U.S. patent application number 12/188625 was filed with the patent office on 2009-02-19 for packaging apparatus for handling pills and associated method.
This patent application is currently assigned to Aylward Enterprises, Inc.. Invention is credited to John T. Aylward.
Application Number | 20090044495 12/188625 |
Document ID | / |
Family ID | 39769283 |
Filed Date | 2009-02-19 |
United States Patent
Application |
20090044495 |
Kind Code |
A1 |
Aylward; John T. |
February 19, 2009 |
Packaging Apparatus for Handling Pills and Associated Method
Abstract
An automated packaging apparatus and associated method are
provided for depositing pills into a container. A cylindrical
rotary slat is rotatable about a longitudinal axis and defines a
plurality of pill apertures for receiving pills deposited into an
interior space of the cylinder, at a first angular position of the
rotary slat. A negative pressure system applies a negative pressure
the pill apertures for retaining the pills therein, as the rotary
slat rotates from the first to a second angular position. A removal
system interacts with the pill apertures, as the respective pill
aperture is at the second angular position, to remove the pill
therefrom through a radially outward portion of the rotary slat. A
collection system, adjacent to the radially outward portion of the
rotary slat about the second angular position, is configured to
direct each pill removed from each respective pill aperture toward
a container for deposition therein.
Inventors: |
Aylward; John T.; (New Bern,
NC) |
Correspondence
Address: |
ALSTON & BIRD LLP
BANK OF AMERICA PLAZA, 101 SOUTH TRYON STREET, SUITE 4000
CHARLOTTE
NC
28280-4000
US
|
Assignee: |
Aylward Enterprises, Inc.
|
Family ID: |
39769283 |
Appl. No.: |
12/188625 |
Filed: |
August 8, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60954969 |
Aug 9, 2007 |
|
|
|
Current U.S.
Class: |
53/473 ; 53/244;
53/248; 53/493; 53/51 |
Current CPC
Class: |
B65B 1/14 20130101; B65B
35/46 20130101; B65B 35/48 20130101; B65B 1/16 20130101; B65B 5/103
20130101 |
Class at
Publication: |
53/473 ; 53/244;
53/248; 53/51; 53/493 |
International
Class: |
B65B 5/10 20060101
B65B005/10; B65B 57/00 20060101 B65B057/00 |
Claims
1. An automated packaging apparatus for depositing pills into a
container, comprising: a rotary slat configured as a cylinder
rotatable in a rotational direction about an axis extending
longitudinally therethrough, the cylinder comprising a radially
outward portion and an opposing radially inward portion, and
defining a plurality of pill apertures therein, each pill aperture
being adapted to receive a pill from a plurality of pills deposited
into an interior space defined by the cylinder, the pills being
received by the pill apertures from the interior space at a first
angular position of the rotary slat; a negative pressure system in
fluid communication with the pill apertures of the rotary slat, the
negative pressure system being configured to apply a negative
pressure to the pill apertures so as to retain the pills therein,
as the rotary slat rotates about the axis from the first angular
position to a second angular position; a removal system configured
to interact with each of the pill apertures of the rotary slat, as
the respective pill aperture is disposed at the second angular
position, so as to remove the respective pill therefrom through the
radially outward portion of the rotary slat; and a collection
system disposed adjacent to the radially outward portion of the
rotary slat about the second angular position, the collection
system being configured to direct each pill removed from each
respective pill aperture toward a container for deposition
therein.
2. An apparatus according to claim 1 further comprising a shroud
member configured to extend about the radially outward portion of
the rotary slat, the shroud member being configured so as to allow
the negative pressure system to apply the negative pressure to the
pill apertures therethrough, while maintaining the pills within the
pill apertures, and extending from proximate to the first angular
position to proximate to the second angular position.
3. An apparatus according to claim 2 wherein the shroud member
further defines a dispensing aperture about the second angular
position, the dispensing aperture being configured so as to allow
the pill to pass therethrough from the radially outward portion of
the rotary slat defining the pill aperture, about the second
angular position.
4. An apparatus according to claim 3 wherein the removal system is
further configured to provide a negative pressure at least
partially radially outward of the pill aperture of the rotary slat,
as the pill aperture is disposed about the second angular position,
so as to remove the pill therefrom through the radially outward
portion of the rotary slat and through the dispensing aperture
defined by the shroud member.
5. An apparatus according to claim 4 wherein the removal system
further comprises an air blower configured to emit air into a
channel, the channel being directed outwardly of the pill aperture
disposed about the second angular position, so as to form the
negative pressure for removing the pill from the pill aperture
through the radially outward portion of the rotary slat and through
the dispensing aperture defined by the shroud member.
6. An apparatus according to claim 5 wherein the channel is defined
by at least one of the rotary slat and the shroud member.
7. An apparatus according to claim 1 further comprising of
plurality of adjacently-disposed rotary slats, each rotary slat
being independently rotatable about the axis and having a separate
removal system associated therewith.
8. An apparatus according to claim 1 wherein the collection system
further comprises a chute configured to receive the pill removed
from the pill aperture, and to direct the pill toward the
container.
