High page count method for mail inserts

Abstract

The invention is directed to a High Page Count method for mail inserters. The High Page Count method utilizes multiple source feeders to deposit source material onto a moving track at a rate equal to the speed at which the track operates. The High Page Count method is designed to optimize the mail inserter process by ensuring that no track position goes unfilled.

1 . A method for processing mail inserts, comprising the steps of: 
 selectively operating two source feed units to compile and deposit therefrom source material;    at least one of the source feed units being located downstream from an upstream source feed unit;    depositing source material onto a track from the upstream source feed unit onto a track position;    detecting when the upstream source feed unit is unable to deposit source material onto a track position; and,    depositing source material onto the track from the downstream source feed unit when the upstream source feed unit fails to deposit source material onto a track position.    
     
     
         2 . The method described in  claim 1  including, 
 detecting whether the downstream source feed unit is prepared to deposit source material; and,  
 operating the upstream source feed unit to purposely leave an empty track position when the downstream source feed unit is prepared to deposit source material.  
 
     
     
         3 . A method for processing mail inserts, comprising the steps of: 
 selectively operating two source feed units to compile and deposit therefrom source material;    at least one of the source feed units being located downstream from an upstream source feed unit;    selectively operating a common feeder located upstream from the upstream source feed unit;    depositing common material from the common feeder onto a track at positions therealong;    depositing source material from the upstream source feed unit onto the track at positions therealong;    detecting when the upstream feed unit is unable to deposit source material onto a track position; and    depositing source material from the downstream source feed unit onto the track at positions therealong at which positions the upstream source feed unit fails to deposit source material thereat.    
     
     
         4 . A method for processing mail inserts, comprising the steps of: 
 placing two source feed units adjacent the same position along a track;    selectively operating said two source feed units to compile and deposit therefrom source material;    one of the source feed units being a primary source feed unit the other being a secondary source feed unit;    depositing source material from the primary source feed unit onto the track at positions therealong;    detecting when the primary source feed unit is unable to deposit source material onto a track position; and    depositing source material from the secondary source feed unit onto the track at positions at which the primary source unit has failed to deposit source material thereat.    
     
     
         5 . The method described in  claim 4  including, 
 detecting when the secondary source feeder unit is prepared to deposit source material; and,  
 operating the primary source feed unit to purposely leave an empty track position when the secondary source feed unit is prepared to deposit source material.  
 
     
     
         6 . A method for sorting compiled pieces of source material, comprising the steps of: 
 selectively diverting source material, compiled from a source feed unit feeding selected track positions, from said selected track positions into a sorting path for said source material from the source feed unit;    depositing the source material from the sorting path to an output station; and    distributing the source material from the output station to a collector.    
     
     
         7 . The method described in  claim 6  including, 
 selectively operating a plurality of source feed units to compile source material and separately diverting and depositing source material corresponding to each one of said plurality of source feed units.