Method and system for sorting postal mail

A method for sorting mail into groups based on predefined sets of physical attributes, wherein a first group has a first set of physical attributes such that mail pieces of the first group can be sorted by a first type of postal automated sorting machine, a second group has a second set of physical attributes such that mail pieces of the second group can be sorted by a second type of postal automated sorting machine, which second automated sorting machine has extended capability in comparison to the first automated sorting machine such that it can sort mail pieces having certain attributes outside of one or more of the first set of physical attributes, and a third group comprises mail pieces that fail to meet either of the first and second sets of physical attributes, comprising:

• feeding a series of singulated mail pieces into a conveyor system;
• measuring physical attributes of each mail piece as it is being conveyed on the conveyor system:
• analyzing the measured physical attributes of each mail piece to determine if it meets the first and second sets of physical attributes;
• segregating mail pieces of the third group from the mail pieces that meet either the first or second sets of physical attributes, wherein measuring the mail pieces of the third group is performed using successive steps of measuring length, height, width, stiffness, and weight, and the mail pieces of the third group are selectively diverted according to the measurements;
• and
• segregating mail pieces that meet the first set of physical attributes from mail pieces that meet the second set of physical attributes but do not meet the first set of physical attributes;
• wherein the first set of physical attributes comprises that the mail piece is rectangular and:
• (a) not less than 5 inches long, 3½ inches high, and 0.007-inch thick;
• (b) not more than 11½ inches long, or more than 6⅛ inches high, or greater than ¼-inch thick;
• (c) if more than 4¼ inches high or 6 inches long, the thickness is not less than 0.009 inch;
• (d) weight is not more than 3.3 ounces;
• and (e) aspect ratio is from 1.3 to 2.5.

A method for sorting mail into groups based on predefined sets of physical attributes, wherein a first group has a first set of physical attributes such that mail pieces of the first group can be sorted by a first type of postal automated sorting machine, a second group has a second set of physical attributes such that mail pieces of the second group can be sorted by a second type of postal automated sorting machine, which second automated sorting machine has extended capability in comparison to the first automated sorting machine such that it can sort mail pieces having certain attributes outside of one or more of the first set of physical attributes, and a third group comprises mail pieces that fail to meet either of the first and second sets of physical attributes, comprising:

• feeding a series of singulated mail pieces into a conveyor system;
• measuring physical attributes of each mail piece as it is being conveyed on the conveyor system using a plurality of detection sensors arranged in a matrix;
• analyzing the measured physical attributes of each mail piece to determine if it meets the first and second sets of physical attributes;
• segregating mail pieces of the third group from the mail pieces that meet either the first or second sets of physical attributes;
• and
• segregating mail pieces that meet the first set of physical attributes from mail pieces that meet the second set of physical attributes but do not meet the first set of physical attributes, wherein segregating is performed using measurements obtained by successive steps of measuring length, height, width, stiffness, and weight.