Data card and mailer data match/inserter system

• US 5,012,073 A
• Filed: 05/20/1987
• Issued: 04/30/1991
• Est. Priority Date: 02/25/1983
• Status: Expired due to Term

• Current Assignee: Fujitsu Limited
• Original Assignee: Fujitsu Limited
• Inventors: Seibel, David D., Hewitt, Donald W.
• Primary Examiner(s): Pitts, Harold I.
• Application Number:
  US07/053,608
• Time in Patent Office: 1,441 Days
• Field of Search: 53/29, 270/52, 270/58, 271/172, 235/380, 235/375, 235/419, 235/431
• US Class Current: 235/375
• CPC Class Codes: B43M 3/04 automatic
• CPC Class Codes: B65H 2301/51616 involving simultaneous deformation of parts of the material to be bound
• CPC Class Codes: B65H 2701/11231 Fan-folded material or zig-zag or leporello
• CPC Class Codes: B65H 2701/121 Perforations
• CPC Class Codes: B65H 2701/1914 Cards, e.g. telephone, credit and identity cards
• CPC Class Codes: B65H 37/04 for securing together articles or webs, e.g. by adhesive, stitching or stapling adhering replacement to expiring web during change of web roll B65H19/18
• CPC Class Codes: B65H 39/14 Associating sheets with webs

Abstract

An automated system for inserting data cards into preprinted and addressed mailing forms. A computer controls the automatic asynchronous operation of the overall system. Each mailing form bears the account number and mailing address of the intended card recipient, and a designation of the number of cards to be inserted. The cards are pre-embossed and encoded, and supplied in number and sequence corresponding to the requirements of the successoin of forms. The forms advance in succession from a fan-fold continuous strip supply through a read station and into an insert station. Cards are picked from the supply in individual succession and transported past a read station at which account number data is read from the card for comparison with the data of the form currently positioned in the insert station. The insert station includes a number of bins corresponding to the card insert positions on the form and is controlled to receive the proper number of correctly matched cards in the appropriate bins for the form. Should a no-match condition occur or if the corresponding number of proper cards is not satisfied, the card transport terminates to permit a visual operator check. Operator controls permit selectively rejecting cards and forms where matching requirements are not met and manual overrides for correction of same and for re-initiating automated operation. Forms with the proper inserted cards are automatically burst from the strip and proceed through a folder to an output transport for stacking in sequence into an output hopper.

Claims

1. An inserter system for attaching a card of generally planar, rectangular configuration to a form at a predetermined card attachment location thereon by inserting first and second diagonally opposite corners of the card into corresponding first and second card-corner receiving apertures provided in the form and defining the said card attaching location thereof, said apertures being spaced apart by a distance less than the diagonal dimension of the card between said first and second diagonally opposite corners thereof, comprising:

a card inserter mechanism including means for receiving and releasably retaining a card in a first position,

means for positioning a mailer form with the said card attachment location thereof aligned with and substantially parallel to and displaced from said first position of the releasably retained card to be inserted therein,

said inserter mechanism further including means for supporting said card in a central portion thereof and means for engaging said card adjacent said first and second diagonally opposite corners for deflecting said corners beyond said first position and towards said form, and

means for actuating said receiving and supporting means to release said card and for actuating said deflection means to deflect said diagonally opposite corners of said card about said central support means to enable insertion of said first and second diagonally opposite corners of said card into the said corresponding apertures of the card attachment location of said mailer form aligned therewith, and for thereafter displacing said central support to permit said card to flex to its original planar configuration with the said diagonally opposite corners thereof projecting through the said corresponding apertures and underlying the form, thereby attaching the card to the form.

2. An inserter system as recited in claim 1 wherein said means for receiving and releasably supporting a card comprises:

a plurality of arms, at least a first and a second arm being in opposed relationship to receive therebetween opposite edges of a card, said arms each having a first end including an inwardly directed projection for retaining thereon a card received between said first and second arms, and

first and second support elements, said second ends of said first and second arms being joined to said first and second support elements, respectively, for supporting said arms, and

said actuating means actuates said first and second support elements to move said arms and withdraw said projections thereof for releasing a card retained thereon.

3. An inserter system as recited in claim 2 wherein:

said first and second support elements comprise elongated elements mounted for rotation at the ends thereof,

said at least first and second arms being joined at said second ends thereof to respective ones of said first and second support elements intermediate said ends thereof and extending radially therefrom, and

said actuating means rotates said elongated support elements thereby to rotate said arms to an inward, closely opposed relationship to receive and releasably retain a card on the inward projections of said arms, and rotates said support elements in an opposite direction to rotate said arms to an outward, displaced relationship thereby to release a card theretofore retained on the projections of said arms.

4. An inserter system as recited in claim 2 wherein said means of said inserter mechanism for supporting a card in a central portion thereof comprises:

a finger element disposed to extend parallel to the plane of a card received in said inserter mechanism, generally centrally of the card and transversely of the greater longitudinal dimension of the card, and

said actuating means for displacing said central support means comprises means for selectively maintaining said support finger to extend underneath said card at said first position thereof for supporting said central portion of said card during deflection of said card by said deflection means, and moving said support finger to a position closely adjacent the surface of a form to which the card is to be attached, to permit the card to flex to its original planar configuration.