9. An apparatus according to claim 1 wherein the axis is
substantially horizontally disposed, and the apparatus further
comprises a conveyor device configured to move the container into
coincidence with the collection system such that the container
receives the pills from the collection system.
10. An apparatus according to claim 9 wherein a conveyor device is
further configured to move the container into coincidence with the
collection system along a horizontal path substantially
perpendicular to the axis.
11. An apparatus according to claim 1 further comprising a counter
device operably engaged with at least one of the collection system
and the rotary slat, the counter device being configured to
determine an amount of pills deposited into the container.
12. An apparatus according to claim 1 further comprising a pill
reservoir operably engaged with the rotary slat, the pill reservoir
being configured to receive the plurality of pills and to direct
the plurality of pills into the interior space of the rotary
slat.
13. An apparatus according to claim 1 further comprising a drive
mechanism operably engaged with and configured to rotate the rotary
slat about the axis.
14. An apparatus according to claim 13 further comprising a
controller device operably engaged with and configured to control
the drive mechanism operably engaged with the rotary slat.
15. An apparatus according to claim 1 wherein each pill aperture
further includes a retaining flange about the radially inward
portion of the rotary slat, the retaining flange being further
disposed about a leading edge of the pill aperture, in the
rotational direction of the rotary slat, for retaining the pill
within the pill aperture.
16. An apparatus according to claim 1 wherein the rotational
direction is clockwise, wherein the first angular position is below
a horizontal plane extending through the axis, and wherein the
second angular position is above the horizontal plane.
17. A method of automatically depositing pills into a container,
comprising: receiving a pill in each of a plurality of pill
apertures defined by a rotary slat, the rotary slat being
configured as a cylinder rotatable about an axis extending
longitudinally therethrough, from a plurality of pills deposited
into an interior space of the cylinder and at a first angular
position of the rotary slat, the rotary slat comprising a radially
outward portion and an opposing radially inward portion; rotating
the rotary slat in a rotational direction about the axis, from a
first angular position to a second angular position; applying a
negative pressure to the pill apertures so as to retain the pills
within the pill apertures, as the rotary slat rotates in the
rotational direction from the first angular position to the second
angular position; removing the pills from the pill apertures, at
the second angular position of the rotary slat, through the
radially outward portion of the rotary slat; and directing each
pill removed from each respective pill aperture toward a container
for deposition therein.
18. A method according to claim 17 wherein applying a negative
pressure further comprises applying a negative pressure to the pill
apertures with a negative pressure system in fluid communication
therewith.
19. A method according to claim 17 wherein removing the pills
further comprises removing the pills from the pill apertures with a
removal system configured to interact therewith.
20. A method according to claim 17 wherein directing each pill
further comprises collecting and directing the pills with a
collection system disposed adjacent to the radially outward portion
of the rotary slat about the second angular position.
21. A method according to claim 17 wherein rotating the rotary slat
in a rotational direction further comprises rotating the rotary
slat in a clockwise rotational direction, with the first angular
position being below a horizontal plane extending through the axis,
and with the second angular position being above the horizontal
plane.
22. A method according to claim 17 wherein applying a negative
pressure further comprises applying a negative pressure to the pill
apertures in conjunction with a shroud member extend about the
radially outward portion of the rotary slat, wherein the shroud
member is configured to allow the negative pressure to be applied
to the pill apertures therethrough, while maintaining the pills
within the pill apertures, and extends from proximate to the first
angular position to proximate to the second angular position.
23. A method according to claim 22 wherein removing the pills
further comprises removing the pills from the radially outward
portion of the rotary slat defining the pill apertures, through a
dispensing aperture defined by the shroud member, about the second
angular position.
24. A method according to claim 23 wherein removing the pills
further comprises removing the pills from the radially outward
portion of the rotary slat and through the dispensing aperture by
applying a negative pressure at least partially radially outward of
the pill apertures disposed about the second angular position.
25. A method according to claim 24 wherein removing the pills by
applying a negative pressure further comprises removing the pills
from the radially outward portion of the rotary slat by emitting
air into a channel directed outwardly of the pill apertures
disposed about the second angular position, the channel being
defined by at least one of the rotary slat and the shroud member,
whereby the outwardly-directed air forms the negative pressure for
removing the pills.
26. A method according to claim 17 wherein directing the pills
toward the container further comprises directing the pills through
a chute configured to receive the pills removed from the pill
aperture, and to direct the pills toward the container.
27. A method according to claim 20 wherein the axis is
substantially horizontally disposed, and the method further
comprises moving the container into coincidence with the collection
system with a conveyor device such that the container receives the
pills from the collection system.
28. A method according to claim 27 wherein moving the container
into coincidence with the collection system further comprises
moving the container into coincidence with the collection system
along a horizontal path substantially perpendicular to the
axis.
29. A method according to claim 20 further comprising determining
an amount of pills deposited into the container using a counter
device operably engaged with at least one of the collection system
and the rotary slat.
30. A method according to claim 17 further comprising receiving the
plurality of pills in a pill reservoir and directing the plurality
of pills from the pill reservoir into the interior space of the
rotary slat.
