Method and apparatus for processing envelopes containing contents

Abstract

A mail processor and a method for processing mail is provided. The mail processor severs envelopes along one or more edges and transports the envelopes to a work desk where an operator removes contents from the envelopes. A feeder draws envelopes from the bottom of a stack of mail placed in a hopper. The envelopes are serially fed by the feeder to a cutting assembly that severs each envelope along one or more edges. A transport assembly tilts each envelope in an inclined plane and presents the tilted envelope to an operator. An extractor opens the severed faces of the envelope to expose the contents to the operator and permit the operator to remove the contents from the envelope. In one embodiment of the invention, the envelope is discharged from the extractor to a verifier that confirms that the envelope is empty prior to disposal of the envelope.

1 . A device for processing envelopes containing contents, comprising: 
 a feeder for receiving a stack of envelopes and serially feeding the envelopes, wherein the feeder comprises an input bin angled downwardly so that the envelopes in the stack are angled downwardly;    a cutting area disposed forwardly of the feeder, having a substantially planar horizontal base for receiving an envelope from the feeder in a generally horizontal orientation, the cutting area comprising three cutters separated from one another, each of the cutters being operable to sever an edge of the envelope so that the envelope can be opened along three edges, wherein the cutters are positioned around the cutting area so that the envelope follows a u-shaped path in a substantially horizontal orientation over the base as the envelope is conveyed past each of the three cutters in the cutting area;    a justifier disposed adjacent the cutting area, having a base that is substantially co-planar with the base of the cutting area, wherein the justifier is operable to receive the envelope from the cutting area in a substantially horizontal orientation and justify an edge of the envelope;    an extractor operable to pull open the edge-severed envelopes, to present the contents to an operator while the contents are in the envelope, so that the operator can manually remove the contents;    a document transport operable to receive the envelope from the justifier and convey the envelope to the extractor, wherein the transport is operable to twist the envelope so that the envelope forms an angle relative to horizontal.    
   
   
       2 . The device of  claim 1  comprising a gate associated with each of the cutters in the cutting area, wherein the gates selectively impede movement of the envelope in the cutting area.  
   
   
       3 . The device of  claim 2  wherein each gate is pivotable between a raised position in which the gate impede movement of the envelope in the cutting area, and a lowered position in which the envelope can be moved forward through the cutting area.  
   
   
       4 . The device of  claim 3  wherein each gate is selectively controlled to dampen the noise made when each gate is pivoted between the raised position and the lowered position.  
   
   
       5 . The device of  claim 1  wherein each gate operates to justify an edge of the envelope.  
   
   
       6 . The device of  claim 1  wherein the input bin is configured to receive a vertical stack of envelopes.  
   
   
       7 . The device of  claim 1  comprising a work area positioned in front of the extractor, wherein the work area is configured for the operator to be stationed in front of the extractor to remove documents from envelopes, and the cutting area is positioned adjacent the work area so that an operator can grasp an envelope at any of the three cutters while remaining at the work area.  
   
   
       8 . The device of  claim 7  wherein envelopes in the cutting area, justifier and transport remain readily accessible to the operator, so that the operator can readily remove envelopes in the event of a jam.  
   
   
       9 . A device for processing a stack of envelopes containing contents, comprising: 
 a feeder operable to feed an envelope from a stack of envelopes, wherein the feeder comprises: 
 a feed belt having an engagement portion having at least one hole through the belt, and a smooth section extending substantially the entire length of the belt wherein the smooth section has a lower coefficient of friction than the engagement portion;  
 a manifold having at least on hole to cooperate with the hole in the engagement portion of the feed belt;  
   a vacuum source for providing negative pressure to the manifold, so that when the feed belt rotates to align the belt hole with the manifold hole, negative pressure is provided through the aligned holes to pull the envelope from the stack, wherein the vacuum source provides a constant negative pressure to the manifold;    a cutter configured to receive the envelope from the feeder and sever the envelope along one or more edges;    an extractor operable to open the envelope along one or more severed edges to present contents of the envelope to an operator so that the contents can be manually removed.    
   
   
       10 . The device of  claim 9  wherein the feeder comprises a retard element to impede the feeding of two envelopes simultaneously.  
   
   
       11 . The device of  claim 10  wherein the retard is pivotable upwardly away from the belt.  
   
   
       12 . The device of  claim 9  wherein the engagement portion of the belt comprises a plurality of spaced apart holes and the manifold comprises a plurality of holes spaced apart to align with the holes in the engagement portion of the belt.  
   
   
       13 . The device of  claim 12  wherein the surface of the belt adjacent the engagement portion comprises a low friction surface so that after the engagement portion of the belt engages the envelope, the low friction portion of the belt engages the next envelope in the stack to impede the feeding of two envelopes simultaneously.  
   
