Methods and systems to create a mailpiece with an inline buckle folder

A method of folding an envelope sheet around one or more insert sheets to create a mailpiece, the method comprising:

• forming an insert stack from the one or more insert sheets;
• transporting the insert stack to a merge region along an insert transport path;
• transporting the envelope sheet to the merge region along a primary transport path;
• receiving the insert stack at an insert stager that is connected to the insert transport path and arranged proximate to the primary transport;
• holding the insert stack within the insert stager;
• detecting the envelope sheet at a first position on the primary path;
• dispensing the insert stack onto the envelope sheet as the envelope sheet is transported along the primary transport path, wherein the insert stack is dispensed at substantially a same speed as a speed at which the envelope sheet moves along the primary transport path;
• folding the envelope sheet around the insert stack to form an unsealed envelope for the mailpiece, wherein the unsealed envelope comprises, on a first side of the insert stack, a back side of the mailpiece and, on a second side of the insert stack opposite the first side, a flap and a front of the mailpiece;
• and
• closing and sealing the unsealed envelope by folding the flap over the back side and adhesively sealing the flap to the back side of the mailpiece.

A device configured to sequentially receive and dispense one or more insert sheets as an insert stack onto an adjacent envelope sheet, the device comprising:

• a holding slot for the insert stack;
• a stop gate disposed at an exit of the holding slot;
• and
• a mechanical linkage system configured to produce first and second motion profiles from a single input, the mechanical linkage system comprising:
• a motor configured to generate a locomotive force, wherein the locomotive force is the single input;
• a crank arm that is connected to the motor;
• a coupler linkage coupled, at a first end, to the crank arm via a coupler bearing and, at a second end, to a pivot bearing;
• a first linkage subassembly rotatably connected, at a first end, to the coupler linkage at the pivot bearing and comprising a stop gate arranged at a distal end of the first linkage subassembly, the single input being transmitted to the first linkage subassembly through the pivot bearing to generate the first motion profile, wherein the first motion profile is a rotary movement of the stop gate along a stop gate travel path;
• one or more insert drive rollers arranged so that one or more portions thereof protrude, at least partially, through a bottom side of the holding slot;
• one or more insert idler rollers arranged substantially vertically over the one or more insert drive rollers;
• a second linkage subassembly rotatably connected, at a first end, to the coupler linkage at the pivot bearing and comprising the one or more insert idler rollers, the single input being transmitted to the second linkage subassembly through the pivot bearing to generate the second motion profile, wherein the second motion profile is a substantially vertical movement of the one or more insert idler rollers about an idler pivot;
• wherein the mechanical linkage system is configured such that the single input simultaneously causes the first and second motion profiles of the stop gate and the one or more insert idler rollers, respectively, and
• wherein the first and second motion profiles are different from each other.