Document Transporter for Use in Forwarding System

The volume of mail and other documents handled daily by large businesses, institutions and governmental entities has steadily increased through the years. For example, credit card companies, utilities, mail order houses and other advertisers send and receive huge quantities of mail daily. Typically, the documents or envelopes containing the material to be mailed are addressed and then sorted into common groups for mailing. Similarly, mail received by such entities is commonly sorted into groups based upon the subject matter of the received material. A third category of such envelopes are the returned mail category the creation of which is primarily due to the addressee having moved from a particular address resulting in the envelope being undeliverable. The present invention is a system directed to the solution of this latter type of problem, namely, the correction of the address that will permit its proper delivery.

Several different types of machines have been developed to assist in the handling of such mail, other than manual review and correction by the individual mail carrier. These prior art devices typically comprised an envelope feeder, a read station, a selection of label station where a supply of labels permitter selection of an appropriate label and its application to an envelope, and a sorting and storage means.

None of these prior art machines and systems proved satisfactory since they were large unwieldly machines that required not only a large amount of space but also required frequent replenishment of a vast array of pre-printed label supplies and applicating equipment.

The contemplated system provides a unique computer- operator controlled system with a plurality of unique stations that are suitable for use with conventional mail sorting machines as well as other document handling equipment.

The system includes a feeder module wherein incoming documents or envelopes are separated from each other and delivered to a unique transport module. The present invention relates to that unique transport module which moves the individual envelopes or documents sequentially to a plurality of "read" stations; observation means, then can be audible, visual, or tactile, such as a cathode ray tube (CRT) monitor, conveniently disposed for operator observation; and correction means, such as an input keyboard means tied to a main computer data source, for use and control by an operator.

Observation of indicia by the operator and selective input into the keyboard means results in an electable response by the operator, the elected information then being sent to a print module for use in creation of an appropriate corrective means.

The unique transport module generally includes a plurality of stations in each of which the operator has an unobstructed view of the entire side surface of the envelope while reading the address or other identifying data thereon. Once the address or zip code has been ready by the operator, the operator makes a codified entry which is processed by the computer, with which the machine is associated, and into which computer the changes of address have been introduced on a frequent periodic basis. If the limited information introduced by the operator is applicable to more than one individual addressee, alternatives will be displayed to the operator for the operator to choose from. The information so chosen is then forwarded to the next module and the envelope or document released for movement along the various stations in the transport module and thence out of the operators visual range serially into the next module.

Another object of the invention is to provide a document forwarding system of the type contemplated that includes this improved transport module within the system that will reliably operate over extended time parameters with minimal down times, as well as being relatively simple and economical to construct and operate.

Other and further objects of this invention, together with all of the features of novelty appurtenant thereto, will appear in the course of the following description.

FIG. 1 is a perspective view of a system utilizing an embodiment of the present invention;

FIG. 2 is a partial perspective view of a prior art transport module;

FIG. 3 is a partial perspective view of a preferred embodiment of the transport module showing the various viewing stations thereon;

FIG. 4 is a partial perspective view of a second embodiment of the transport module;

FIG. 5 is a schematic plan view of the transport module shown in FIG. 3; and

FIG. 6 is a schematic plan view of the second transport module shown in FIG. 4.

Referring now to the drawing, wherein similar parts are designated by similar numerals, and particularly FIG. 1, a computer assisted document forwarding system of the type contemplated by the present invention is generally designated by the numeral 20 and includes an integrated system of several modules, each of which in the forwarding system being discussed are interrelated with the other and mutually interdependent, but which under other circumstances can be independently operable for other functions. Such forwarding systems are designed to reduce the labor factor involved in updating a mailing list and also to forward mail that has been erroneously deposited at a local post office.

A system of the type contemplated by the present invention would include a feeder module 22, a transport module 24 which has a plurality of observation means stations, a print module 26, a labeler module 28, a label cassette 30, and a sorting and stacking module 32. It is such a system,, referred to earlier, that can be used by the local post offices where documents, i.e., mail envelopes of various sizes, have been stopped because a customer has entered a change of address order and hence existing documents are not properly addressed for delivery purposes. It is recognized that there are a broad variety of applications for such a system, other than postal usage, in the catalogue, credit card, mail order/mail system categories and any others where a billing or form of address means must accommodate changes in address. It provides a ready update system and reduces the labor expenses by providing an accurate, readily available listing of correct addresses for immediate application to a document. The system is basically an ancillary arm to a master computer where all of the address changes are fed and maintained for a predetermined time frame. The information in the master computer is made available to the subsidiary or remote stations for use by an operator to update on a ready basis the address to which particular pieces of mail are to be forwarded.

