserter 10 is adapted for use with a first feeder 11 and with a second feeder 12. The first feeder 11 is operative to sequentially feed sheets of material 14 to the inserter 10. Each sheet of material 14 typically will comprise a single piece of paper. However, a plurality of attached papers may comprise the sheet material 14, as may any other generally planar flexible non-paper material. Each sheet 14 includes opposed first and second surfaces 15 and 16 and opposed leading and trailing edges 17 and 18.

The first feeder 11 may merely be adapted to sequentially feed blank or previously printed sheets of material 14. Preferably, however, the first feeder 11 will be adapted to print selected material on each sheet 14 prior to feeding successive sheets 14 therefrom. More particularly, the first feeder 14 may include or be in communication with control means 20 which instructs the first feeder 11 as to the specific indicia to be printed on each sheet 14. Typically, each sheet 14 will be printed with unique information such as a name, address, identification number, and/or invoice material.

Each sheet 14 is fed from the first feeder 11 toward the inserter 10. To insure proper alignment of the sheet 14 between the first feeder 11 and the inserter 10, a support 22 extends substantially the entire distance therebetween. The principal requirement of the support 22 is to provide a substantially rigid surface extending at a preferred angle and in a preferred direction to insure proper entry of each sheet 14 into the inserter 10. As depicted in FIGS. 1 and 2, however, the support 22 includes generally arcuate guides 24. The guides 24 cause each sheet of material 14 to move through the inserter 10 in such a way as to receive a single fold therein. In alternate embodiments, however, the support 22 and the guides 24 are configured to cause each sheet of material to receive two folds at selected locations thereon as each sheet moves through the inserter 10. This alternate embodiment will be illustrated and described further below.

The dimensions of support 22 will be determined by the dimensions of each sheet 14 and the dimensions of the envelopes into which sheets 14 are to be inserted. The dimension "a" of support 22 will always be less than the length of sheet 14. Typically, the support 22 will be dimensioned to leave space "a" of approximately 4 inches between the first feeder 11 and the inserter 10.

The inserter 10 is provided with a first motor 26 which is mounted to the frame 27 and is operative to rotatably drive a primary gear 28. The primary gear 28 is operatively engaged with gear 30 which in turn is operatively engaged with gears 32 and 34. The gears 30, 32 and 34 are rotatably mounted to frame 27 and are fixedly mounted respectively to rollers 31, 33 and 35 respectively. The relatively rotational movements of the gears 28, 30, 32 and 34 are the associated rollers 31, 33 and 35 are indicated by the arrows in FIG. 1. The roller 33 is provided with undercut portions 33' which are located and dimensioned to receive guides 24.

As explained previously, the first feeder 11 and the inserter 10 are spaced from one another by a distance "a" which is less than the length of each sheet 14, and which preferably is approximately 4 inches. As a result of these dimensions, each sheet 14 will be properly directed by the support 22 and guides 24 into the nip between rollers 31 and 33. The rollers 31 and 33 will continue to urge the sheet 14 in the desired direction even after the sheet 14 is completely separate from the first feeder 11. The rollers 31 and 33 are disposed such that the sheet will contact roller 31 first. These relative positions of rollers 31 and 33 assist guides 24 in effecting the directional change of sheet 14.

The guides 24 of support 22 will urge the sheet 14 through a substantially 90.degree. change of direction such that the leading edge of the sheet 14 is engaged between and advanced by rollers 31 and 35. The sheet 14 then continues to to advance along a generally straight line for substantially its entire length.

The inserter 10 further includes gear 36 which is operatively engaged with the primary gear 28, and gear 38 which is operatively engaged with gear 36. Gears 36 and 38 are rotatably mounted to frame 27 and are fixedly mounted respectively to rollers 37 and 39. Preferably, the rotational axes of rollers 31, 37 and 39 are parallel and lie in a common plane and will be adjacent side 15 of sheet 14. Furthermore, the spacing between the rollers 31 and 37 is such that the intended location for a fold on sheet 14 will be approximately in line with the nip between rollers 37 and 39 when the sheet 14 is beginning to move out of the control of rollers 31 and 35.

