Pharmaceutical bulk-up system
Disclosed is a method and system for providing a rapid, semiautomatic or fully automatic prescription drug bulk-up apparatus that is compatible with process protocols used in mail order pharmacies, high volume drug repackaging facilities and drug distribution centers. The unique gripping mechanism gives the system the capability to open a wide range of bottle sizes, shapes and thickness.
This application is based upon and claims the benefit of U.S. provisional application No. 60/667,711, entitled “Pharmaceutical Bulk-Up System”, filed Apr. 1, 2005, the entire disclosure of which is hereby specifically incorporated by reference for all that it discloses and teaches.
BACKGROUND OF THE INVENTION1. Field of the Invention
The present invention relates to methods and systems for accessing and removing the contents of containers and more specifically for access and removal of pharmaceuticals from plastic pharmaceutical bottles for subsequent repackaging.
2. Description of the Background
Pharmaceutical capsules and tablets are typically packaged by the manufacturer in bottle form and in standardized quantities. Physicians typically will prescribe these medications in numbers that differ from the standard quantity, and thus, necessitate unpacking, bulking and repackaging of the contents within the bottles.
SUMMARY OF THE INVENTIONThe present invention overcomes the disadvantages and limitations of the prior art by providing a method and apparatus for rapid and efficient content removal of capsule and tablet medications from a wide variety of standardized pharmaceutical or other plastic bottles.
The present invention may therefore comprise an apparatus for producing an opening in a closed plastic container bottle in order to remove at least a portion of the contents of the bottle comprising: a gripping apparatus for securely holding the bottle, the gripping apparatus comprising two lateral clamps, each lateral clamp comprising a plurality of clamp jaws arranged in a substantially parallel orientation and perpendicular to a vertical axis; a cutting assembly that passes a cutting blade through an entire cross section of the bottle thereby severing the bottle along the cross section to provide access to the contents of the bottle.
The present invention may also comprise a method of producing an opening in a closed plastic container bottle in order to remove at least a portion of the contents of the bottle comprising: gripping and securely holding the bottle with two lateral clamps comprising a plurality of clamp jaws arranged in a substantially parallel orientation and perpendicular to a vertical access; producing an opening in the bottle by severing the bottle along a cross section of the bottle by passing a cutting blade through the entire cross section; and, removing the contents of the bottle through the opening.
The present invention may also comprise an apparatus for severing a cross section of a closed plastic container bottle in order to remove at least a portion of the contents of the bottle comprising: a cutting blade comprising: two sharp leading edges that form a point; two leading surfaces that transition the thickness of the cutting blade from a nominal blade thickness to a leading edge thickness at a cut angle; a cutting force that drives the cutting blade into a sidewall of the bottle to create a discontinuity with the point; the leading surfaces that propagate the discontinuity through the cross section to sever the bottle.
The present invention may also comprise a method of severing a cross section of a closed plastic container bottle in order to remove at least a portion of the contents of the bottle comprising: forming a discontinuity in a sidewall of the bottle by forcibly penetrating the sidewall with a point of a cutting blade formed by. the intersection of two sharp leading edges; and, propagating the discontinuity in two directions through the cross section to sever the bottle with each sharp leading edge.
BRIEF DESCRIPTION OF THE DRAWINGSIn the drawings,
While this invention is susceptible to embodiment in many different forms, there is shown in the drawings and will be described herein in detail specific embodiments thereof with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not to be limited to the specific embodiments described.
The particular geometry that is accomplished by the overlapping “V” shaped jaws allows a wide variety of pharmaceutical bottles to be gripped by the jaw clamp assembly 100. The “V” shape of the clamp jaws 102 may also contain a flat portion at the apex of the “V” allowing further versatility. In this manner, both cylindrical as well as rectangular objects and bottles can be readily and securely gripped by the jaw clamp assembly. A mounting plate 112 is secured in a horizontal orientation behind the clamp jaws and covers the mechanisms which are used to operate and engage the lateral clamps.
The relative motions of the lateral clamps 108 and 110 are regulated and coordinated with one another by a rack-and-pinion gear mechanism that is also mounted on the underside of mounting plate 112 and connected to the left gripper arm 118 on one side, and to the right gripper arm 120 on the other side. Within this mechanism, a pinion gear 122 is centrally mounted between the diametrically opposed actuator cylinders 114 and 116. A front rack gear race 124 regulates the lateral movement of the left gripper arm 118, and similarly, a rear rack gear race 126 regulates the lateral movement of the right gripper arm 120. Typically, the jaw clamps of the aforementioned embodiment will contain a mechanism, such as a spring (not shown), to enable the gripping jaws to remain closed when power or air pressure to the system is lost. This allows the jaw clamp assembly to maintain a secure grip on an object when the system is powered down or momentarily paused during its course of operation.
The minimum and maximum separation of each jaw clamp assembly 100 can be adjusted by setting the two corresponding gripper width adjustments 144 to match to a variety of particular pharmaceutical bottle sizes and shapes. This feature allows an operator to easily configure the pharmaceutical bulk-up system from one bottle to the next, with minimum effort and downtime, and without removing the jaw clamp assemblies 100 from the rotary dial assembly 400. A particle isolation tray 142 covers the center portion of the rotary table 140 and keeps the inner workings of the rotary dial assembly 400 free from contamination and assists in making the machine easy to clean.