31. A method according to claim 17 wherein rotating the rotary slat
further comprises rotating the rotary slat about the axis using a
drive mechanism operably engaged therewith.
32. A method according to claim 31 further comprising controlling
the drive mechanism using a controller device operably engaged
therewith.
33. A method according to claim 17 further comprising retaining the
pill within the pill aperture using a retaining flange disposed
about the radially inward portion of the rotary slat, toward a
leading edge of the pill aperture with respect to the rotational
direction of the rotary slat.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application No. 60/954,969, filed Aug. 9, 2007, which is
incorporated by reference herein in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] Embodiments of the present invention relate to packaging
machines and, more particularly, to an automated packaging machine
for filling containers with pills, and associated method.
[0004] 2. Description of Related Art
[0005] Pharmaceutical medicines and associated packaging apparatus
are typically subject to relatively strict consumer protection
guidelines. For example, pills, capsules, and the like, must be
produced and packaged in such a way as to at least meet the minimum
sterility requirements mandated by federal regulations. In
addition, the pills should be delivered into the packaging such
that the contents accurately meet the claimed labeling "count",
i.e., such that each package includes exactly the predetermined
number of pills. Notwithstanding the above, it is also desirable to
package the product in a mass production operation to offset costs
typically attributed to a labor intensive operation, in order to
provide an economical product.
[0006] In the past, pill filling machines have been proposed that
provide automated bottle counts by filling a hopper with pills and
causing a plurality of the pills to be caught by a pill capturing
device, such as an array of rotary slats. The rotary slats drop the
captured pills into a plurality of bottles disposed in alignment
with the dropping pills. The bottles are distributed along an
endless conveyor belt that is timed to advance and stop the bottles
according to the filling operation.
[0007] Some conventional pill capturing devices more particularly
include a series of rotary slats each configured to receive, hold,
and move a plurality of capsules or pills along a closed path. The
rotary slats are typically discs fixed on a rotatable shaft and
have a plurality of openings in the outer peripheral edge portion
thereof for capturing individual pills. Accordingly, the closed
path is arcuate and generally disposed between a pill hopper and
discharge area above a conveyor belt. By the rotary action of the
slats, the pills move in a direction normal to the conveyor belt.
The pill capturing device then generally discharges the pills by
rotating the slats, which move in correspondence with the closed
path, such that the pills fall out of the respective openings at
the filling station. The pills are often funneled through a chute
that empties into a corresponding bottle.
[0008] The "count," or number of pills in the bottle, is typically
determined by positioning the bottles in the pill dropping zone for
a predetermined time. The duration of the filling operation for
each bottle corresponds to the number of openings in each slat that
the machine is capable of delivering to the bottles per unit of
time. The duration of the filling operation, speed of the rotary
slats, and configuration of the pill capturing device, are thus
used to calculate the count.
[0009] Unfortunately, if the pill capturing device fails to capture
a pill in each and every cavity or receptacle of the slats, or if a
pill should mistakenly be diverted away from a path toward the
bottles, at least one of the bottles can be improperly filled. A
conventional solution to this problem is to situate an operator
adjacent to the slats to ensure that each receptacle is filled with
a pill. If a pill is missing, the operator manually places a pill
in the receptacle. However, such an approach involves additional
labor costs and can be unsatisfactory for sterility purposes. In
addition, the accuracy of the count of each bottle is largely
determined by the operator and, as such, a fully and
consistently-accurate counts cannot be guaranteed.
[0010] U.S. Pat. No. 6,185,901 to Aylward, which is incorporated
herein by reference, provides an exemplary solution to this problem
by way of a machine with a plurality of independently-driven rotary
slats. The pills are allowed to fall into an exterior receptacle of
each rotary slat and, in one embodiment, passed under a rotary
brush, in an attempt to prevent two pills from being disposed in
the same receptacle. A separate counting device is associated with
each rotary slat for counting each pill as it falls from the slat
into the container. A positive count is provided for each container
and improperly-filled slats will not affect the total count for
that container. If a particular container has a low count, the
respective slat can be further rotated to fill the container.
Because the slats are independently driven, the other slats can
remain stationary to prevent overfilling. Thus, such a machine is
capable of accomplishing an accurate filling of each bottle, but
consistent filling of the exterior receptacles of each rotary slat
may be difficult and may require additional provisions for assuring
continuous filling of the receptacles in a reliable manner.
[0011] One alternative apparatus is a rotatable drum, as provided
in U.S. Pat. No. 4,094,439 to List. The rotatable drum includes a
plurality of parallel rows of throughgoing holes that constitute
receptacles for dragees. The dragees enter the receptacles in the
drum from the interior of the drum at an inner input location, exit
to the exterior of the drum at an outer retrieval location, and are
filled into bottles. An ordering device facilitates the entry of
the dragees into the receptacles, and feeler blades engage the
receptacles. If any of the receptacles in an axially extending row
do not contain a dragee, one of the feeler blades actuates a bolt
pusher, which prevents any of the dragees in the row from being
deposited into the bottles. Instead, a solenoid and knockout bar
empty the receptacles of the row. By preventing the bottles from
being filled from partially-filled rows of receptacles, the
apparatus prevents the different bottles from being filled at
different rates. However, the additional mechanical components
required for emptying the partially filled rows of apertures
undesirably increase the complexity, cost, and likelihood of
failure or inaccurate count of the apparatus. Additionally,
emptying the partially filled rows slows the process of filling the
bottles, since no pills are dispensed from those rows.