5. An inserter system as recited in claim 4 wherein:

said form positioning means is operable to withdraw a form from said inserter mechanism in a first direction transverse to said greater longitudinal dimension of said card, the opposite longitudinal edges of said card thereby defining leading and trailing edges of said card during said withdrawal, and

said central support finger extends underneath said card from the trailing longitudinal edge of said card as thus defined, thereby to permit withdrawal of the form and attached card when said central support finger is positioned closely adjacent the form.

6. An inserter system as recited in claim 5 wherein said means for engaging said card adjacent said first and second diagonally opposite corners comprises:

first and second elongated deflecting elements,

support means for supporting said first and second elongated deflecting elements to extend in a direction generally normal to the plane of a card supported in said first position in said inserter mechanism and displaced from the surface of the card, and

said actuating means actuates said support means for said elongated deflecting elements for moving same from said first position displaced from said card surface to a second position engaging and deflecting the corresponding said diagonally opposite corners of said card when said card is supported by said central support finger, thereby to project said card corners through said corresponding apertures of said card attachment location of said mailer form, and

said actuating means actuates said elongated deflection elements to engage and deflect said corners of said card after actuating said arms to said outwardly displaced positions for releasing said card from said projections thereof and prior to moving said central support finger from supporting the central portion of a card at the first position thereof to the position closely adjacent the form,

said elongated deflection elements in said second, card-deflecting position thereof being displaced slightly from the surface of the credit card when said credit card is flexed to its original planar configuration upon moving of said central support finger to said second position closely adjacent a form.

7. An inserter system as recited in claim 1 wherein each said mailer form is provided from a fan-fold strip supply of plural said mailer forms and each said card is provided from a supply of plural cards arranged in sequence for attachment to corresponding forms, wherein said form positioning means selectively positions said plural forms in individual succession in said aligned position in said inserter mechanism for insertion of respectively corresponding cards in the attachment location of each thereof, further comprising:

means for selecting a predetermined number of cards from said supply of plural cards for attachment to a given said form, and

means for supplying said cards selected for attachment to said form to said card inserter mechanism, and

said receiving means of said card inserter mechanism is supplied with and receives up to at least two selected cards for insertion in a corresponding, single card attachment location of said form.

8. An inserter system as recited in claim 7, wherein each said form includes at least two card attachment locations thereon, and wherein:

said card inserter mechanism includes first and second means, each for receiving and releasably retaining up to at least two cards, and

said inserter mechanism further includes in corresponding, respective association with said first and second receiving and releasably retaining means, first and second said means for supporting a card in a central portion thereof, first and second said means for engaging each said card adjacent said first and second diagonally opposite corners thereof, and

said actuating means actuates, in common, each of said first and second releasable retaining means, said first and second deflection means, and said first and second central support means, thereby simultaneously to attach cards received in each of said first and second receiving means to the respectively associated first and second attachment locations of the aligned form to which the cards are to be attached.

9. An inserter system as recited in claim 8 wherein:

said inserter mechanism further includes a transport means for receiving a card and transporting same along a transport path adjacent said first and second receiving and releasably retaining means, and

first and second deflection means normally positioned adjacent to, but displaced from said transport path to enable each said card to be transported past said first and second receiving means, and selectively movable into said transport path to deflect a card from said transport path into the corresponding receiving means, thereby to provide for selective receipt of cards in the respectively associated, first and second receiving means of said inserter mechanism.

10. An inserter system for automatically attaching pre-coded cards of generally planar, rectangular configuration to respectively corresponding, pre-coded mailer forms at predetermined card attachment locations on each said mailer form, by inserting first and second diagonally opposite corners of each card associated with the form into corresponding first and second card-corner receiving apertures provided in the associated form and defining the said card attaching location of said form, said apertures being spaced apart by a distance less than the diagonal dimension of the card between the said first and second diagonally opposite corners thereof, said mailer forms being supplied in a continuous fan-fold strip with each said mailer form pre-coded in accordance with the code of cards to be received therein and the number of such common-coded cards to be attached to said form, and said cards being provided in succession as to code and number thereof, in accordance with the succession of mailer forms, comprising:

a card inserter mechanism including means for receiving and releasably retaining in a first position, at least one card,

means for advancing said fan-fold strip supply of mailer forms for selectively positioning each said mailer form, in succession, with the card attachment location thereof aligned with and substantially parallel to and displaced from said first position of the releasably retained, at least one card to be inserted therein,

means for reading the pre-printed code of said mailer form for identifying the card code and the number of cards to be attached to each said mailer form, prior to said mailer form being advanced to said aligned position,

means for picking cards, in individual succession, from said supply thereof,

means for transporting said picked cards,

means for reading each individual card, in succession as picked from said supply, said transporting means transporting each successively picked card past said reading means,

control means for comparing the code read from each card and the number of cards bearing a common code picked in sequence from said supply thereof with the pre-printed code and card number read from a corresponding mailer form, to determine compliance of the picked cards as to code and the number of cards of a common code with the card code and number of card requirements of each said form, in individual succession for each of the plurality of forms and each of the successively picked cards,

said transporting means transporting and supplying to said receiving means of said card inserter mechanism each successive said card which satisfies the requirements of a corresponding mailer form,

said inserter mechanism further including means for supporting each said card received therein in a central portion of the card and means for engaging said cards adjacent said first and second diagonally opposite corners for deflecting said corners beyond said first position and towards said form, and

means for actuating said receiving and releasably retaining means to release said card and for actuating said deflection means to deflect said diagonally opposite corners of said card about said central support means to enable insertion of said first and second diagonally opposite corners of said card into said corresponding apertures of the card attachment location of the mailer form aligned therewith, and for thereafter displacing said central support means to permit said card to flex to its original planar configuration with the said diagonally opposite corners thereof projecting through the said corresponding apertures and underlying the form, thereby attaching the card to the form,

said control means controlling said actuating means in accordance with the codes read from said cards and the number of cards bearing that code complying with the preprinted card code and number of card requirements of the associated form.