Generic station IV 138 may take on a variety of uses depending on the particular needs of the user and on the configuration of generic station III 136. Typically, station IV 138 can be used to offload pharmaceutical bottles either before or after the contents have been removed. This offload may be performed by a robotic arm, operator or other type of automated offloading system.
The cutting operation is a cyclical sequence of steps that begins with presenting the bottle within the gripper to the cut station II 134. At this point the pancake cylinder 168 is extended down to qualify the bottle within the gripper to a nominal preset height. This function is completed to eliminate operator set-up error and protect the contents of the bottle as much as possible. The pancake cylinder 168 places the contact disk 170 in contact or directly above the bottom surface of the bottle and when the cutting blade 160 is actuated. As the blade extends through the bottle, the severed part is compressed between the top surface of the blade and the contact disk 170. This results in the bottle bottom being sandwiched or held thereby facilitating a complete cut. Without this compression, one side of the bottle would tend to cut before the other, allowing the bottom to flip, and resulting in an incomplete or rough cut.
The cutting blade 160 comprises a sharply pointed blade angle 172 to facilitate penetration of the bottle material and incorporates a single beveled “V” shaped edge that is sharpened to form a leading edge 176 with additional cutting capability. The leading edge 176 of the cutting blade 160, transitions to the surface of the cutting blade 160 at a cut angle 174 forming a leading surface 178. Once the initial material separation occurs with the initial penetration the bottle material, the leading edge 176 perpetuates the separation by cutting the perimeter of the bottle. As the cutting blade 160 moves through the bottle, the leading surface 178, which is disposed at a cutting angle 174, forces the severed material upward allowing the bottom of the bottle to be peeled up into the contact disk 170 as it is cut off. This upward force that is provided by the leading surface 178 greatly reduces the amount of cutting force needed to sever the material at leading edge 176 and thereby facilitating a clean, smooth cut while extending the life of the cutting blade 160. The point of the cutting blade 160 is designed to act as a blunt force penetrating device with minimal bending and breaking capability. The blade angle 172 and the cutting angle 174 have been specifically optimized to perform this operation in an optimal manner with maximum tool life and minimal cutting force.
The bottle is therefore severed by a penetration of the blade point and propagated circumferentially in both directions from the penetration point by the leading edge 176 around the perimeter of the bottle. The perimeter cut is initiated from the outside-in on the first half of the bottle, and transitions to cutting from the inside-out on the second half of the bottle. Additionally, the blade continually covers the pills as it removes the bottom of the bottle thereby protecting the bottle contents from potential debris as the cutting and air-jet and/or ejection takes place.
As the blade actuator cylinder 150 reaches full inward stroke, all cutting is complete and the pancake cylinder 168 retracts back to the up position. As the pancake cylinder 168 retracts, the compression on the severed material sandwiched between the contact disk 170 and the cutting blade 160 is relieved in preparation for the ejection. Compressed air is fed to the severed part through the air ejector plate 162 and the cut material is disposed to a discard chute or a collection hopper. After the air ejects the severed bottom of the bottle, the blade retracts, exposing the product in preparation to repeat the cycle on the next bottle.
The disclosed systems, therefore provide a rapid, semiautomatic or fully automatic prescription drug bulk-up apparatus that is compatible with process protocols used in mail order pharmacies, high volume drug repackaging facilities and drug distribution centers. The unique gripping mechanism gives the system the capability to open a wide range of bottle sizes, shapes (round, square, oval, rectangular, etc. . . . ) and thickness. The cutting blade design and implementation keeps plastic particulates to a minimum level while providing a quick, clean cut, with long blade life and durability.
The foregoing description of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and other modifications and variations may be possible in light of the above teachings. The embodiment was chosen and described in order to best explain the principles of the invention and its practical application to thereby enable others skilled in the art to best utilize the invention in various embodiments and various modifications as are suited to the particular use contemplated. It is intended that the appended claims be construed to include other alternative embodiments of the invention except insofar as limited by the prior art.
Claims
1. An apparatus for producing an opening in a closed plastic container bottle to allow removal of at least a portion of the contents of said bottle comprising:
- a gripping apparatus for securely holding said bottle, said gripping apparatus comprising two lateral clamps, each said lateral clamp comprising a plurality of clamp jaws arranged in a substantially parallel orientation and perpendicular to a vertical axis; and,
- a cutting assembly that passes a cutting blade through an entire cross section of said bottle thereby severing said bottle along said cross section and provide access to said contents of said bottle.
2. The apparatus of claim 1 wherein said severing said bottle is performed on a bottom portion of said bottle.
3. The apparatus of claim 1 wherein said bottle is positioned at a specific height with respect to said cutting blade with an alignment cylinder.
4. The apparatus of claim 1 wherein relative motion of said lateral clamps is controlled by a rack-and-pinion gear.
5. The apparatus of claim 3 wherein said rack-and-pinion gear is mounted between diametrically opposed pneumatic actuator cylinders and a rack gear race controls movement of said gripping apparatus.
