Small flats sorter

A system for sorting mail pieces received from an inserter, the system comprising:

• a first pair of sprockets secured at a predetermined distance therebetween;
• a second pair of sprockets secured at the predetermined distance therebetween wherein the second pair of sprockets are longitudinally and laterally displaced, but not vertically displaced, from the first pair of sprockets;
• a first transport chain mounted to rotate about the first pair of sprockets;
• a second transport chain mounted to rotate about the second pair of sprockets;
• a plurality of carriers each having a carrying surface, the carriers secured by directly supporting opposite corners on opposite sides of each carrier between the first transport chain and the second transport chain to maintain each of the carrying surfaces of the plurality of carriers in a horizontal position between two levels during transport of the plurality of carriers and further wherein the carriers have sloped ends that extend in a first position in a direction away from the carrying surface and a second position that is parallel to the carrying surface wherein each of the ends are maintained in opposite positions;
• a first plurality of bins stacked between the first pair of sprockets and the second pair of sprockets to receive the mail pieces from the carriers;
• a rake assembly above each of the plurality of bins for removing a designated mail piece from at least one of the carriers into one of the bins;
• and
• a sensor monitoring for presence or absence of a mail piece on each of the plurality of carriers, the sensor constructed and arranged at the inserter of the mail pieces.

A method for sorting mail pieces received from an inserter, the method comprising the steps of:

• providing a first pair of sprockets secured at a predetermined distance therebetween having a first transport chain mounted to rotate thereon;
• providing a second pair of sprockets secured at the predetermined distance therebetween having a second transport chain mounted to rotate thereon wherein the second pair of sprockets are longitudinally and laterally displaced, but not vertically displaced, from the first pair of sprockets;
• feeding the mail pieces onto a plurality of carriers each having a grooved, horizontally planar bottom surface wherein each of the plurality of carriers is horizontally and directly secured and maintained at opposite corners on opposite sides between the first transport chain and the second transport chain to hold at least one mail piece flushly on the grooved bottom surface and further wherein the carriers have sloped ends that extend in a first position in a direction away from the planar, bottom surface and a second position that is parallel to the planar, bottom surface wherein each of the ends are maintained in opposite positions;
• transporting the mail pieces on each of the plurality of carriers wherein the transporting occurs on two horizontal planes;
• removing one of the mail pieces from the grooved bottom surface of each of the plurality of carriers during transport wherein each of the mail pieces is designated for a specific bin;
• and
• sensing for removal of each mail piece from each of the plurality of carriers wherein a sensor is constructed and arranged at the inserter to sense presence or absence of a mail piece on each of the plurality of carriers.