11. An inserter system as recited in claim 10 wherein said card transport means for transporting cards from said picking means to said inserter mechanism is capable of containing therewithin a predetermined maximum number of cards, and wherein there is further provided:

means for detecting each card picked from said supply thereof and provided to said transport means, and means for detecting each card transported into said inserter mechanism by said transport means, and

said controlling means responds to the detection of each picked card and the detection of each card delivered into said inserter means to determine the number of cards in said transport means and thereby to enable said picking means to continue picking of cards from said supply so as not to exceed the predetermined number of cards permitted in said transport means, and to control said transport means to continue to deliver cards to said inserter mechanism only for cards having codes corresponding to the card code and number of card requirements of a given mailer form positioned at said inserter mechanism for attachment of cards thereto, and to control said reading means for said mailer forms, to read a successive mailer form while the next preceding mailer form is at said aligned position at said inserter mechanism.

12. An inserter system as recited in claim 10 wherein:

each said form includes at least two card attachment locations thereon, and wherein;

said card inserter mechanism includes first and second means, each for receiving and releasably retaining up to at least two cards, and

said inserter mechanism further includes in corresponding, respective association with said first and second receiving and releasably retaining means, first and second said means for supporting a card in a central portion thereof, first and second said means for engaging each said card adjacent said first and second diagonally opposite corners thereof, and

said actuating means actuates, in common, each of said first and second releasably retaining means, said first and second deflection means, and said first and second central support means, thereby simultaneously to attach cards received in each of said first and second receiving means to the respectively associated first and second attachment locations of the aligned form to which the cards are to be attached, and

said controlling means controls said insert mechanism to selectively receive said corresponding cards in said first and second card receiving means thereof in a predetermined sequence in accordance with the total number of cards to be attached.

13. An inserter system as recited in claim 12 wherein said mailer forms are supplied in double-width of two side-by-side mailer forms, each mailer form having first and second card receiving locations thereon for attachment at each location of up to at least two cards, the fan-fold strip supply of mailer forms defining a predetermined sequence thereof in accordance with the said side-by-side relationship of two forms for each fan-fold section of said fan-fold strip, each said form being pre-printed in accordance with a code card and a number of cards to be attached to that form, and said cards being supplied in corresponding sequence as to code number and number of cards, wherein:

said inserter mechanism includes four card receiving means respectively corresponding to the two card attachment locations of each of the side-by-side forms, and

said controlling means controls the said four receiving means of said inserter mechanism selectively to receive, in predetermined sequence and number, the total cards to be attached to the corresponding form.

14. An inserter system as recited in claim 13 wherein said inserter mechanism includes:

means defining a transport path for transporting each card received therein from said transport mechanism past each of said receiving means of said inserter mechanism,

means for selectively deflecting a card from said inserter mechanism transport means into a selected receiving means,

means associated with each said receiving means of said insert mechanism for detecting the transport of a card into the vicinity of the receiving means, and

said controlling means selectively controls said deflecting means of said plural receiving means of said inserter mechanism for deflecting cards into the respectively associated receiving means in accordance with the said predetermined sequence and number of cards to be received in each said receiving means for the total number of cards satisfying the requirements of the form, and receives the outputs of said detecting means to confirm that a card has been deflected and received into the intended receiving means of the inserter mechanism.

15. An inserter system for automatically attaching pre-coded cards of generally planar, rectangular configuration to respectively corresponding, pre-coded mailer forms at predetermined card attachment locations on each said mailer form, by inserting first and second diagonally opposite corners of each card associated with the form into corresponding first and second card-corner receiving apertures provided in the associated form and defining the said card attaching location of said form, said apertures being spaced apart by a distance less than the diagonal dimension of the card between the said first and second diagonally opposite corners thereof, successive said mailer forms being supplied in a continuous fan-fold strip with each said mailer form pre-coded in accordance with the code of cards to be received therein and the number of such common-coded cards to be attached to said form and said cards being provided in sequence as to code and number thereof, in accordance with the succession of mailer forms, comprising:

a card supply station containing a supply of plural cards arranged in sequence in accordance with the card code number and number of cards of a common code number to comply with the pre-printed code and number of coded cards of said successive pre-printed mailer forms,

a pick station for picking cards from said supply station, in succession,

a transport station and an inserter station, said transport station transporting cards from said pick station to said inserter station,

a form supply and transport station for transporting the forms of said fan-fold strip individually and in succession into an aligned position at said inserter station,

means for reading a code on each said card,

said card transport station transporting each card in succession past said reading means,

said form supply and transport station including means for reading the card code and number of cards pre-printed on each said form,

an inserter station for attaching cards to a form aligned therewith at the inserter station, and

control means for selectively controlling the operations of said pick station, said transport station, said form supply and transport station, and said inserter station to permit operation of each thereof in asynchronous relationship with respect to the others, said controlling means comparing the card code and number of cards read from each said form, in succession, with the code and number of commonly coded cards read by said card reading means for the successive cards to determine compliance of the sequence of cards with the requirements of each of the sequence of forms, in succession and for supplying the cards in individual succession to said inserter station for each card which satisfies the requirements of a corresponding form, and for actuating said inserter station to insert said cards into the corresponding form when said form is positioned at said inserter station,

said inserter station including an inserter mechanism for receiving the cards supplied thereto and for deflecting diagonally opposite corners of the cards supplied to and received by said inserter mechanism into said receiving apertures of said form thereby to attach the appropriate cards to the corresponding form.