6. The apparatus of claim 1 wherein said clamp jaws are held in a normally closed position when said apparatus is not powered.
7. The apparatus of claim 1 that is a rotary assembly containing at least two stations for said removal of at least a portion of the contents of said bottle.
8. The apparatus of claim 1 wherein said bottle is severed without rotation of said bottle or said cutting blade.
9. The apparatus of claim 1 wherein said bottle is severed by a penetration of a point of said cutting blade and a discontinuity is propagated circumferentially in both directions from said penetration point around a perimeter of said bottle.
10. The apparatus of claim 1 wherein said cutting blade covers said contents of said bottle as it divides said bottle along said cross section, thereby protecting said contents of said bottle.
11. The apparatus of claim 1 wherein said clamp jaws comprise a V shape to accommodate said container bottles of various cross sectional geometries.
12. The apparatus of claim 1 wherein said gripping apparatus can rotate about a substantially perpendicular axis to said bottle to position said bottle in any rotational orientation.
13. A method of producing an opening in a closed plastic container bottle to allow removal of at least a portion of the contents of said bottle comprising:
- gripping and securely holding said bottle with two lateral clamps comprising a plurality of clamp jaws arranged in a substantially parallel orientation and perpendicular to a vertical access;
- producing an opening in said bottle by severing said bottle along a cross section of said bottle by passing a cutting blade through the entire said cross section; and, removing said contents of said bottle through said opening.
14. The method of claim 13 further comprising said process of:
- severing said bottle on a bottom portion of said bottle.
15. The method of claim 13 further comprising said process of:
- positioning said bottle at a specific height with respect to said cutting blade with an alignment cylinder.
16. The method of claim 13 further comprising said process of:
- controlling relative motion of said lateral clamps with a rack-and-pinion gear.
17. The method of claim 13 further comprising said process of:
- severing said bottle without rotation of said bottle or said cutting blade.
18. The method of claim 13 further comprising said process of:
- severing said bottle by penetrating a point of said cutting blade and propagating a discontinuity circumferentially in both directions from said penetration point around a perimeter of said bottle.
19. The method of claim 13 further comprising said process of:
- protecting said contents of said bottle by covering said contents of said bottle with said cutting blade as said cutting blade divides said bottle along said cross section.
20. The method of claim 13 further comprising said process of:
- accommodating said container bottles of various cross sectional geometries with said clamp jaws that comprise a V shape.
21. The method of claim 13 further comprising said process of:
- rotating said gripping apparatus about a substantially perpendicular axis to said bottle to position said bottle to facilitate loading or offloading operations.
22. The method of claim 13 further comprising said process of:
- rotating said bottle gripped in said clamp jaws from a loading station to a cutting station prior to said removal of said contents of said bottle.
23. An apparatus for severing a cross section of a closed plastic container bottle to allow removal of at least a portion of the contents of said bottle comprising:
- a cutting blade comprising: two sharp leading edges that form a point; two leading surfaces that transition the thickness of said cutting blade from a nominal blade thickness to a leading edge thickness at a cut angle; and,
- a cutting force that drives said cutting blade into a sidewall of said bottle to create a discontinuity with said point, said leading surfaces that propagate said discontinuity through said cross section to sever said bottle.
24. The apparatus of claim 23 wherein said severing said bottle is performed on a bottom portion of said bottle.
25. The apparatus of claim 23 wherein said bottle is severed without rotation of said bottle or said cutting blade.
26. The apparatus of claim 23 wherein said discontinuity is propagated circumferentially in both directions from said penetration point around a perimeter of said bottle.
27. The apparatus of claim 23 wherein said severing said cross section is initiated from outside-in on a first half of said bottle and transitions to cutting from inside-out on a second half of said bottle.
28. A method of severing a cross section of a closed plastic container bottle to allow removal of at least a portion of the contents of said bottle comprising:
- forming a discontinuity in a sidewall of said bottle by forcibly penetrating said sidewall with a point of a cutting blade formed by the intersection of two sharp leading edges; and,
- propagating said discontinuity in two directions through said cross section to sever said bottle with each said sharp leading edge.
29. The method of claim 28 further comprising the process of:
- severing said bottle on a bottom portion of said bottle.
30. The method of claim 28 further comprising the process of:
- severing said bottle without rotation of said bottle or said cutting blade.
31. An apparatus for producing an opening in a closed plastic container bottle that allows removal of at least a portion of the contents of said bottle comprising:
- gripping means for securely holding said bottle, said gripping means comprising two lateral clamp means, each said lateral clamp means comprising a plurality of clamp jaws arranged in a substantially parallel orientation and perpendicular to a vertical axis; and,
- a cutting means that passes a cutting blade through an entire cross section of said bottle to sever said bottle along said cross section and provide access to said contents of said bottle.
Type: Application
Filed: Mar 31, 2006
Publication Date: Nov 2, 2006
Inventors: Timothy Chambers (Longmont, CO), Timothy McFadden (Roseburg, OR)
Application Number: 11/396,292
International Classification: B65B 43/00 (20060101);