To broadly describe the operation of the device, a plurality of documents or envelopes are fed sequentially in serial fashion, one at a time to the first of the plurality of observation means stations located in the transport module 24. The operator reads the address of the document and types into the computer an abbreviated version of the address, for example, the first three letters of the addressee's last name and the last two digits of the zip code. The keyboard 25 being the input mechanism into an electronic information storage means (not shown) interconnected with the input means also serves as a retrieval means to inform the operator. Normally, where there is only one combination of such letters and digits on file, the computer automatically selects the proper address. If there are more than one possible responses to the input they all are provided to the operator, for example, they can be visually displayed on a cathode ray tube (CRT), however, audible or tactile means could also be used. The operator then selects the correct one and continues the operation by striking an appropriate key. The document is then fed to a buffer station on the transport module 24 where it remains while corrective means are chosen from the selected data fed to it by the computer. The document is then released from the buffer station and transported to the next module 28 where the correct address information for the particular addressee is applied to the document. It is then moved through and to the sorter and stacker, which movement can also be controlled on the basis of the same data fed from the computer to the corrective module so that it is immediately broadly sorted for delivery to the correct address.

FIG. 2 is broadly representative of a prior art type of transport module. A document or envelope was delivered from a feeder module to a position on the upper supporting surface of the module, not shown, in front of an elongated guide 30 that projects outwardly over the supporting means of the module and is positioned above one or more constantly rotating rollers 32 that project outwardly beyond the plane of the lower edge 31 of guide 30. It was necessary to provide envelope pressure against the rotating rollers 32 as by a similar number of moveable rollers 34 to ensure movement of the envelopes. The rollers 34 illustrated in FIG. 2 were each mounted on an arm 35 capable of oscillation about a fixed pivot 36, with each arm powered by suitable means, not shown, to force the envelopes, not shown, into engagement with the constantly rotating rollers 32.

This prior art had several disadvantages. A few of the primary objections being the disposition of the oscillating arm mechanism in front of the envelope, with the resultant disturbance of the operator both from a noise and motion standpoint. Additionally, the illustrated mechanism does not stop the motion of the envelope at a constant position each time, due to the inertia of the document. The exposed mechanism was also subject to collection of dust and dirt that resulted in a requirement for an undue amount of maintenance. The combination of these problems made the prior art mechanism highly undesirable.

Referring now to FIG. 3, a transport module 24 of the type contemplated by the present invention includes a plurality of viewing stations disposed on a generally vertically disposed panel member 38, canted slightly to the rearward, and extending upwardly from a desk-like operator station, as best seen in FIG. 1. These viewing stations provide the operator a full view of the broad front or address side of the envelope for reading and correcting purpose. As the envelope 40 comes out of engagement with the last double pair of feed rollers 42 and 44, the envelope 40 engages and transfers to a moving belt 50 riding on rollers 52 and 54. The belt 50 is supported by a lubricious frame member 56. The envelope 40 is shown in the first or previewing station 60; the envelope 40a is shown in the viewing station 62 where the envelope 40a abuts and is temporarily restrained against movement with the belt 50 by the stop means 70. The serially next preceding envelope 40b is positioned in the reviewing station 64 where the envelope is held in a temporarily restrained configuration by the stop 72. The last station in the transport module is a buffering or holding station 66 illustrated by envelope designated 40c. (The indicated names and arrows are purely for purposes of illustration only and are not meant to be limiting.)

As the envelope 40 proceed across in front of the operator, the operator reads the address and the name of the addressee in the previewing station and in the viewing station. In the viewing station 62, the operator types the coded information into a computer keyboard terminal, not shown in this figure, which information is fed into the computer having the corrected information. After typing in the last digit of the code and viewing it on a monitor 80, the program in the computer causes the stop means 70 and 72 to be simultaneously activated and rotated about pivots 71 and 73, respectively, which causes the stop means or fingers 70 and 72 to be moved out of the way and permit envelope 40a to move with the belt 50 into the position of 40b; and similarly envelope 40b to move into the buffering station, as shown with envelope 40c. Activation of the stop means 70 and 72 can be equated to that of a pair of simultaneously opening gates that permit those items on the moving belt to be passed to the next station.

When an envelope 40a moves to the reviewing station 64 the operator will look at the monitor 80 to determine whether there is a possibility of a multiple choice from the code type in when the envelope was at viewing station 62. If this multiple choice exists, the operator will make the necessary selection to correspond go the remainder of the information that had not been fed into the computer with the abbreviated code. Selection of one of the choices will then be made and the envelope passed on to the buffering station 66. It should be noted that the envelope 40c will be retained in the buffering station 66 until the printing operation has been completed and the label ready to be applied to envelope 40c. Needless to say, the stop 72 would not be activated until buffering station 66 has been cleared and available to accept the next envelope.