16. An inserter system as recited in claim 15, further comprising:

a burster station,

said controlling means operating said form advance station to advance the fan-fold strip forms after completion of insertion of a form currently positioned at said inserter station to position the completed form at the burster station and simultaneously to advance the next successive form into said inserter station and to advance the further next successive form into position for reading by said reader means of said transport station,

said controlling means controlling said burster station to burst the completed form from the form in said inserter station along a burst/fold line delineating successive said forms of the fan-fold strip.

17. An inserter system as recited in claim 16 wherein said forms are supplied in side-by-side relationship in said fan-fold strip, establishing a predetermined sequence of forms of said side-by-side and said fan-fold strip sequential relationship, said side-by-side forms being delineated by a perforation line for separating same into separate forms, and wherein:

said burster station includes a slitter mechanism for slitting said side-by-side forms along said perforation line to separate same, during withdrawal of said side-by-side forms, after bursting, from said burst station.

18. An inserter system as recited in claim 16 further comprising:

a folder station adjacent said burster station for receiving at least the leading edge of a completed form advanced into the burster station,

said controlling means actuating said folder station to advance and withdraw said completed and burst form from said burster station during the completion of an inserter operation of said inserter station.

19. An inserter system as recited in claim 18 wherein said folder station comprises a folder transport mechanism selectively operable to fold said forms along at least one transverse fold line.

20. An inserter system as recited in claim 19 wherein said folder mechanism is selectively operable to fold each said form along at least two fold lines.

21. An inserter system as recited in claim 20 wherein said folder mechanism selectively operable to transport a form having no fold lines.

22. An inserter system as recited in claim 18, further comprising:

a folder outfeed mechanism for receiving forms from said folder mechanism,

an outfeed transport station including an outfeed transport mechanism for receiving folded forms from said folder outfeed mechanism of said folder station and transporting same, and

an output stacker station including an ejector mechanism for receiving folded forms from said outfeed mechanism of said outfeed transport station and ejecting same into an output stacker in sequence.

23. An inserter system as recited in claim 15 wherein said card supply station includes means for receiving first and second trays of coded cards arranged in said predetermined sequence in accordance with the requirements of the successive mailer forms,

sensing means for detecting the presence of cards in each of said first and second input trays,

said pick station includes first and second pick mechanisms respectively associated with said first and second trays of cards for selectively picking cards from the respectively associated tray, and

said controller means selectively controls said first and second picker mechanisms to enable a selected one thereof to pick cards from the respectively associated one of the first and second trays.

24. An inserter system as recited in claim 23 wherein said controller means is responsive to the outputs of said detecting means for said trays to automatically enable the picking mechanism for a tray having cards therein upon depletion of the supply of cards from the other of said trays.

25. An inserter system as recited in claim 24 wherein said control means automatically enables a predetermined one said first and second picking mechanisms to pick cards from the respectively corresponding one of said first or second trays.

27. An inserter system as recited in claim 22 wherein said output stacker station includes first and second ejector means, first and second output trays and corresponding first and second detection means for detecting the availability of the respectively associated first and second output trays for receiving ejected, folded forms from said first and second ejector means, respectively, and

said control means automatically selects a first of said first and second output trays and selectively controls said first and second ejector means to enable a selected one thereof to eject folded forms into the thus correspondingly selected output tray, and is responsive to the detectors for said output trays to select the other of said trays when one thereof is not available to receive ejected forms.

26. An inserter system as recited in claim 26 wherein there is further provided:

operator selection means for manually selecting the other of said first and second trays and overriding the automatic selection of said predetermined one by said control means.

28. A method for attaching a card of generally planar, rectangular configuration to a mailer form at a predetermined card attachment location thereon by inserting first and second diagonally opposite corners of the card into corresponding first and second card-corner receiving apertures provided in the form and defining the said card attaching location thereof, said apertures being spaced apart by a distance less than the diagonal dimension of the card between said first and second diagonally opposite corners thereof, comprising:

receiving and releasably retaining a card in a first position,

positioning a mailer form with the said card attachment location thereof aligned with and substantially parallel to and displaced from said first position of the releasably retained card to be inserted therein,

supporting said card in a central portion thereof and engaging said card adjacent said first and second diagonally opposite corners for deflecting said corners beyond said first position and towards said form, thereby to insert said first and second diagonally opposite corners of said card into the said corresponding apertures of the card attachment location of said mailer form aligned therewith, and thereafter terminating the support of said card in said central portion thereof to permit said card to flex to its original planar configuration with the said diagonally opposite corners thereof projecting through the said corresponding apertures and underlying the form, thereby attaching the card to the form.