[0012] Accordingly, there is a need for a packaging apparatus which
provides an accurate count for each container and operates at a
high speed. The apparatus should require a minimum of operator
intervention. Additionally, the apparatus should be cost effective,
both in initial cost and maintenance costs.
BRIEF SUMMARY OF THE INVENTION
[0013] The above and other needs are met by embodiments of the
present invention which, according to one aspect, provides an
automated packaging apparatus for depositing pills into a
container. Such an apparatus comprises a rotary slat configured as
a cylinder rotatable in a rotational direction about an axis
extending longitudinally therethrough, wherein the cylinder
comprises a radially outward portion and an opposing radially
inward portion, and defines a plurality of pill apertures therein.
Each pill aperture is adapted to receive a pill from a plurality of
pills deposited into an interior space defined by the cylinder. The
pills are received by the pill apertures, from the interior space,
at a first angular position of the rotary slat. A negative pressure
system is in fluid communication with the pill apertures of the
rotary slat, wherein the negative pressure system is configured to
apply a negative pressure to the pill apertures, so as to retain
the pills therein, as the rotary slat rotates about the axis from
the first angular position to a second angular position. A removal
system is configured to interact with each of the pill apertures of
the rotary slat, as the respective pill aperture is disposed at the
second angular position, so as to remove the respective pill
therefrom through the radially outward portion of the rotary slat.
A collection system is disposed adjacent to the radially outward
portion of the rotary slat, about the second angular position, and
is configured to direct each pill removed from each respective pill
aperture toward a container for deposition therein.
[0014] Another aspect of the present invention comprises a method
of automatically depositing pills into a container. Such a method
includes receiving a pill in each of a plurality of pill apertures
defined by a rotary slat, wherein the rotary slat is configured as
a cylinder rotatable about an axis extending longitudinally
therethrough and comprises a radially outward portion and an
opposing radially inward portion. The pills are provided from a
plurality of pills deposited into an interior space of the
cylinder, and are received by the pill apertures at a first angular
position of the rotary slat. The rotary slat is rotated in a
rotational direction about the axis, from a first angular position
to a second angular position, while a negative pressure is applied
to the pill apertures, so as to retain the pills within the pill
apertures, as the rotary slat rotates in the rotational direction
from the first angular position to the second angular position. The
pills are removed from the pill apertures, at the second angular
position of the rotary slat, through the radially outward portion
of the rotary slat. Each pill removed from each respective pill
aperture is then directed toward a container for deposition
therein.
[0015] Thus, embodiments of the present invention include an
automated packaging apparatus and associated method providing an
accurate count of pills dispensed to each container. Such an
apparatus requires a minimum of operator intervention, and can
operate at a high speed. Additionally, such an apparatus is cost
effective, both in initial cost and maintenance cost.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0016] Having thus described the invention in general terms,
reference will now be made to the accompanying drawings, which are
not necessarily drawn to scale, wherein:
[0017] FIGS. 1A and 1B are perspective views of a pill packaging
apparatus according to one embodiment of the present invention;
[0018] FIGS. 2A-2C are cross-sectional views of a pill packaging
apparatus according to one embodiment of the present invention;
[0019] FIGS. 3A and 3B are perspective views of a complete pill
packaging apparatus and an exploded pill packaging apparatus,
respectively, according to one embodiment of the present
invention;
[0020] FIGS. 4A and 4B are perspective views of a rotary slat
configured to receive pills and a rotary slat configured to receive
capsules, respectively, according to various embodiments of the
present invention; and
[0021] FIG. 5 is a magnified cross-sectional view of a pill
packaging apparatus according to one embodiment of the present
invention.
DETAILED DESCRIPTION OF THE INVENTION
[0022] The present invention now will be described more fully
hereinafter with reference to the accompanying drawings, in which
preferred embodiments of the invention are shown. This invention
may, however, be embodied in many different forms and should not be
construed as limited to the embodiments set forth herein; rather,
these embodiments are provided so that this disclosure will be
thorough and complete, and will fully convey the scope of the
invention to those skilled in the art. Like numbers refer to like
elements throughout.
[0023] Embodiments of the present invention are generally directed
to a pill handling apparatus 10, such as an automated packaging
machine. Such a pill handling apparatus can be used for dispensing
pills into containers, as discussed, for example, in U.S. Pat. No.
6,185,901 to Aylward, and in U.S. Pat. No. 6,401,429 to Aylward,
the contents of which are incorporated herein by reference. In
other embodiments, such a pill handling apparatus can be used for
other handling operations, besides pill packaging, such as
transporting pills during manufacture, inspection, or the like.