   
       14 . The device of  claim 9  wherein the belt has a single engagement portion, such that a complete rotation of the belt feeds a single envelope.  
   
   
       15 . A device for processing envelopes containing contents, comprising: 
 a feeder operable to feed an envelope from a stack of envelopes;    a cutter for cutting the envelope along an edge;    a pivotable gate adjacent the cutter operable to selectively impede forward movement of the envelope past the cutter, wherein the gate is operable between an opened position in which the envelope can be readily displaced past the gate, and a closed position in which the gate impedes forward movement of the envelope;    a controller operable to control operation of the gate to decelerate the gate as the gate is displaced between the opened and closed positions to dampen the noise made by the gate as the gate is displaced between the opened and closed positions.    
   
   
       16 . The device of  claim 15  wherein the controller controls the gate by providing a driving force to drive the gate between the opened and closed positions, and then temporarily discontinuing the driving force while the gate is being displaced between the opened and closed positions.  
   
   
       17 . The device of  claim 16  wherein the controller is operable to reapply the driving force after the gate has been displaced between the opened and closed positions to maintain the gate in either the opened or closed position.  
   
   
       18 . The device of  claim 15  comprising a cushion positioned adjacent the gate to cushion the gate when it is displaced into the opened or closed position.  
   
   
       19 . The device of  claim 15  comprising a biasing element biasing the gate toward either the opened or closed position.  
   
   
       20 . A method for processing envelopes containing contents, comprising the steps of: 
 providing a stack of envelopes;    feeding an envelope from the stack of envelopes;    cutting the envelope along an edge;    selectively impeding forward movement of the envelope past the cutter with a gate, wherein the gate is operable between an opened position in which the envelope can be readily displaced past the gate, and a closed position in which the gate impedes forward movement of the envelope;    controlling the operation of the gate to decelerate the gate as the gate is displaced between the opened and closed positions to dampen the noise made by the gate as the gate is displaced between the opened and closed positions.    
   
   
       21 . The method of  claim 20  comprising the step of providing a driving force to drive the gate between the opened and closed positions, and then temporarily discontinuing the driving force while the gate is being displaced between the opened and closed positions.  
   
   
       22 . The method of  claim 21  comprising the step of reapplying the driving force after the gate has been displaced between the opened and closed positions to maintain the gate in either the opened or closed position.  
   
   
       22 . The method of  claim 20  comprising the step of cushioning the gate when the gate is displaced into the opened or closed position.  
   
   
       23 . A device for processing envelopes containing contents, comprising: 
 a feeder operable to feed an envelope from a stack of envelopes;    a cutter for cutting the envelope along an edge;    an extractor comprising: 
 a pair of arms pivotable between a first position in which the arms are pivoted away from one another and a second position in which the arms are pivoted toward one another so that an end of each arm contacts the envelope;  
 a vacuum source for selectively providing negative pressure to the end of each arm;  
   a controller operable to control the displacement of the arms and the vacuum source, wherein the controller is operable to decelerate the arms as the arms are displaced toward the second position, and the controller operates to control the vacuum source to provide negative pressure while the arms decelerate toward the envelope; and    a transport for conveying the envelope from the cutter to the extractor;    
   
   
       24 . The device of  claim 23  comprising a drive element connected with the arms for driving the arms from the first position to the second position, wherein the controller is operable to control the drive element to provide a drive force to drive the arms toward the second position, and wherein the controller is operable to control the driving element to temporarily discontinue the driving force before the arms are displaced into the second position.  
   
   
       25 . The device of  claim 24  herein the controller is operable to control the driving element to provide a further driving force after the driving force is discontinued and before the second arm is disposed in the second position.  
   
   
       26 . The device of  claim 23  comprising a collapsible bellows attached to the end of each arm, wherein the negative pressure from the vacuum source is provided through the bellows.  
   
   
       27 . A method for processing envelopes containing contents, comprising the steps of: 
 feeding an envelope from a stack of envelopes;    cutting the envelope along an edge;    conveying the cut envelope to an extractor comprising a pair of arms pivotable between a first position in which the arms are pivoted away from one another and a second position in which the arms are pivoted toward one another so that an end of each arm contacts the envelope;    pivoting the arms from the first position to the second position while the envelope is positioned between the arms;    decelerating the arms as the arms are pivoted toward the second position; and    providing negative pressure to the arms while the arms decelerate toward the envelope.    
   
   
       28 . The method of  claim 27  comprising the step of providing a drive force to pivot the arms toward the second position, and temporarily discontinuing the driving force before the arms are pivoted into the second position.  
   
   
       29 . The method of  claim 28  comprising the step of providing a further driving force after the driving force is discontinued and before the second arm is disposed in the second position.