29. A method for automatically attaching pre-coded cards of generally planar, rectangular configuration to respectively corresponding, pre-coded mailer forms at predetermined card attachment locations on each said mailer form, by inserting first and second diagonally opposite corners of each card associated with the form into corresponding first and second card-corner receiving apertures provided in the associated form and defining the said card attaching location of said form, said apertures being spaced apart by a distance less than the diagonal dimension of the card between the said first and second diagonally opposite corners thereof, said mailer forms being supplied in a continuous fan-fold strip with each said mailer form pre-coded in accordance with the code of cards to be received therein and the number of such common-coded cards to be attached to said form and said cards being provided in succession as to code and number thereof, in accordance with the succession of mailer forms, comprising:

receiving and releasably retaining a first position, at least one card,

advancing said fan-fold strip supply of mailer forms for selectively positioning each said mailer form, in succession, with the card attachment location thereof aligned with and substantially parallel to and displaced from said first position of the releasably retained, at least one card to be inserted therein,

reading the pre-printed code of said mailer form for identifying the card code and the number of cards to be attached to each said mailer form, prior to said mailer form being advanced to said aligned position,

picking cards, in individual succession, from said supply thereof,

reading each individual card, in succession as picked from said supply,

comparing the code read from each card and the number of cards bearing a common code picked in sequence from said supply thereof with the pre-printed code and card number read from a corresponding mailer form to determine compliance of the picked cards as to code and the number of cards of a common code with the card code and number of card requirements of each said form, in individual succession for the plurality of forms and picked cards,

placing each successive said card which satisfies the requirements of a corresponding mailer form in alignment with a selected, card attachment location of the corresponding form,

supporting each said selected and placed card in a central portion and engaging same adjacent said first and second diagonally opposite corners for deflecting said corners beyond said first position and towards said form, and

releasing said card while maintaining said central support thereof and deflecting said diagonally opposite corners of said card about said central support position to enable insertion of said first and second diagonally opposite corners of said card into said corresponding apertures of the card attachment location of the mailer form aligned therewith, and thereafter terminating said central support thereof to permit said card to flex to its original planar configuration with the said diagonally opposite corners thereof projecting through the said corresponding apertures and underlying the form, thereby attaching the card to the form.

30. A method as recited in claim 29 further comprising:

detecting each card picked from said supply and incrementing a count for each thereof,

detecting each card placed for insertion, and decrementing the count for each thereof, and

controlling said picking so as to continue picking of cards from said supply only so long as said count does not exceed a predetermined value.

31. A method for automatically attaching pre-coded cards of generally planar, rectangular configuration to respectively corresponding, pre-coded mailer forms at predetermined card attachment locations on each said mailer form, by inserting first and second diagonally opposite corners of each card associated with the form into corresponding first and second card-corner receiving apertures provided in the associated form and defining the said card attaching location of said form, said apertures being spaced apart by a distance less than the diagonal dimension of the card between the said first and second diagonally opposite corners thereof, said mailer forms being supplied in a continuous fan-fold strip with each said mailer form pre-coded in accordance with the code of cards to be received therein and the number of such common-coded cards to be attached to said form and said cards being provided in succession as to code and number thereof, in accordance with the succession of mailer forms, comprising:

supplying plural cards in sequence in accordance with the card code number and number of cards of a common code number to comply with the preprinted code and number of coded cards of each of said sequence of preprinted mailer forms,

picking cards from said supply station, in succession,

transporting the forms of said fan-fold strip individually and in succession into an aligned position for card insertion,

reading a code on each said card,

reading the card code and number of cards pre-printed on each said form,

comparing the card code and number of cards read from each said form, in succession, with the code and number of commonly coded cards, as read from the successive cards to determine compliance of the sequence of cards with the requirements of the successive forms,

placing the cards in individual succession in aligned positions for card insertion, for each card which satisfies the requirements of a corresponding form,

inserting said cards into the corresponding form when said form is positioned in aligned position for card insertion by deflecting diagonally opposite corners of the placed cards into said receiving apertures of said form thereby to attach the appropriate cards to the corresponding form, and

selectively controlling said pick, said form supply and transport, and said inserter operations to occur in asynchronous relationship.

32. A method as recited in claim 31, further comprising:

advancing the fan-fold strip forms after completion of card insertion into a given form to position the completed form for bursting away from the strip, and simultaneously advancing the next successive form into aligned position for card insertion and the further next successive form into position for reading, and

bursting the completed form from said next successive form along a burst/fold line delineating successive said forms of the fan-fold strip in a common cycle while inserting cards into that next successive form and reading the further next successive form.

33. A method as recited in claim 32 further comprising:

folding the completed and burst form during the same cycle of card insertion into the said next successive form.

34. A method as recited in claim 31 further comprising:

supplying first and second trays of coded cards arranged in said predetermined sequence in accordance with the requirements of the sequence of mailer forms,

detecting the presence of cards in each of said first and second input trays, and

selectively picking cards automatically, initially from a predetermined one of said trays and thereafter automatically switching from a tray having no cards therein to pick cards, from the other of said trays.

35. An inserter device for attaching flexible cards of normally planar, rectangular configuration to respectively associated forms, said forms having spaced-apart apertures for receiving diagonally opposite corners of the cards when said corners are deflected toward said forms, comprising:

means for selectively positioning at least one form from a supply of plural said forms, in succession at a predetermined position for attaching a card thereto;

means for receiving and releasably retaining cards to be attached to a corresponding form when selectively positioned at the predetermined card attaching position;

means for selectively providing to said receiving and releasable retaining means, from a supply of plural cards, at least one card to be attached to a corresponding form, and

means for actuating said releasable retaining means to release said selectively provided card and for deflecting said card to project the diagonally opposite corners of said at least one selected card into the receiving apertures of the associated form, and thereafter to terminate the deflecting of said at least one card to permit same to flex to a planar configuration with the card corners projecting through the apertures and underlying the opposite surface of the form thereby to attach the selected at least one card to the form.