The inserter 10 also is provided with feed rollers 41 and 43 which are mounted to gears 40 and 42 respectively and are driven by gears 44 and 46, which in turn are driven by gears 36 and 38. The feed rollers 41 and 43 define a nip which is substantially in line with the nip between rollers 37 and 39. However, the rollers 41 and 43 are disposed to be aligned adjacent side 16 of the sheet 14.

The sheet 14 is prevented from diverging from its intended path by panel 48 which is fixedly mounted to the frame 27. The panel 48 is generally in line with the roller 31 and includes a flange 49 disposed at an angle to the intended direction of movement of the sheet 14. The flange 49 ensures that sheet 14 advances along the proper side of the panel 48.

The apparatus 10 also includes a hinged guide assembly 50 which cooperates with the panel 48 to guide the sheet 14. The hinged guide assembly 50 comprises a stationary guide plate 52 and a rotating guide plate 54 which are articulated to one another at hinge 56. The stationary guide plate 52 and the hinge 56 can be slidably inserted into the frame 27 such that the stationary guide plate 52 can not rotate relative to the frame 27. When inserted into the frame 27, the stationary guide plate 52 is generally aligned with the panel 48 and spaced therefrom.

The rotating guide plate 54 is free to rotate about hinge 56 and away from the stationary guide plate 52. The rotating guide plate 54 is maintained slightly spaced from the panel 48 by switch 58 a distance sufficient to positively guide sheet 14. The switch 58 is operative to generate a signal if the rotating guide plate 54 is separated therefrom by a jam, a multiple feed or other such malfunction. The signal also could be operative to completely stop inserter 10.

The rotating guide plate 54 includes a flange 55 which is angled opposite the flange 49 such that each sheet 14 is assured of advancing between the panel 48 and the rotating guide plate 54. As shown in FIG. 1, the rotating guide plate 40 has a length "b" about as long as the combined lengths of the panel 48 and the stationary guide plate 52.

As shown in FIGS. 1 and 3, the rotating guide plate 54 also is provided with a cut out 60 which is generally aligned with the nip between feed rollers 41 and 43, and with the space between the stationary guide plate 52 and the stationary panel 48. The cut out 60 has a length "c" sufficient to receive a card or similar item from the second feeder 12.

The inserter 10 further includes applicators 62 which are in line with the cut out 60. The applicators 62 are spaced apart a distance greater than the width of a card to be fed by the second feeder 12. The applicators 62 are operative to dispense a liquid onto surface 16 of sheet 14. The liquid may be adhesive or a wetting agent to activate an adhesive previously applied to sheet 14. The applicators 62 may also be operatively connected to gear 34 or 40 such that the applicators 62 move into an operative position only when a sheet 14 is present.

The second feeder 12 is operative to sequentially feed cards 64 or similar items that will be inserted into an envelope along with an associated sheet 14. More particularly, the second feeder 12 is operative to feed card 64 toward sheet 14 at a location in line with the nip between feed rollers 41 and 43. The cards 64 fed by the second feeder 12 may be credit cards, identification cards, return postcards or envelopes. The second feeder preferably is adapted to print selected indicia on the card 64. For example, the indicia printed on card 64 by the second feeder 12 may be identical to or compatible with the selected and unique information printed on the sheet 14 by the first feeder 11. For example, the second feeder may print or emboss the name and identification number of an individual on a credit card or identification card 64. The first feeder 11 may print the same name on sheet 14 along with an associated address and appropriate explanatory material for the individual named on both sheet 14 and the card 64. In the preferred embodiment both the first feeder 11 and the second feeder 12 will be controlled by a common control means 20. The control means 20 will not only provide the required information to both the first feeder 11 and the second feeder 12, but will also insure coordinated and preferably substantially simultaneous printing by both the first and second feeders 11 and 12. As will be explained herein, the preferred dimensions enable the substantially simultaneous printing by feeders 11 and 12 to eliminate any possible collating mistakes.

