Method and apparatus for merging and attaching documents to envelopes

An automatic document merging system for merging and attaching images of remittance documents to their respective envelopes comprising:

• a first hopper means comprising a bin for receiving and holding a plurality of paper sheets containing images of remittance documents and having a plurality of feeder belts situated along the bottom of said bin for advancing or transporting said sheets to a cutter means;
• a cutter means for receiving said sheets and for cutting said sheets, if necessary, into strips of predetermined dimensions, said cutter means further comprising one or more advancement rollers for advancing said strips onto a first conveyor means for further processing;
• a second hopper means comprising a bin for receiving and vertically holding a plurality of remittance envelopes and having an urging means for advancing and transporting said envelopes toward and into a securing means for further processing;
• a securing means for receiving said envelopes from said second hopper means and for applying an adhesive strip along the advancing side of each remittance envelope, said securing means having an applicator device for applying said adhesive and further having a plurality of advancement rollers for laterally advancing each envelope toward a second conveyor means as the applicator device is applying adhesive to said envelope;
• a first conveyor means comprising a plurality of conveyor belts for receiving and advancing said strips from said cutter means toward a pinch point, positioned along a third conveyor means, said belts also rotate each strip from a horizontal position to a vertical position as said strip is caused to travel along said first conveyor means;
• a second conveyor means comprising a plurality of advancement rollers situated along an advancement channel for advancing said remittance envelopes from said securing means, simultaneously and synchronously with the advancement of said strips along said first conveyor means, toward said pinch point of said third conveyor means for eventual merger with said strips;
• a third conveyor means comprising a merger channel and an advancement channel, said channels having a plurality of advancement rollers operably situated thereon, said merger channel being divided into a pair of channels which converge at said pinch point and are designed to receive, merge and unite the strips and envelopes being synchronously advanced from said first and second conveyor means, said merged and united strips and envelopes being further advanced by said advancement channel rollers along said advancement channel to a third hopper means;
• a third hopper means comprising a bin for receiving and holding the merged strips and envelopes received from said third conveyor means and further comprising a gate means for automatically sensing the arrival of said merged documents and for applying tension against said merged documents after entry into said bin for proper stacking;
• and,
• a control means comprising an advancement control device for controlling the speed and positioning of said strips and envelopes as they advance through said system and a brake/advance pedal for starting and stopping the operation of the system.