36. An inserter device as recited in claim 35 wherein said releasable retaining means includes plural arms selectively disposed to engage opposite edges of the card for releasably retaining each card received therein, said arms being mounted for selectively controlled relative movement toward and away from the edges of said card, and

said actuating means moves said arms away from said card edges to release said card during deflection thereof for attachment to said form.

37. An inserter device as recited in claim 36 wherein said deflecting means comprises a pair of projections for engaging the said diagonally opposite corners of said card to effect said deflection thereof.

38. An inserter device as recited in claim 37 wherein said deflecting means further includes a finger element extending centrally of the card along the surface thereof adjacent to said form, for supporting the central card portion during deflection thereof by said deflecting means to maintain said central portion bowed outwardly from said form during deflection of said card corners toward said form.

39. An inserter device as recited in claim 37 wherein each of said cards is pre-coded with data and said means for selectively supplying plural cards comprises:

an input card hopper containing a supply of plural cards;

means for picking cards, individually and in succession, from said supply hopper,

a card transport for receiving picked cards and transporting same;

a card read station for reading data coded on said cards, and

said transport means transporting said cards from said pick means through said card station and to said releasable retaining means.

40. The inserter device of claim 39 wherein each form is pre-coded with data, and wherein there is further provided:

means for feeding a supply of forms selectively to position a given form at said predetermined card attaching position for having a card inserted therein,

means for reading data from each said form for determining the coding thereon,

means for comparing the data read from the card with the data read from the form and means for comparing the data read from the card with the data read from the form to identify the cards correctly, corresponding to the form currently positioned for card insertion,

said card providing means being responsive to said comparing means for selectively supplying to said receiving means the said correctly corresponding cards for attachment to that corresponding form.

41. The system as set forth in claim 40 wherein each said form is coded with a number of cards of a given code identification to be attached thereto, and said form reading means reads the data coded on each form, and there is further provided:

computer means responsive to the data read from the form and the data read from successively picked cards to control said card providing means to provide the number of cards of the given code identification as required by the corresponding form to said receiving means for insertion into said corresponding form.

42. A transport apparatus for transporting forms of a serial, continuous supply thereof, comprising:

means for engaging said serial form supply for feeding thereof in simultaneous, serial succession,

motor means for driving and engaging means,

encoding means associated with said motor means and driven thereby for establishing in each rotation thereof a basic timing cycle of said apparatus,

further encoder means driven by said motor and having a predetermined ratio of rotation with respect to said first encoder means and producing an output in each complete rotation there of corresponding to transport of said serial forms by a distance corresponding to an individual one of said serial forms,

form alignment means associated with said transport means for initial alignment of a top edge of a first form of said serial supply thereby to establish initial alignment of said serial form supply in synchronism with said further encoder means associated with said motor means,

control means for initialing said transport apparatus to drive said motor for positioning said further encoder means at a top of form position, corresponding to initial alignment of a top of a first form of said serial supply with said top of form alignment position of said transport engaging means, and having further associated therewith means for supplying cards,

an insert mechanism for inserting said cards into specially configured apertures on respectively corresponding, individual forms as each said form is positioned in said inserter mechanism,

said form transport apparatus advancing said forms in individual succession into said inserter mechanism for insertion of cards into the apertures thereof, thereby attaching cards to corresponding forms, for plural association of said forms and cards in respectively corresponding succession.

43. Form transport apparatus as recited in claim 42, wherein individual ones of said serial supply of forms are delineated by transverse perforation lines for separating each said form from said serial supply thereof, further comprising:

burster means having a predetermined burster location corresponding to the form delineating perforation line of a form advanced out of said inserter station by said transport means when positioning a successive form in said inserter station, and

said control means controlling said burster means to burst the advanced form with cards inserted therein from the next successive form in said inserter station during the insertion of cards into said form in said inserter station.

44. A card and mailer form apparatus comprising:

positive feed means for inputting serially connected mailer forms into the apparatus for the purpose of having correct cards attached therewith, means for reading pre-provided information on each of said mailer forms, input means for supplying pre-coded cards, means for reading the pre-coded information on each of said cards, computer means for comparing the information as read on the mailer forms and the cards to initiate an operation if a proper match is made, insertion means for attaching the respective cards to the respective individual forms when initiated by said proper match operation, and form separating means to detach and prepare each filled mailing form ready for mailing.

45. The structure set forth in claim 44, together with folder means for folding each of said mailer forms with card attached therewith into a proper shape for the mailing thereof, said means for the positive feeding of the serially connected input mailer includes tractor means for positive engagement with mating tractor portions provided on said serially connected mailer forms, motor means for operating said tractor means, and timing cycle means operated by said motor means for providing control signals to the computer means.

46. The structure set forth in claim 45, wherein said timing cycle means includes a basic timing cycle cam, associated photosensor structure connected to the computer means and responsive to said basic timing cycle cam, and geared down form timing structure also operated by said motor means for controlling the feed and positioning of said mailer forms by the positive feed means therefore.