The operation of the first and second feeders 11 and 12 is coordinated by the controller 20 such that the card 64 produced by the second feeder 12 is ejected therefrom when the sheet 14 has passed substantially entirely through the rollers 31 and 35. When the sheet 14 is leaving rollers 31 and 35, the preferred location for the fold in the sheet 14 will be substantially in line with the nip between rollers 37 and 39. The card 64 ejected from the second feeder 12 will then be carried by feed rollers 41 and 43 into the sheet 14. More particularly, the card 64 will be urged into contact with sheet 14 substantially at its intended fold which may be at or near its midpoint. Thus, card 64 will urge sheet 14 into the nip between rollers 37 and 39. The sheet 14 thus will be folded around and envelop the card 64, and the adhesive applied or activated by applicators 62 wil ensure that the card is positively engaged in an enclosure on sheet 14. To place this aspect of the operation in context, it should be restated that card 64 may be a credit card or identification card produced by the second feeder 12 and assigned to a particular individual. The sheet 14, on the other hand, may be a letter or information sheet uniquely adapted to match a credit card or other such card 64 produced by the second feeder 12. The system described thus far will produce a perfectly matched pair. In other applications, the sheet 14 may be an invoice, advertisement or the like, while the card 64 may be a return envelope or postcard.

The inserter 10 further includes an envelope feeder 70 which is operative to feed envelopes into a position to receive the folded sheet 14 and the card 64 as they are passed from the rollers 37 and 39. As shown more clearly in FIG. 4, the envelope inserter 70 includes a supply of envelopes 72 which are fed individually into position to receive the folded sheet 14 and card 64.

An envelope 72 preferred for use with the inserter 10 is illustrated in FIG. 5. More particularly, the envelope 52 includes a rectangular frint face 74 and a rear face indicated generally by the numeral 76. The rear face 76 is formed by flaps 78, 80 and 82 which are articulated to the front face 74 along fold lines 79, 81 and 83 respectively. The flaps 78, 80 and 82 are folded into overlapping relationship to define an opening 84 in envelope 72. The envelope 72 further includes a flap 86 articulated to the front face 54 along fold line 87. As illustrated in FIG. 5, the flap 86 is of generally triangular shape in accordance with the standard construction of most envelopes. However, a rectangular flap 86A, as indicated in broken lines, may also be used. The flaps 78 and 80 are provided with slits 88 and 90 which are disposed generally in proximity to the respective fold lines 79 and 91. Slit 90 is illustrated as being immediately adjacent to the fold line 81. Although this location of slit 90 is functionally desirable, it may be considered to detract from the security of envelope 72 in that the flap 86 may not entirely cover the slit 90. Therefore, as an alternative to the location of slot 90, slot 88 is shown as being slightly spaced from its corresponding fold line 79. Typically, an envelope 72 would have its respective slits 88 and 90 symmetrically disposed relative to the fold lines 79 and 81 such that both slits 88 and 90 will either be immediately adjacent the corresponding fold lines 79 and 81 or both will be slightly spaced therefrom. The envelope 72 further includes a spot of metallic ink 91 or other metallic material on the front face thereof and spaced slightly from fold line 83. As explained below, the metallic ink 91 will enable accurate control of the inserter 10. A strip of metallic material, such as tape, may also be used. The metallic material may be an edge of the glassine address window.

Returning to FIG. 4, the envelopes 72 are fed serially by frictional interaction with the belt 92 which is driven by motor 93 through wheels 94 and 96. Preferably, the envelopes 72 are fed such that the rear face 76 thereof is disposed upwardly and in contact with the belt 92. Inserter 10 includes a pair of guides 98 and 100 which extend generally parallel to rollers 37 and 39 and slightly on opposite sides of the nip therebetween. The guides 98 and 100 also converge slightly toward one another at their respective opposed ends. The guides 98 and 100 further are disposed relative to the envelope feeder 70 to be substantially in line with the opening 84 in each envelope 72 ejected therefrom. Thus, as the envelopes 72 are moved by the belt 92, the flap 86 thereof will contact the converging portion of guide 100 and be urged away from the rear face 96 as the envelope 72 is moved relative to guide 100. This will cause a slight opening in the envelope 72. More particularly, the flap 86 and a portion of the front face 74 will be urged away from the rear face 86 by virtue of the slits 88 and 90. The rear face 76 will further be urged away from the front face 74 as the rear face 76 is moved into contact with the guide 98. The slits 88 and 90 will enable a bending of the rear face 76 for easily accepting the material to be inserted therein.

