Patch transfer and inspection apparatus

Abstract

The invention provides an interlinked device for producing sealed packaging units, with a clocked delivery device for web-like material, with a separating device for separating in each case at least one portion of the web-like material, with a clocked packaging device, and with a sealing device, the sum of the stoppage intervals per cycle of the delivery device differing from the sum of the stoppage intervals per cycle of the packaging device, and a method for producing such a packaging unit. For this purpose, the device comprises an intermediate conveyor device which, in the material flow, is arranged between the delivery device and the packaging device. An optical inspection device is also arranged on the intermediate conveyor device and used at least for geometric inspection of the separated portion. With the present invention, a device and a method are disclosed for producing packaging units in an interlinked device, in which the content of the packaging unit can be inspected.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This is a continuation-in-part application of U.S. Provisional Application No. 61/125,505 filed Apr. 25, 2008, and claims the benefit of said U.S. Provisional Application.

BACKGROUND OF THE INVENTION

The invention relates to an interlinked device for producing sealed packaging units, with a clocked delivery device for web-like material, with a separating device for separating in each case at least one portion of the web-like material, with a clocked packaging device, and with a sealing device, the sum of the stoppage intervals per cycle of the delivery device differing from the sum of the stoppage intervals per cycle of the packaging device, and a method for producing such a packaging unit.

Sealed packaging units, which are used for example for therapeutic systems or for wafers containing active substances, are in most cases produced in an interlinked production process that ranges from the manufacture of the systems to the packaging in packaging units. For example, single-layer or multi-layer material webs are produced, shaped cuts are introduced, and the systems imprinted. During this manufacture, a so-called release liner, for example, is used as system carrier. It is only directly before the packaging station that individual portions are separated from this carrier for singulation of the systems and are placed between the packaging material webs. They are then carried along with the packaging material webs and sealed within these by means of the sealing device.

The individual separated portion may have geometric defects or positioning errors. For example, it may be too long or too short. It is also possible for narrow portions to be inadvertently sealed in individually or in addition to a geometrically correct portion. There is also a danger of part of the separated portion falling into the area of the sealing seam. Inspecting the content of the packaging unit prior to the packaging operation is not possible in the arrangement used hitherto.

The object of the present invention is therefore to develop a device and a method for producing packaging units in an interlinked device, in which the content of the packaging unit can be inspected.

SUMMARY OF THE INVENTION

The invention provides an interlinked device for producing sealed packaging units, with a clocked delivery device for web-like material, with a separating device for separating in each case at least one portion of the web-like material, with a clocked packaging device, and with a sealing device, the sum of the stoppage intervals per cycle of the delivery device differing from the sum of the stoppage intervals per cycle of the packaging device, and a method for producing such a packaging unit. For this purpose, the device comprises an intermediate conveyor device which, in the material flow, is arranged between the delivery device and the packaging device. An optical inspection device is also arranged on the intermediate conveyor device and used at least for geometric inspection of the separated portion. With the present invention, a device and a method are developed for producing packaging units in an interlinked device, in which the content of the packaging unit can be inspected.

In the production process, a web-like starting material is delivered in a clocked manner. During a stoppage interval of the delivery device, portions of the web-like starting material are separated from the web-like starting material by means of a separating device. An optical inspection device inspects these portions at least geometrically on an intermediate conveyor device arranged downstream of the separating device in the material flow. A lower packaging material web and an upper packaging material web are delivered in a clocked packaging device. The intermediate conveyor device transfers the portions between the packaging material webs. During a stoppage interval of the packaging device, the packaging material webs are sealed in a sealing device such that the packaging unit is closed in a moisture-tight and aroma-tight manner.

BRIEF DESCRIPTION OF THE DRAWINGS

Further details of the invention will become evident from the drawings showing exemplary embodiments of the invention as follows:

FIG. 1 shows schematically a device according to the invention for producing packaging units;

FIG. 2 is a path-time diagram of the delivery device;

FIG. 3 is a path-time diagram of the intermediate conveyor device; and,

FIG. 4 is a path-time diagram of the packaging device.

DETAILED DESCRIPTION OF PARTICULAR EMBODIMENTS

FIG. 1 shows an interlinked device (1) for producing packaging units (80), for example for medical products such as transdermal therapeutic systems (95) or wafers (95) containing active substances. The device (1) comprises a delivery device (10), a separating device (20), an intermediate conveyor device (30), an inspection device (40), a packaging device (50), and a sealing device (60). In this illustrative embodiment, all of said parts (10, 20, 30, 40, 50, 60) of the device (1) are rigidly interlinked one after another in the material flow without buffers. This means that any malfunction of a part (10, 20, 30, 40, 50, 60) or in a part (10, 20, 30, 40, 50, 60) of the device (1) adversely affects the material flow and the availability of the whole device (1).

The starting material for the item (95) to be packaged is a web-like material (90) which is conveyed by means of the delivery device (10). The delivery device (10) for this purpose comprises an intermittent conveyor (11). The stroke cycle of an intermittent conveyor (11) comprises a delivery stroke and a return stroke. The return stroke is an idle stroke which runs counter to the conveying direction (5) and in which the load-bearing parts return to their starting position. In the illustrative embodiment shown here, the intermittent conveyor (11) comprises feeding pincers (12) which engage the web-like material (90) from below and from above, for example at its outer edges. Several feeding pincers (12) have, for example, a common drive mechanism for advancing the material. In the illustrative embodiment, they are in each case clamped with spring loading by a compression spring (13). If appropriate, the clamping can also be effected via a common drive mechanism, or a common drive mechanism can effect both the clamping and the advancing movement. Instead of using the feeding pincers (12), the web-like material (90) can also be advanced by means of grippers or other intermittent conveyors (11).