47. The structure as set forth in claim 44, wherein said means for reading the pre-provided information on the mailer forms includes a read head, means for supporting said read head for traversing movement across the path of movement of said serially connected mailer forms, and sensor means for controlling the traverse movement of said read head mounted at each of the ends of said path of traverse movement.

48. The structure set forth in claim 47 wherein said sensor means includes two photosensors, associated flag structure mounted at each of the ends of said path of traverse movement, and appropriate connections to said computer means for effecting said traverse movement under the control of said photosensors.

49. The structure set forth in claim 44, wherein the input means for pre-coded cards includes an individual card selector structure and a card transport structure, and read means closely associated with said card transport structure for reading the pre-coded information on each of said individual cards as transported thereby.

50. The structure as set forth in claim 49, wherein said read means includes an optical card reader structure, said pre-coded information is embossed on each of said individual cards, and said optical card reader obtains the desired information by reading said embossed characters.

51. An apparatus for attaching data cards to corresponding carrier forms for a plurality of accounts, each said card having account information encoded thereon, and said carrier forms being supplied as a continuous web of successive forms, each said form having account information thereon and information on a predetermined number of cards to be attached thereto for the respective account, comprising:

(a) means for supplying a continuous web of said carrier forms;

(b) means for supplying a plurality of said data cards in individual succession;

(c) means for reading account information from said data cards;

(d) means for reading information from said carrier forms of the continuous web, including account information and the predetermined number of cards to be attached thereto for the corresponding account;

(e) means for comparing information read from said data cards and from said forms of the continuous web and identifying said data cards for attachment to an associated form of the continuous web having corresponding account information, for each form in succession;

(f) data card collecting and attaching means for collecting data cards identified by said comparing and identifying means for attachment to an associated form of the continuous web and then simultaneously attaching said predetermined number of data cards to the associated form on the continuous web in response to said predetermined number of cards having been identified and collected for the associated form; and

(g) control means for stopping the supply of a data card from said data card supplying means to said data card collecting and attaching means when said comparing and identifying means determines that there is a mismatch of the information read from a data card and the associated carrier form of the continuous web.

52. The apparatus of claim 51, further comprising carrier form and data card inspection stations for visual examination of a data card and a carrier form of the continuous web by the operator upon a mismatch of the information read from the data card and the associated carrier form of the continuous web.

53. The apparatus of claim 52, further comprising means for advancing a carrier form of the continuous web positioned in said collecting and attaching means to said form inspection station upon a mismatch of the read account information.

54. The apparatus of claim 51, wherein each carrier form of the continuous web includes at least one card attachment location thereon, wherein said data card collecting and attaching means receives and releasably retains up to at least two data cards in a card attachment position, and wherein said apparatus further comprises means for positioning a card attachment location of a carrier form on the continuous web adjacent said card attachment position.

55. The apparatus of claim 51, wherein each carrier form of the continuous web includes at least two card attachment locations thereon, wherein said data card collecting and attaching means comprises first and second means, each for receiving and releasably retaining up to at least two cards in a card attachment position, transport means for receiving a card and transporting same along a transport path adjacent said first and second receiving and releasably retaining means, and first and second deflections means normally positioned to enable each of said data cards to be transported along said transport path past said first and second receiving and retaining means, and individually selectively moveable into said transport path to deflect an individual card from said transport path into the corresponding one of said first and second receiving and retaining means, thereby to provide for selective receipt of cards in their respectively associated, first and second receiving and retaining means, and wherein said apparatus further comprises means for positioning the at least two card attachment locations of a carrier form on the continuous web adjacent the corresponding two card attachment positions.

56. The apparatus of claim 55, further comprising means for controlling and actuating said first and second receiving and releasably retaining means for simultaneously attaching the cards received in each of said first and second receiving and retaining means to the respective first and second card attachment locations of the associated form of the continuous web when said predetermined number of data cards has been identified and collected.

57. The apparatus of claim 56, wherein said carrier forms are supplied to said data card collecting and attaching means in double-width of two side-by-side mailer forms of a continuous web, each carrier form of the continuous web having first and second card attachment locations thereon for attachment at each location of up to at least two cards, and wherein said data collecting and attaching means further comprises third and fourth receiving and releasably retaining means and wherein said apparatus further comprises means for controlling and actuating said first, second, third, and fourth receiving and releasably retaining means for simultaneously attaching the cards received in each of said four receiving and releasably retaining means to the respective four attachment locations of the two carrier forms on the continuous web.

58. The apparatus of claim 52, wherein each carrier form of the continuous web includes at least one card attachment location thereon, wherein said data card collecting and attaching means receives and releasably retains up to at least two data cards in a card attachment position and wherein said apparatus further comprises means for positioning a card attachment location of a carrier form on the continuous web adjacent said card attachment position.

59. The apparatus of claim 53, wherein each carrier form of the continuous web includes at least one card attachment location thereon, wherein said data card collecting and attaching means receives and releasably retains up to at least two data cards, in a card attachment position and wherein said apparatus further comprises means for positioning a card attachment location of a carrier form on the continuous web adjacent said card attachment position.

60. The apparatus of claim 54, wherein said data card collecting and attaching means positions first and second diagonally opposite corners of the data cards into corresponding first and second card-corner receiving apertures provided in the carrier form defining the card attachment location on said carrier forms of the continuous web.