[0024] As illustrated in FIGS. 1-4, the pill handling apparatus 10
is adapted to deliver pills 12 into a series of containers 16. As
used herein, the term "pill" is not intended to be limiting and
includes any discrete articles of the type used in the
pharmaceutical industry or otherwise, including, but not limited
to, capsules, caplets, gelcaps, dragees, and tablets. Similarly,
the receiving containers 16, although illustrated as blister
packages throughout, are not limited thereto and can be any of
various configurations which provide an opening for receiving
discrete articles therein, such as bottles, pouches, boxes, or any
other suitable containers.
[0025] The pill handling apparatus 10 includes a rotary slat 18 for
receiving pills 12 and transporting the pills 12 to the receiving
containers 16. The rotary slat 18 is generally configured as a
cylinder defining a longitudinal axis therethrough, wherein the
plurality of pills 12 is received within an interior space 20
defined by a radially inward portion 21A (i.e., an inner surface)
of the cylinder. The radially inward portion 21A further defines
receptacles or pill apertures 22 (wherein the terms "receptacle"
and "aperture" are used interchangeably herein with respect to
element 22) along one or more paths about the rotary slat 18. For
example, the slat 18 is illustrated as having parallel paths of
receptacles 22, with each path extending about the inner surface
21A perpendicularly to the longitudinal axis (i.e., about the inner
circumference thereof). In some instances, the radially inward
portion 21A of the rotary slat 18 can define adjacent continuous
grooves or slots (see, e.g., FIG. 4A illustrating a rotary slat
configured to receive pills and FIG. 4B illustrating a rotary slat
configured to receive capsules) that extends about the inner
circumference of the cylinder around the slat 18, with the
receptacles 22 being defined in the grooves so that the pills 12
are received by each groove and guided thereby into the receptacles
22. While the receptacles 22 are illustrated to be pocket-like
apertures that extend radially outward from the radially inward
portion 21A of the slat 18, the apertures can have other
configurations. For example, the apertures can be holes, grooves,
flat portions on the radially inward portion 21A of the slat 18, or
the like. Thus, the receptacles 22 can define positions on the
radially inward portion of the slat 18 where the pills 12 are
received, i.e., positioned, and held during transport of the pills
12 to the containers 16. The receptacles 22 need not define a
contour that corresponds to the shape of the pills 12, and the
receptacles 22 can be provided with or without the groove(s). That
is, the receptacles 22 can be defined on or by the radially inward
portion 21A of the slat 18, or on or by the surface of an
outwardly-extending groove, as shown in FIGS. 4A and 4B.
[0026] As shown in FIGS. 1-4, the pills 12 are fed into the
interior space 20 of the cylindrical rotary slat 18 from a
reservoir 14, by way of a chute 14A extending therebetween. If
necessary, the opposed lateral sides of the rotary slat 18 may have
retaining plates 20A operably engaged therewith for retaining the
pills 12 within the interior space 20 of the cylindrical rotary
slat(s) 18. In some instances, a controller or controller device 46
may also be in communication with a level sensor (not shown) within
the common interior portion, and a reservoir gate switch (not
shown) controlling a reservoir gate (not shown) disposed between
the reservoir 14 and the interior space 20 of the rotary slats 18
(i.e., along the chute 14A). The level sensor may be configured to
detect the quantity of pills 12 in the interior space 20 and to
communicate a corresponding value or signal to the controller 46 so
as to appropriately control the feed of the pills 12 from the
reservoir 14 via the reservoir gate/reservoir gate switch. For
example, the level sensor can detect the level of pills 12 in the
interior space 20 of the rotary slat 18 and, when the controller 46
detects that the level of pills 12 is below the desired level, the
controller 46 signals the reservoir gate switch to open the
reservoir gate to release more pills 12 from the reservoir 14 into
the interior space 20. By opening and closing the reservoir gate,
the controller 46 maintains a desired number of pills 12 within the
cylinder defined by the rotary slat 18. The desired level of pills
12 may thus be adjusted, for example, to optimize the seating of
pills 12 in the pill apertures 22 and/or to prevent wear or
breaking of the pills 12 caused by overfilling of the interior
space 20.
[0027] The rotary slat 18 may be engaged with and rotated by a
drive arrangement or mechanism 120 to transport the pills 12 from
the interior space 20 to the containers 16. The rotary slat 18
rotates in a first direction 19 defining an arcuate delivery path
from a pill capture or first angular position 23A to a release or
second angular position 23B, where the pills 12 are released. The
release position 23B is generally more than about 180 degrees away
from the pill capture position 23A, but nonetheless above a
horizontal plane extending through the longitudinal axis (whereas
the pill capture position 23A is below the horizontal plane). In
one embodiment, the first angular position 23A may be, for
instance, about the "six o'clock" position (i.e., between about
"four o'clock" and about "eight o'clock"), while the second angular
position 23B may be, for instance, about the "two o'clock"
position. The drive arrangement may be configured, for example, to
engage an outer surface or an end surface of the rotary slat 18 by
friction or geared engagement to turn the rotary slat 18 in the
first direction 19.