The motor 93 which drives the wheel 94 is operative to start and stop intermittently. More particularly, the motor 93 is operative to stop after the envelope 72 has been fed into a proper position to receive a sheet 14. The motor will subsequently start to eject the properly inserted envelope 72 and to feed the next envelope into proper position to receive another insert. The proper timing of this intermittent action is achieved by a metallic sensor 102 which is mounted to the inserter 10 and is operative to detect the metallic ink 91 of envelope 72. More particularly, the metallic sensor 102 is in a position where it senses the metallic ink 91 when the envelope 72 is in a position to receive a folded sheet 14 and card 64. The rollers 37 and 39 will direct the combined sheet 14 and card 64 into the waiting envelope 72. Upon full insertion, the sheet 14 and card 64 will cover the metallic ink 91, thereby preventing receipt of a signal by the metallic sensor 102. The failure of the sensor 102 to sense the metallic ink 91 will cause the motor 93 to start again. Preferably, the motor 93 is operatively connected to the control means 20 such that the motor 93 when the first and second feeders 11 and 12 have stopped. Similarly, the control means 20 will insure that the first and second feeders 11 and 12 are stopped when the supply of envelopes 72 is exhausted.

Alternatives to the metallic sensor 102 may also be employed. For example the inserter 10 may include light sensors and sources to control the movement of the envelope 72. A first light source 200 and sensor 201 may be positioned to indicate proper alignment of the envelope 72, thus stopping further movement of the envelope. A second light source 202 may have sufficient intensity to shine through the empty envelope 72 and to be received by the second sensor 203. However, the presence of the inserts in envelope 72 will block the light from the second source 202. This interruption in the signal received by the second sensor 203 will cause the motor 93 to start again, thereby ejecting the envelope 72 with the inserts and feeding the next empty envelope.

As explained previously, the inserter 10 is especially effective for coordinating the insertion of a plastic credit or identification card 64 and a corresponding sheet of material 14, such as a letter, into an envelope 72. Additionally, as explained previously, collating errors had been a particularly serious and prevalent error in prior art systems for mailing plastic credit or identification cards with an accompanying letter. To protect against these problems, the subject inserter is provided with several fail-safe checks. Specifically, the two types of collating errors that could occur are the inclusion of two cards with a single sheet and the inclusion of no card with a sheet. It will be appreciated that these two problems could occur substantially sequentially and would go undetected by the prior art spot checks.

One fail-safe system incorporated into the subject inserter 10 comprises a pressure sensitive switch 104 disposed substantially in line with the nip between rollers 37 and 39 and operatively connected to the control means 20. The pressure sensitive switch 104 is adjustably mounted to detect an insert having a thickness greater than the predetermined thickness for a folded sheet 14 plus one card 64. If a thickness greater than the predetermined amount is sensed by the pressure sensitive switch 104, an appropriate signal will be sent to the control means 20 to stop the operation of the first and second feeders 11 and 12 and the envelope feeder 70. A specific embodiment of the pressure sensitive switch 104 may include a spring loaded ball bearing which is biased a controlled amount toward the surface of the insert passing from the nip between rollers 37 and 39. An insert having a thickness greater than the predetermined amount will cause the ball bearing of the pessure sensitive switch 104 to be biased into a position for completing an electric circuit that will send an appropriate signal to the control means 20.

Another fail-safe system comprises the magnetic switch 58 incorporated into the guide assembly 50 which detects jams or the presence of too many sheets 14 being advanced simultaneously through the inserter 10.

Still another fail-safe system comprises the metallic sensor 102 described above. If no material is placed in the envelope 72 or if only the sheet 14 or only a card 64 is inserted, the sensor 102 will continue to sense the presence of metallic ink 91. Thus the controller 20 will stop all operations.

