System and method for producing and arranging sheet material for use in a mailpiece inserter

1. A system for producing printed sheet material for a mailpiece inserter; comprising:

an input module for supplying the printed sheet material associated with a mailpiece fabrication job;

a transfer module adapted to receive the printed sheet material from the input module and dispense the printed sheet material;

an output module adapted to receive the printed sheet material from the transfer module and convey the printed sheet material along a feed path, the output module including a support structure adapted to rotate about an axis substantially parallel to the feed path of the printed sheet material, an actuator for rotating the support structure about the axis, and at least two transport decks disposed in combination with the rotating support structure, each of the transport decks adapted to receive printed sheet material from the transfer module depending upon a selected operating mode, and

a processor, operatively coupled to a mail run data file of the mailpiece fabrication job for controlling the input, transfer and output modules to stack the printed sheet material in accordance with the mail run data file.

2. The system according to claim 1 wherein the input module includes one of a web supply module and a sheet feed module.

3. The system according to claim 1 wherein the transfer module dispenses printed sheet material onto one of the transport decks in accordance with the mail run data file associated with the mailpiece fabrication job.

4. The system according to claim 1 wherein one of the transport decks of the output module is adapted to receive a shingled stack of printed sheet material from the transfer module.

5. The system according to claim 1 wherein one of the transport decks of the output module includes a plurality of separators each projecting substantially orthogonally of the transport deck, and wherein a pair of separators define a pocket for receipt of the printed sheet material.

6. The system according to claim 1 wherein one of the transport decks is adapted to receive a shingled stack of printed sheet material from the transfer module in one of the selected operating modes, and another of the transport decks is adapted to receive stacks of printed sheet material in another of the selected operating modes.

7. The system according to claim 6 wherein one of the transport decks is adapted to receive stacks of printed sheet material includes a plurality of separators each projecting substantially orthogonally of the transport deck and wherein a pair of separators defines a pocket for receipt of the printed sheet material.

8. The system according to claim 1 further comprising:

a linear actuation device for extending and retracting the support structure of the output module relative to the transfer module in a direction substantially parallel to the rotational axis of the support structure;

the linear actuation device extending the support structure to an extended position such that the transport decks may rotated to a position corresponding to the selected operating mode and retracting the support structure to a retracted position to such that the transport deck may receive the printed sheet material from the transfer module.

9. The system according to claim 1 further comprising:

an accumulator module, receiving the printed sheet material from the input module, and accumulating printed sheet material associated with one of the feed input modules of a the mailpiece inserter.

10. A method for producing printed sheet material for use in a mailpiece inserter, comprising the steps of:

selecting one of at least two operating modes associated with processing the printed sheet material in accordance with a mailpiece fabrication job of the mailpiece inserter, in one operating mode, the sheet material being folded, and, in another operating mode, the sheet material being unfolded;

adapting an output module of the sheet processing system to receive the sheet material onto one of at least two transport decks, and to receive the printed sheet material as one of (i) a shingled stack of sheet material, and (ii) at least one stack of printed sheet material;

feeding the printed sheet material associated with the mailpiece fabrication job, the sheet material including printed characters/symbology providing information associated with processing of the sheet material;

reading the printed characters/symbology to obtain information necessary for accumulating and stacking the printed sheet material onto a transport deck; and

processing the printed sheet material through at least one of a series of processing modules including one of (i) an accumulating module, (ii) a folding module and (iii) a transfer module; and

receiving the printed sheet material from the at least one of a series of processing modules onto one of the at least two transport decks in accordance with the selected operating mode.

11. The method according to claim 10 wherein the step of processing the printed sheet material through at least one of a series of processing modules includes the step of accumulating the printed sheet material into a group associated with the content material of an individual mailpiece.

12. The method according to claim 10 wherein the step of processing the printed sheet material through at least one of a series of processing modules includes the step of accumulating the printed sheet material into a group having common content material.

13. The method according to claim 10 wherein the step of processing the printed sheet material through at least one of a series of processing modules includes the step of accumulating the printed sheet material into groups which are separated based upon a threshold number of accumulated sheets.

14. The method according to claim 10 wherein the step of processing the printed sheet material through at least one of a series of processing modules includes the step of accumulating the printed sheet material into groups having a common fold configuration.

15. The method according to claim 10 wherein the step of processing the printed sheet material through at least one of a series of processing modules includes the step of accumulating the printed sheet material into groups having a common size.

16. The method according to claim 10 wherein the step of adapting the output module of the sheet processing system includes the step of partitioning at least one of the transport decks into a plurality of pockets, each pocket receiving a stack of printed sheet material.

17. The method according to claim 16 wherein the step of partitioning at least one of the transport decks includes the step of varying the dimension of at least two pockets to receive stacks having a variable width dimension.