[0028] The rotary slat 18 is configured such that each pill
aperture 22 extends from the radially inner portion 21A (i.e.,
inner surface) to the outer radial portion 21B (i.e., outer
surface) of the cylinder. Each pill aperture 22 is thus configured
such that the pills 12 can pass therethrough. The pill apertures 22
therefore include several aspects for retaining the pills 12
therein, as the pills 12 are transported from the first angular
position 23A to the second angular position 23B with respect to the
rotary slat 18 rotating in the rotational direction 19 (i.e.,
clockwise) about the longitudinal axis thereof. In one instance,
each pill aperture 22 may include a retaining flange or lip 100
about the radially inward portion 21A of the rotary slat 18, and
about the leading edge of the pill aperture 22 with respect to the
rotational direction 19. The retaining flange 100 at least
partially facilitates retention of the pill 12 within the
respective pill aperture 22, as the pill 12 is deposited therein
from the interior space 20.
[0029] The rotary slat 18 may be formed as an integral,
single-piece component. In such instances, a suitable forming
device such as, for example, a laser sintering device may be
implemented to form the rotary slat 18. In other instances, the
rotary slat 18 may be cast, machined, molded, or otherwise formed.
A variety of materials can be used for the construction of the
rotary slat 18 including, but not limited to, metals, metal alloys,
and polymers. In some instances, the rotary slat 18 is formed of a
durable, low friction material that is cost effective for
manufacture, such as a compound comprising
acrylonitrile-butadiene-sytrene and polytetrafluoroethylene.
Depending on the type of pills 12 fed by the rotary slat 18, it may
also be important that the material of the rotary slat 18 does not
chemically affect the pills 12. Other components of the pill
handling apparatus 10 can be made of the same or different
materials.
[0030] Further, in order to prevent the pills 12 from exiting the
pill apertures 22 through the radially outward portion 21B of the
rotary slat 18, as the pills 12 are transported from a first
angular position 23A to a second angular position 23B, the radially
outward portion 21B of the rotary slat 18 may be at least partially
covered by a shroud member 30 disposed adjacent thereto. That is,
the shroud member 30 is disposed adjacent to the rotary slat 18, at
least between about the first angular position 23A and about the
second angular position 23B, so as to cover the pill apertures 22
from the radially outward portion 21B of the rotary slat 18, while
allowing the rotary slat 18 to rotate with respect thereto in the
rotational direction 19.
[0031] A controller 46 may be configured to control the operation
of the drive arrangement such that the rotary slat 18 can be
rotated at various speeds, if desired or appropriate. For example,
the rotary slat 18 can be rotated at a fast speed during the
initial portion of the pill filling operation, until a
predetermined number of the pills 12 is delivered to the respective
container 16, and subsequently rotated at a slower speed to finish
the filling operation and to prevent under-filling or over-filling
of the container 16. Additionally, the controller 46 can
alternately accelerate and decelerate the rotary slat 18 to cause a
jerking or vibratory motion for agitating the pills 12. Such
agitation of the pills 12 can be useful in encouraging the pills 12
to become seated in the pill receptacles 22.
[0032] In some embodiments, a negative pressure system or vacuum
assembly 90 may be disposed in fluid communication with the rotary
slat 18 to apply suction, or draw air into, the receptacles 22 of
the rotary slat 18 through, for example, appropriate holes defined
by the shroud member 30 so as to act upon pills 12 to be received
from the interior space 20 or retained within the receptacles 22.
In particular, the vacuum assembly 90 may include the shroud member
30 disposed adjacent to the rotary slat 18 so as to extend at least
partially about the radially outward portion 21B thereof. Air may
be drawn from the pill apertures 22 and through the shroud member
30 by a fan, pump, or other appropriate low pressure source through
a vacuum chamber 32 associated with the shroud member 30, whereby
the receptacles 22 can be affected by suction applied via the
shroud member 30. As such, the receptacles 22 temporarily disposed
between the first angular position 23A and the second angular
position 23B are temporarily disposed in fluid communication with
the suction applied via the shroud member 30 such that, as air is
drawn from the vacuum chamber 32, suction is created in the
receptacles 22. The disposition of the receptacles 22, in this
regard, is referred to herein as "temporary" because the rotary
slat 18 is generally being rotated when the pill handling apparatus
10 is used. Thus, the vacuum assembly 90 can selectively draw air
into or apply suction to the receptacles 22 according to the
rotational position of the rotary slat 18 so that the pills 12 are
urged into the receptacles 22 at the first angular position (e.g.,
the "capture" position 23A of the rotary slat 18) and released from
the receptacles 22 at the second angular position (e.g., the
release position 23B for dispensing the pills 12 into the
containers 16).