A unique sheet 114, as shown in FIGS. 6-8, is particularly suited for use with the inserter 10 described above. Sheet 114 includes opposed sides 115 (FIG. 6) and 116 (FIG. 7). The sheet 114 is of generally rectangular shape and is defined by opposed leading and trailing parallel edges 117 and 118 and a pair of opposed parallel side edges 119 and 120. A score line 121 extends the entire distance between edges 119 and 120 and substantially parallel to edges 117 and 118 but approximately 1/4 inch closer to edge 117. Perforation lines 122 and 124 extend substantially the entire distance between edges 117 and 118 and parallel to the edges 119 and 120. The spacing between perforation lines 122 and 124 and the location of perforation lines 122 and 124 relative to the edges 119 and 120 may vary depending upon the particular application. However, the spacing between perforation lines 122 and 124 should be sufficient to enable the placement of an appropriate plastic card therebetween. The sheet 114 further includes arcuate cut outs 126 and 128 which are disposed intermediate the perforation lines 122 and 124 and along edges 117 and 118 respectively.

With reference to FIG. 7, it is seen that adhesive areas 130 and 132 are disposed to define narrow strips adjacent perforation lines 122 and 124. The generally rectangular area 134 defined between score line 121 and the adhesive strips 130 and 132 is dimensioned to be slightly larger than a card 64 to be used with the form 114.

Returning to FIG. 1, the form 114 will be printed in the first feeder 11 with appropriate indicia such as the name, address, identification number corresponding to an individual for whom a card 64 is being manufactured in the second feeder 12. After proper printing in the first feeder 11, the sheet 114 is ejected therefrom in the manner described above. More particularly, the sheet 114 will be oriented such that edge 117 defines the leading edge and such that the surface 116 will be contacted by the card 64 printed in and ejected from the second feeder 12. As sheet 114 advances through inserter 10, applicators 62 will activate the adhesive strips 130 and 132. Furthermore, the first and second feeders 11 and 12 will be aligned relative to one another such that the card 64 will be ejected substantially into the area intermediate adhesive strips 130 and 132. As a result of this orientation, the card 64 ejected by the second feeder 12 will contact the form 114 substantially at the score line 121 and intermediate the area defined by adhesive strips 130 and 132. As the sheet 114 and the card 64 are drawn into the nip between rollers 37 and 39, the leading edge of the card 64 will remain substantially in contact with the score line 121 while the trailing edge will be adjacent the cut outs 126 and 128 for easy removal. The sheet 114 may be severed along perforation lines 122 and 124 to define a convenient storage case for card 64. The off-center position of fold line 121 causes edges 117 and 118 to be out of register, thereby facilitating the re-insertion of card 64.

As noted previously, an important objective of the subject invention is to provide an inserter that is significantly versatile for use in a small office that can only justify purchasing one inserter to perform several different functions. As an example, it may be desirable to insert sheets of material 14 into an envelope 72 without a card, return envelope or return postcard such as card 64. In these situations, the second feeder 12 either would not be present at all or would be temporarily out of use. As a result, the card 64 would not be present to urge the sheet 14 into the nip between rollers 37 and 39. To insure the proper grasping of each sheet 14 by the nip between rollers 37 and 39, the hinged guide assembly 50 is mounted in inserter 10 such that the hinge 156 is spaced from rollers 31 and 35 by a distance slightly less than the length of each sheet 14 being processed by the inserter 10. As a result, each sheet 14 will be urged into hinge 156 by the rollers 31 and 35. A continued movement of the sheet 14 by rollers 31 and 35 will require the sheet 14 to buckle somewhere along its length. This buckling is precisely controlled by the panel 48, and guides 52 and 54 such that the sheet 14 is buckled into the nip of rollers 37 and 39. With this embodiment of the invention, an insert 14, such as an invoice, may be inserted into an envelope 72 without a corresponding card 64 to initiate the folding of the sheet 14.