61. The apparatus of claim 55, wherein said data card collecting and attaching means positions first and second diagonally opposite corners of the data cards into corresponding first and second card-corner receiving apertures provided in the carrier form defining the card attachment location on said carrier forms of the continuous web.

62. The apparatus of claim 56, wherein said data card collecting and attaching means positions first and second diagonally opposite corners of the data cards into corresponding first and second card-corner receiving apertures provided in the carrier form defining the card attachment location on said carrier forms of the continuous web.

69. The apparatus of claim 51, wherein said carrier forms are supplied to said data card collecting and attaching means in double-width of two side-by-side mailer forms of a continuous web, each carrier form of the continuous web having first and second card attachment locations thereon for attachment at each location of up to at least two cards, and wherein said data collecting and attaching means further comprises third and fourth receiving and releasably retaining means and wherein said apparatus further comprises means for controlling and actuating said first, second, third, and fourth receiving and releasably retaining means for simultaneously attaching the cards received in each of said four receiving and releasably retaining means to the respective four attachment locations of the two carrier forms on the continuous web.

74. The apparatus of claim 51, wherein said data card collecting and attaching means positions first and second diagonally opposite corners of the data cards into corresponding first and second card-corner receiving apertures provided in the carrier form defining the card attachment location on said carrier forms of the continuous web.

63. An apparatus for attaching data cards to corresponding carrier forms for a plurality of accounts, each said card having account information encoded thereon, and said carrier forms being supplied as a continuous web of successive forms, each said form having account information thereon and information on a predetermined number of cards to be attached thereto for the respective account, comprising:

(a) means for supplying a continuous web of said carrier forms;

(b) means for supplying a plurality of said data cards in individual succession;

(c) means for reading account information from said data cards;

(d) means for reading information from said carrier forms of the continuous web, including account information and the predetermined number of cards to be attached thereto for the corresponding account;

(e) means for comparing information read from said data cards and from said forms of the continuous web and identifying said data cards for attachment to an associated form of the continuous web having corresponding account information, for each form in succession;

(f) data card collecting and attaching means for collecting data cards identified by said comparing and identifying means for attachment to an associated form of the continuous web and then simultaneously attaching said predetermined number of data cards to the associated form on the continuous web in response to said predetermined number of cards having been identified and collected for the associated form; and

(g) control means for stopping the supply of a data card from said data card supplying means to said data card collecting and attaching means when said comparing and identifying means determines that there is a mismatch of the information read from a data card and the associated carrier form of the continuous web.

64. The apparatus of claim 63, further comprising carrier form and data card inspection stations for visual examination of a data card and a carrier form of the continuous web by the operator upon a mismatch of the information read from the data card and the associated carrier form of the continuous web.

65. The apparatus of claim 64, further comprising means for advancing a carrier form of the continuous web positioned in said collecting and attaching means to said form inspection station upon a mismatch of the read account information.

66. The apparatus of claim 63, wherein each carrier form of the continuous web includes at least one card attachment location thereon, wherein said data card collecting and attaching means receives and releasably retains up to at least two data cards in a card attachment position, and wherein said apparatus further comprises means for positioning a card attachment location of a carrier form on the continuous web adjacent said card attachment position.

67. The apparatus of claim 63, wherein each carrier form of the continuous web includes at least two card attachment locations thereon, wherein said data card collecting and attaching means comprises first and second means, each for receiving and releasably retaining up to at least two cards in a card attachment position, transport means for receiving a card and transporting same along a transport path adjacent said first and second receiving and releasably retaining means, and first and second deflection means normally positioned to enable each of said data cards to be transported along said transport path past said first and second receiving and retaining means, and individually selectively moveable into said transport path to deflect an individual card from said transport path into the corresponding one of said first and second receiving and retaining means, thereby to provide for selective receipt of cards in their respectively associated, first and second receiving and retaining means, and wherein said apparatus further comprises means for positioning the at least two card attachment locations of a carrier form on the continuous web adjacent the corresponding two card attachment positions.

68. The apparatus of claim 67, further comprising means for controlling and actuating said first and second receiving and releasably retaining means for simultaneously attaching the cards received in each of said first and second receiving and retaining means to the respective first and second card attachment locations of the associated form of the continuous web when said predetermined number of data cards has been identified and collected.

70. The apparatus of claim 64, wherein each carrier form of the continuous web includes at least one card attachment location thereon, wherein said data card collecting and attaching means receives and releasably retains up to at least two data cards in a card attachment position and wherein said apparatus further comprises means for positioning a card attachment location of a carrier from on the continuous web adjacent said card attachment position.

71. The apparatus of claim 65, wherein each carrier form of the continuous web includes at least one card attachment location thereon, wherein said data card collecting and attaching means receives and releasably retains up to at least two data cards in a card attachment position and wherein said apparatus further comprises means for positioning a card attachment location of a carrier form on the continuous web adjacent said card attachment position.

72. The apparatus of claim 66, wherein said data card collecting and attaching means positions first and second diagonally opposite corners of the data cards into corresponding first and second card-corner receiving apertures provided in the carrier form defining the card attachment location on said carrier forms of the continuous web.

73. The apparatus of claim 67, wherein said data card collecting and attaching means positions first and second diagonally opposite corners of the data cards into corresponding first and second card-corner receiving apertures provided in the carrier form defining the card attachment location on said carrier forms of the continuous web.