[0033] Thus, pills 12 deposited into the interior space 20 of the
cylindrical rotary slat 18 are urged toward receipt and capture by
the receptacles 22 because of the air currents and pressure
differentials present at the receptacles 22 due to the suction
imparted by the vacuum assembly 90 via the shroud member 30. In
some cases, the pills 12, once seated in the receptacles 22, may at
least temporarily partially or entirely block the holes defined by
the shroud member 30. Thus, these descriptions relate to
configurations wherein each seated pill completely seals the
receiving receptacle to prevent further air flow, configurations
wherein each seated pill partially seals the receiving receptacle
to limit further air flow, and configurations wherein air flow is
permitted without significant reduction by a pill seated in a
receptacle. Accordingly, the vacuum assembly 90 may also serve to
clean the pills 12, but may also allow pill fragments or other
particles to fall from the receptacles 22 and back into the
interior space 20 of the rotary slat 18. Such a fragment/particle
removal process is further facilitated by the respective
dispositions of the first and second angular positions 23A, 23B
(i.e., transporting the pills through the "12 o'clock" position
allows the fragments/particles the opportunity to fall from the
receptacles 22). As a receptacle arrives at the release or second
angular position 23B, the vacuum chamber 32 ends and the
receptacles 22 associated therewith lose fluid communication with
the shroud member 30. About the second angular position 23B, the
retaining flange 100 prevents the pill 12 from exiting the rotary
slat 18 through the radially inward portion 21A thereof. That is,
as each receptacle 22 reaches the release or second angular
position 23B, the receptacle 22 is rotated beyond the shroud member
30 so that the pill 12 is no longer held in the receptacle 22 by
suction, but rather by the retaining flange 100. One skilled in the
art will appreciate, however, that other configurations of vacuum
assemblies 90 can be used to provide the desired suction for
controlling the seating of the pills 12 in the rotary slat 18.
Also, while the illustrated vacuum assembly 90 is used to maintain
the pills 12 in the receptacles 22 between the capture and release
positions 23A, 23B, and the retaining flange 100 used to maintain
the pills 12 within the receptacles 22 about the release position
23B, a shroud or cover can be additionally or alternatively be
provided about the radially inward portion 21A of the cylindrical
rotary slat 18 for preventing the release of the pills 12 from the
receptacles 22 through either the radially inward portion 21A or
the radially outward portion 21B.
[0034] In some embodiments of the present invention, a removal
system 95, such as a positive pressure or blower assembly, or other
suitable ejection mechanism, can be disposed in fluid communication
with each receptacle or pill aperture 22 for removing the
respective pills 12 therefrom through the radially outward portion
21B of the rotary slat 18. In order to facilitate the removal of
the pills 12 from the receptacles 22, the shroud member 30 is
configured to define a dispensing aperture 160 about the second
angular position 23B (with the dispensing aperture 160 being
configured to allow the pill 12 to pass therethrough).
[0035] As shown in FIG. 5, the shroud member 30 may be configured
to define a first capillary 150A extending therethrough about the
second angular position 23B toward the radially outward portion 21B
of the rotary slat 18. The rotary slat 18 may further define a
complementary second capillary 150B configured to be, at least
temporarily, in communication with the first capillary 150A as a
corresponding pill aperture 22 is aligned with the dispensing
aperture 160. As shown, the second capillary 150B may, in one
instance, be configured to extend from the radially outward portion
21B toward the radially inward portion 21A (but without extending
through the radially inward portion 21A), and then back toward the
radially outward portion 21B. In doing so, the second capillary
150B extends radially outward through the trailing edge (with
respect to the rotational direction 19) of the pill aperture 22 or
through the radially outward portion 21B about the trailing edge of
the pill aperture 22. In this manner, air blown into the first
capillary 150A by the removal system 95 (i.e., by an air blower)
flows through the second capillary 150B in the rotary slat 18, when
the capillaries 150A, 150B are aligned. The blown air exits the
second capillary 150B about the trailing edge of the pill aperture
22 when the pill aperture 22 is aligned with the dispensing
aperture 160 about the second angular position 23B. The air exiting
the second capillary 150B thus forms a low pressure area (i.e.,
suction) externally to the pill aperture 22 at the radially outward
portion 21B of the rotary slat 18. The low pressure area thus
causes the pill 12 to be removed from the pill aperture 22 through
the radially outward portion 21B of the rotary slat 18 and through
the dispensing aperture 160 defined by the shroud member 30. One
skilled in the art will appreciate that the removal system 95 may,
in some instances, be configured to address individual rows of
apertures within the rotary slat 18. In such instances, the removal
system 95 may be selectively operated such that the apparatus 10
can be used, for example, to fill different sizes of containers 16
or to provide a "fine fill" function whereby the apparatus 10
completes a pill count for a particular container 16.
[0036] In some instances, the removal system 95 may be configured
to at least partially determine the filling of the containers 16.
That is, the pills 12 will be extracted or removed from the pill
apertures 22 as long as the removal system 95 is "on" (i.e., as
long as air is being blown into the first and second capillaries
150A, 150B. In such instances, even though a container 16 is not
being filled and the removal system is "off," the rotary slat 18
and the vacuum system 90 may be continually rotated such that the
rotary slat 18 remains primed with pills 12 in the receptacles 22
in preparation for filling the next container 16. The external
removal system 95 further allows for interchangeability of the
rotary slat 18 without having to reconfigure or adjust the
capillaries 150A, 150B (i.e., each rotary slat 18 includes an
appropriately configured second capillary 150B for cooperating with
the first capillary 150A). Servicing and maintenance of the
apparatus 10 may also be facilitated by such a configuration of the
removal system 95. However, one skilled in the art will also
appreciate that the removal system 95 may be configured in
different manners. For example, the removal system 95 may, in some
instances, be disposed within the interior space 20 of the rotary
slat 18 and configured to blow air outwardly through the second
capillary 150B (the first capillary 150A would not be necessary) to
accomplish a similar effect.