In many situations, it may be desirable for the inserter 10 to accommodate a standard sized 81/2 inch by 11 inch sheet of paper 214 produced by the first feeder 11. This standard sized sheet 214 must be folded two times to fit into the standard envelope. To accomplish this double folding, a planar support 218 is used without upwardly curved guides as shown in FIG. 9. The inserter 10 shown in FIG. 9 is adapted with guide 224 which causes the leading edge 217 of each sheet 214 to be guided downwardly after passing through the rollers 31 and 33. The leading edge 217 thus will not enter the nip between rollers 31 and 35. The guide 224 includes a stop 226 which is mounted to frame 27 at a distance from the nip between rollers 31 and 33 less than one-third the length of sheet 214. When the sheet 214 contacts the stop 226, the sheet 214 will buckle upwardly at location approximately one-third along its length. The guide 224 carefully channelizes this buckling into the nip between rollers 31 and 35 such that a first fold is formed in the sheet 214. The sheet 214 then proceeds as had been described previously with respect to the FIG. 1 embodiment. More particularly, the sheet 214 will advance in a generally straight direction and will be urged into the nip between rollers 37 and 39 either by a card 64 ejected from the second feeder 12 or by a controlled buckling caused by the hinge 56. In either event, the sheet 214 will be urged into the nip between rollers 37 and 39 to form a fold line approximately two-thirds the distance from its leading edge 217. The folded sheet 214 will then be completely inserted into the envelope 52 as had been explained previously.

An alternate inserting apparatus 210 is depicted in FIG. 10. The inserting apparatus 210 is employed with an insert feeder 211 which is operative to feed sheets 214a, 214b which are to be inserted into envelopes as explained herein.

The inserter 210 comprises a power and control source which is schematically shown in FIG. 10 and identified generally by the numeral 220. The power and control source 220 is operative to power the feed means described herein and to coordinate the various feeding activities as explained above. In particular, the power and control means 220 may be operative to rotatably drive a master roller 228 about which a rubber belt "B" is driven. The belt "B" is an alternate the various interengaging gears described above. The belt "B" is effective to decrease the operating noise associated with the inserting apparatus 210 and to further minimize costs by eliminating the need for carefully machined gears.

The apparatus 210 further comprises rollers 231 and 233 which are disposed in parallel relationship and are driven in opposite relative rotational directions as indicated by the arrows thereon. The rollers 231 and 233 are disposed in spaced relationship to define a nip therebetween for feeding the sheets of paper 214a, 214b therethrough. Roller 235 also is disposed in slightly spaced parallel relationship relative to roller 231, and is rotated in an opposite direction relative thereto as indicated by the arrows on rollers 231 and 235. The nip between rollers 231 and 235 enables the feeding of the sheet of paper 214a, 214b in a direction generally orthogonal to the direction of paper moving through the nip between rollers 231 and 233.

The apparatus 210 comprises a guide 225 which is functionally similar to the guide 224 described above and shown in FIG. 9. The guide 225 includes a pair of spaced apart walls defining a slot therebetween into which the paper 214a, 214b is fed by the rollers 231 and 233. The guide 225 includes a stop 227 against which a sheet of paper 214a, 214b will abut, thereby causing each sheet of paper 214a, 214b to buckle into the nip between rollers 231 and 235. As explained above, this buckling will create a fold in the sheet 214a, 214b, and will cause the partially folded sheet 214a, 214b to advance as explained herein. The guide 225 differs from the guide 224 shown above in that it includes an arcuate portion generally opposite the stop 227 thereof. The guide 225 is removably and reversibly mounted in the apparatus 210 such that the arcuate surface 229 can be positioned intermediate the nips between rollers 231, 233 and 235. In this reversed configuration, the guide 225 will guide a sheet 214a, 214b directly from the nip between rollers 231 and 233 into the nip between rollers 231 and 235 without creating a fold.

