Powered fold plate for mail processing equipment

Abstract

Methods and systems are provided which use a powered orientation controller incorporated into mail processing equipment in such a way to reorient materials as they pass through the equipment. In this way, the use of powered orientation controllers can provide significant advances to the flexibility of current mail processing equipment.

1 . A method for folding a sheet-like material, the method comprising:
 feeding an inner portion of the sheet-like material between a first set of rollers comprising a first and a second roller which rotate in opposite directions to form a fold in the sheet-like material;   capturing the sheet-like material into a holding assembly in a certain orientation;   feeding the sheet-like material out from the holding assembly to a second set of rollers in the same orientation.   
     
     
         2 . A method as in  claim 1 , wherein the second set of rollers comprises the second roller and a third roller which rotate in opposite directions. 
     
     
         3 . A method as in  claim 1 ,
 wherein the holding assembly comprises a housing, a solenoid, and a sensor;   wherein the sheet-like material is captured in the housing; and   further comprising actuating the solenoid when the sensor indicates that the sheet-like material is at a certain location in the housing, wherein the solenoid pushes the sheet-like material to the second set of rollers.   
     
     
         4 . A method as in  claim 2 , further comprising feeding the sheet-like material from the second and third rollers to a first deflector which moves the sheet-like material between the third and a fourth roller. 
     
     
         5 . A method as in  claim 4 , further comprising feeding the sheet-like material from the third and fourth rollers to a second deflector which moves the sheet-like material between the fourth roller and a fifth roller. 
     
     
         6 . A method as in  claim 1 , further comprising placing the sheet-like material onto a conveyor. 
     
     
         7 . A method as in  claim 1 , further comprising placing an insert onto the sheet-like material. 
     
     
         8 . A method as in  claim 1 , further comprising stuffing at least the sheet-like material into an envelope. 
     
     
         9 . A method as in  claim 1 , wherein the sheet-like material comprises a sheet of paper, and wherein the first set of rollers folds the sheet-like material substantially in half. 
     
     
         10 . A system for processing sheet-like material, the system comprising:
 a first set of rollers, comprising a first roller and a second roller adjacent the first roller;   wherein the first and the second rollers are configured to rotate in opposite directions so as to grab the sheet-like material at an inner portion and to fold the sheet-like material to form a folded end;   a holding assembly that is configured to receive the sheet-like material from the first set of rollers in a certain orientation;   a second set of rollers; and   wherein the holding assembly is configured to feed the sheet-like material out from the holding assembly to the second set of rollers in the same orientation.   
     
     
         11 . A system as in  claim 10 , wherein the second set of rollers comprises the second roller and a third roller adjacent the second roller, wherein the third roller is configured to rotate in a direction that is opposite the second roller. 
     
     
         12 . A system as in  claim 10 , wherein:
 the holding assembly comprises a housing, a solenoid, and a sensor;   the solenoid is configured to actuate upon receipt of a signal when the sensor senses that the sheet-like material is at a certain location in the housing; and   the solenoid is further configured to push the sheet-like material to the second set of rollers.   
     
     
         13 . A system as in  claim 11 , further comprising:
 a fourth roller that is configured to rotate in a direction opposite the third roller; and   a first deflector spaced apart from the second and third rollers to deflect the sheet-like material between the third roller and the fourth roller.   
     
     
         14 . A system as in  claim 13 , further comprising:
 a fifth roller that is configured to rotate in a direction opposite the fourth roller; and   a second deflector spaced apart from the third and fourth rollers to deflect the sheet-like material between the fourth roller and the fifth roller.   
     
     
         15 . A system as in  claim 10 , further comprising a conveyor for receiving the sheet-like material. 
     
     
         16 . A system as in  claim 10 , further comprising an insertion mechanism for placing an insert onto the sheet-like material. 
     
     
         17 . A system as in  claim 10 , further comprising a stuffing mechanism for stuffing at least the sheet-like material into an envelope. 
     
     
         18 . A system as in  claim 10 , further comprising a control panel for controlling the operation of the system. 
     
     
         19 . A system as in  claim 10 , further comprising a plurality of mail processing devices. 
     
     
         20 . A feeding mechanism comprising:
 a housing having an open end for receiving and dispensing a sheet-like material;   a sensor configured to sense when the sheet-like material has reached a certain location within the housing; and   a solenoid that is configured to move the sheet-like material out of the housing upon the sensor sensing that the sheet-like material is at a certain location in the housing, and to push the sheet-like material to a set of rollers.   
     
     
         21 . A feeding mechanism as in  claim 20 , wherein the solenoid comprises an air cylinder, a plunger and a plate coupled to the plunger. 
     
     
         22 . A feeding mechanism as in  claim 21 , further comprising a stop that is configured to stop the plunger after moving a certain distance. 
     
     
         23 . A feeding mechanism as in  claim 20 , wherein the housing includes at least one window and wherein the sensor is configured to sense a location of the sheet-like material through the window.