Referring now to FIG. 5, a plan schematic of the embodiment shown in FIG. 3, the various modules 22-28 include a plurality of sensing means 82-90 that detect the presence or absence of an envelope at a particular station along the belt 50. The presence of an envelope in a particular station will either stop the driver wheels 42-44 from rotating or prevent the fingers 70-74 from releasing an envelope to the buffering station, prior to entry into the printing and labeling module. Additionally, to ensure coordinated movement by the stop fingers 70, 72 a connecting rod 74 can be provided to interconnect them to move simultaneously as a unit.

Referring now to FIGS. 4 and 6, wherein similar parts are designated by similar numerals with the addition of the suffix "a", a second embodiment of the transport module 24a utilizes a foreshortened or shingled configuration. The module 24a includes the same four stations, namely, previewing, viewing, reviewing and buffering stations. However, the module includes a central portion 100 which lies in a plane that is positioned forwardly of the plane of the two adjoining first and third portions 102 and 104, respectively. The first portion 102 and the third portion 104 are connected to the central portion 100 by tapered surfaces 106 and 108, respectively. Thus, as can be best seen in the semischematic view in FIG. 6, the first envelope 40 when propelled by the driven roller 44a is directed to the previewing station 60a located in the recessed portion 102 behind the preceding envelope 40a which is positioned in the viewing station 62a, which is predominantly located at the central portion 100 in front of the plane of recess 102. As will be noted in FIG. 6, the envelope 40a, hen positioned in the viewing station 62a, extends rearwardly from the central portion and overlaps the next envelope 40 in a shingled effect and with its front edge engaging and temporarily restrained by the rotatable stop 70a. Release of the stop member by rotating out of the path of envelope 40a results in its passing to the next or reviewing station 64a where it assumes the position of envelope 40b and is restrained temporarily by stop 72a. When release, the envelope then assumes the position of envelope 40c in the buffering station 66a in a canted position with one end located against the recess wall 104 and restrained by stop means 73, not shown in FIG. 4 but seen in FIG. 6. It should be noted that while an equivalent stop means was not shown in the embodiment of FIGS. 3 and 5, that device can also employ such stop means, if desired.

When the envelope is in the position of the buffering station 66a and has been released, the belt 50a will move it to the right into the nip of driven roller 74 and idler 76 for movement into the labeler module for application of a label serially printed in a printer module, as generally explained hereinabove.

Referring once again to FIG. 6, it will be noted that a plurality of detector means 82a-90a are provided in spaced locations along the transport module. For example, detector 84a reports the presence or absence of an envelope in the viewing station 62a; detector 86a reports the presence or absence of an envelope in reviewing station 64a; detector 88a reports the presence or absence of an envelope in the buffering station 66a; and detector 90a reports the presence or absence of an envelope in the nip of feed rollers 74-76 at the entrance to the labeler module. The information reported by these detectors, which are commercially available in a wide variety of configurations, is fed to the program controlling the operation of the entire system. When a label has been prepared for a particular piece of mail the envelope is released from the buffering station and driven by rollers 74-76 to the labeler module for application of the label. The movement of belt 50, the stop means 70a and 72a, interconnected by rod 74a are synchronized with the presence or absence of envelopes in their respective locales and additional envelopes are not introduced to the transport module 24a from the feeder module 22a until the detector 82a reports that the position at drive rollers 44a is empty and prepared to accept the next envelope.

This second embodiment, as seen in FIGS. 4 and 6, with its shingled arrangement in front of the operator, provides the following advantages, namely, a foreshortening of the length of the transporter module resulting in space saving; it increases productivity of the operator by reducing the time required for exchange of documents between the different positions of the stations; and a further increase in productivity is realized by sensing the back edge of the first document and reacting to the size of the documents presented for action by the operator.

By referring to FIG. 6, it will be noted that the stops 70a and 72a rotate clockwise to release the documents. When they return to the blocking position, the tip 76a of the second stop 72a will bear against the envelope 40c and cause it to move back into the canted position illustrated and align its front end for delivery to the nip of rollers 74-76 when it is released for further movement.

The next modules are physically interrelated by close proximity, namely, the labeler module 26 and the printer module 28.

It should be recognized that the disposition of the stop means fingers 70-72 and 70a-72a in the front of the envelopes can be positioned behind the canted panel member 38 and project forwardly from the panel. Similarly, the action of the finger stop means does not have to be limited to a swinging action, but could be linear motion means projecting from the panel member 38, however, the swinging action has been found to be preferable for handling the paper produce encountered in devices of this nature.