The apparatus 210 further comprises rollers 237, 239 and 241 which are rotatably driven by the belt "B" in the direction of the arrows shown thereon. Each sheet 214a, 214b is driven through the nip between rollers 237 and 241 and thus is further driven into the guide 250. As explained above, contact of the sheet 214a, 214b with the base of the guide 250 causes the sheet to buckle into the nip between rollers 237 and 239. The guide 250 is structurally and functionally similar to the guide 225 described above, in that it is removably and reversibly mounted in the apparatus 210. Thus, the guide 250 can be reversed to urge the sheet 214a, 214b directly into the nip between rollers 237 and 239 without creating a fold. The combination of guides 225 and 250 can create various fold orientations or can directly feed the sheet with no folds.

The apparatus 210 further comprises an envelope feed for sequentially feeding envelopes 272 into a position where they may receive a sheet 214a, 214b fed through the nip between rollers 237 and 239. The envelope feed is substantially as described above, and is operatively driven by motor 293. The envelopes are fed with the side thereof having the flap 275 upwardly disposed relative to the remainder of the envelope. The envelope feeding portion of the apparatus 210 comprises an elongated generally arcuate guide 299 which is operative to bend the flap 275 of each envelope 272 into an upwardly aligned orientation to permit a sheet 214a, 214b to be inserted therein.

A photocell sensor 301 is disposed to sense the leading edge of the envelope 272 when the envelope 272 is in a position to receive a sheet 214a, 214b therein. Once the presence of the envelope 272 is sensed by the photocell 301, the envelope feed motor 293 will stop or otherwise interrupt the feeding of envelopes. As explained above, this feeding of envelopes 272 is coordinated with the feeding of sheets 214a and 214b to ensure that the envelope 272 is in proper position to receive a sheet 214a, 214b being fed through the nip between rollers 237 and 239.

A light sensor 392 and a light source 303 are provided on opposed sides of the envelope 272. The sensitivity of the sensor 302 and the power of the source 303 are such that light from the source 303 can be sensed by the sensor 302 when the envelope 272 is empty. However, the light will be blocked when a sheet 214a or 214b is in the envelope 272. This termination of the signal sensed by the sensor 302 will initiate the feeding of envelopes 272 to eject one envelope and sequentially feed an empty envelope into position to receive the next sequential insert.

To ensure that the envelope 272 is in a generally opened orientation for receiving a sheet 214a, 214b, the apparatus 210 is provided with a slotted roller 260 which extends generally parallel to the roller 237 and generally in opposed relationship to the envelope 272. More particularly, the slotted roller 260 is generally in line with the flap 275 and the elongated guide 299. The slotted roller 260 includes a plurality of generally radially extending slots 262 which are operative to generate a flow of air upon rotation of the roller 260. As depicted in FIG. 10, the slots 262 may be of generally arcuate configuration for efficient channelization of air in the general direction of rotation shown by the arrow adjacent roller 260. The apparatus 210 may further comprise a generally arcuate cowl 264 partly surrounding the roller 260 and for further channelizing the air. The roller 260 is not necessarily required to perform a feeding function for either the sheets 214a, 214b or envelopes 270, and may be disposed in spaced relationship thereto. Rather, the slots 262 create a controlled flow of air which is directed generally toward the flap 275 and the adjacent opening in the envelope 272 to ensure that the envelope 272 is in an opened condition for receiving the sheet 214a or 214b. The cowl 264 ensures proper channelization of this flow of air and prevents any inefficient dispersion of the air. The roller 260 can be driven by belt "B" and is substantially simpler than known devices employing suction and/or fingers to ensure opening of an envelope.

In summary, an inserting apparatus is provided for use with one or more feeders. The inserter will receive sheets of material sequentially and will fold each sheet and urge each sheet toward an awaiting envelope. This folding may be coordinated with and facilitated by the matching of a second insert or card with the first insert. The envelopes will be fed into a position to receive the one or more inserts and will be opened gradually as they are advanced into the receiving position. To facilitate this opening, each envelope preferably includes a pair of slits. The operations of the feeders and the inserter preferably are coordinated by a control means. The inserter may be provided with fail-safe means to detect jams, multiple feeds and to assure complete insertion into the envelope. Sheets are provided to securely engage a card and to function as a carrying case.

While the invention has been described relative to certain preferred embodiments, it is clear that various modifications thereto may be provided without departing from the scope of the invention as defined by the appended claims.