[0037] Once the pills 12 are removed from the rotary slat 18
through the radially outward portion thereof and through the
dispensing aperture 160 defined by the shroud member 30, the pills
12 are collected by a collection system 60 and directed toward the
container(s) 16 for deposition therein. More particularly, the
collection system 60 may comprise one or more chutes 62 disposed
adjacent to the release or second angular position 23B of the
rotary slat 18 (and adjacent to the dispensing aperture 160) for
receiving the pills 12 and guiding the pills 12 from the rotary
slat 18 to a container 16. Accordingly, as a receptacle 22 having a
pill 12 therein arrives at the release position 23B, the pill 12 is
removed from the receptacle 22 and is collected by a chute 62
through the dispensing aperture 160. The chutes 62 may be comprised
of, for example, an acetal or Delrin.TM. polymer, available from
DuPont.
[0038] The number of pills 12 delivered to each container 16 must
also be determined. In this regard, a counting device or counter
device 200 can be associated with the rotary slat 18 or the
chute(s) 62 of the collection system 60 prior to the pills 12 being
deposited into the container 16. For example, one or more counting
devices 200 can be positioned adjacent, above, below, or within a
chute 62 so that any pill 12 which travels through the chute 62
will be detected by the counting device 200. One exemplary counting
device 200 includes an infrared light source and a light receiver
positioned substantially opposite the light source across a central
passage (i.e., the chute 62). The light source generates a light
beam that is detected by the opposing light receiver. When the
light beam is interrupted by a falling pill 12, the light receiver
transmits a signal which increases the count in the controller 46.
Thus, the number of interruptions corresponds to the number of
pills 12 delivered into a particular container 16.
[0039] In some embodiments, the controller 46 may also be
configured to control the quantity of pills 12 provided in the
reservoir 14. For example, a level sensor can detect the quantity
of pills 12 in the reservoir 14. The quantity may be determined
optically, by weight, or otherwise. The level sensor communicates a
corresponding value or signal to the controller 46. When the
controller 46 detects that the level of pills 12 in the reservoir
14 is below the desired level, the controller 46 can open a
reservoir gate that controls the passage of pills 12 from a bulk
bin to the reservoir 14, thereby maintaining a desired number of
pills 12 in the reservoir 14. The desired level of pills 12 in the
reservoir 14 can be adjusted to optimize the seating of pills 12 in
the receptacles 22 of the rotary slat 18 and to prevent wearing or
breaking of the pills 12 caused by overfilling of the reservoir
14.
[0040] In some instances, a pill inspection device (not shown) may
also be implemented, wherein the counting device 200 may be a
separate and different component, or may be incorporated with the
pill inspection device. For example, the counting device(s) and/or
inspection device(s) can be configured to detect the pills by
counting and/or inspecting the pills. In some cases, the inspection
device may be, for example, an optical imaging device, such as a
camera, configured to monitor the chute(s) 62 for pills 12 passing
therethrough by detecting an image of each pill to determine the
size, shape, and/or other characteristics of the pill. Thus, the
inspection device can be configured to determine the presence of
the pills 12 in the chute(s) 62 (i.e., as a counting device) and/or
determine a characteristic of the pills 12, such as whether the
pills are broken or otherwise defective. If provided, the
inspection device is disposed in communication with the controller
46, e.g., so that the controller can use the inspection device to
determine, for example, if a chute 62 is blocked.
[0041] In one embodiment, the container 16 may be brought into
position under the chute(s) 62 by a conveyor device 70 or other
suitable container-movement system, as will be appreciated by one
skilled in the art, wherein the container 16 may be appropriately
placed, for example, by mechanical stops or any number of placement
arrangements. Since the pills 12 are dispensed from the rotary slat
18 in parallel to the longitudinal axis thereof, the conveyor
device 70 may be configured to move the container 16 into
coincidence with the collection system 60 (i.e., presuming that the
collection system 60 directs the pills 12 directly downward from
the respective apertures 22) along a horizontal path substantially
perpendicular to the axis. In such a manner, a plurality of pill
packaging apparatuses 10, represented by a corresponding plurality
of rotary slats 18 (i.e., as shown in FIGS. 1A and 1B), each with
their own removal system 95, may be implemented to fill the
containers 16 in a serpentine-like manner. After the container 16
has been filled, the container 16 is transported away for further
processing or packaging and a different, unfilled container 16 is
transported into coincidence with the collection system 60.
[0042] Many modifications and other embodiments of the invention
will come to mind to one skilled in the art to which this invention
pertains having the benefit of the teachings presented in the
foregoing descriptions and the associated drawings. Therefore, it
is to be understood that the invention is not to be limited to the
specific embodiments disclosed and that modifications and other
embodiments are intended to be included within the scope of the
appended claims. Although specific terms are employed herein, they
are used in a generic and descriptive sense only and not for
purposes of limitation.
* * * * *