In the illustrative embodiment, the separating device (20) comprises two intersecting knives (21, 22), of which one (21) is arranged above, and the other (22) below, the web-like material (90).

To convey the web-like material (90), it is first of all clamped by means of the feeding pincers (12). The advancing drive mechanism, which has a predefined stroke, for example, then pushes the web-like material (90) in the direction of the separating device (20). As soon as the end position of the stroke is reached, the separating device (20) separates a portion (95) of the web-like material (90). This portion (95) is, for example, a transdermal therapeutic system (95) or a wafer (95). During the separating operation, the delivery device (10) is stopped. The feeding pincers (11) are now opened and, by means of the advancing drive mechanism, travel to the starting position arranged away from the separating device (20). The next conveying cycle of the intermittent conveyor (11) now begins. If appropriate, the separating device (20) can also be actuated only after every second advance cycle or after another whole-number multiple of an advance cycle. This results from the ratio of the length of a wafer (95) to the advance stroke.

FIG. 2 shows a path-time diagram of the advance movement of the web-like material (90). In this diagram, an abrupt change of speed is assumed for reasons of simplicity, and the acceleration and deceleration paths and times are not shown. The time (t) is plotted on the abscissa, e.g. in seconds, and the path traveled (s) is plotted on the ordinates, e.g. in millimeters. The gradient of the resulting curve—the mathematical first derivation of the path function over time—is a measure of the speed of advance of the delivery device (10).

The web-like material (90) is advanced, for example, at constant speed as far as time point (121). From this time point (121), the web-like material (90) is stopped. For example, during a time interval (102) that lasts up to time point (124), a portion (95) of the web-like material (90) is separated and the feeding pincers (12) are moved back to the starting position relative to the device (1). They engage the web-like material (90) in the next segment. Starting from time point (124), the web-like material (90) is conveyed onward in the direction of the separating device (20). The conveying speed in the time interval (103) beginning at time point (124) corresponds to the conveying speed in the time interval (101) between the origin of the coordinates and time point (121).

As the web-like material (90) is being conveyed, it passes through a cutting plane defined by the separating device (20). The end lying at the front in the conveying direction (5) places itself flat, for example, on the moving intermediate conveyor device (30) and is taken up by the latter. The conveying speed of the intermediate conveyor device (30) corresponds, for example, to the conveying speed of the delivery device (10). After the time interval (102), which corresponds for example to the quotient of the wafer length and the conveying speed of the delivery device (10), both the delivery device (10) and the intermediate conveyor device (30) are stopped, and the part of the web-like material (90) passing through the cutting plane is cut off as portion (95).

The intermediate conveyor device (30) comprises a continuous conveyor (31) which is driven by means of a servo motor via a driving drum (32) and is guided by means of a guide drum (33). In the continuous conveyor (31), there is no reversal of the stroke direction. The conveyor means is guided back during the conveying operation to its starting point. The conveyor means (34) of this continuous conveyor (31) is, for example, a continuously circling endless conveyor belt (34). The latter has, for example, a plurality of apertures, for example having a mesh-like structure. A suction device (36) is arranged below the upper load strand (35) of the conveyor belt (34). In the area between the driving drum (32) and the guide drum (33), this suction device (36) sucks the portions (95) lying on the load strand (35), which load portions (95) are thus pressed onto the load strand (35) and are conveyed in the conveying direction (5) without slip.

FIG. 3 shows a simplified path-time diagram of the portions (95) conveyed by means of the intermediate conveyor device (30). The abscissa and ordinate scales correspond for example to the corresponding scales in FIG. 2. Starting from the origin of the coordinates (the origin of the time axis in FIG. 3 corresponds, for example, to the origin of the time axis in FIG. 2), the path change per unit of time is constant up to a time point (121), as a result of which the path-time diagram is depicted as a straight line. The constant gradient, which corresponds to a constant speed, is identical, for example, to the gradient of the curve shown in FIG. 2 between the origin of the coordinates and time point (121) and in the time interval (103) following time point (124).

In the time interval (105) between time point (121) and time point (122), the conveying operation of the intermediate conveyor device (30) is interrupted. In this time interval (105), the separating device (20) cuts off a portion (95) of the web-like material (90).

Starting from time point (122), the intermediate conveyor device (30) conveys the separated portion (95) onward. In the following time interval (106) in which the delivery device (10) is stopped, the separated portion (95) travels a distance, for example, that corresponds to the length difference of a packaging unit (80) and of a portion (95). In this time interval (106), the conveying speed of the portions (95) can be higher or lower than the conveying speed of the web-like material (90) outside of the stoppage times.

At time point (124), a new cycle then begins, for example one that is constructed analogously to the cycle beginning at the origin of the coordinates. The cycle length of the delivery device (10) is identical to the cycle length of the intermediate conveyor device (30). The sum of conveying intervals (101; 103) and of stoppage intervals (102) of the delivery device (10) thus corresponds to the sum of the conveying intervals (104, 106; 107) and stoppage intervals (105) of the intermediate conveyor device (30).

Instead of a continuous conveyor (31), the intermediate conveyor device (30) can also comprise an intermittent conveyor. The return stroke times of an intermittent conveyor then lie in the stoppage interval (105) of the intermediate conveyor device (30) described.

An inspection device (40) is arranged above the load strand (35). It comprises, for example, an optical camera (41) which is connected, for example, to a comparator unit (not shown here). By means of this comparator unit, the geometric dimensions of the surface (96) of each portion (95) lying on the conveyor belt (34) are compared with a stored set-point value during the stoppage interval (105) of the intermediate conveyor device (30). If the inspected portion (95) is too large or too small, or if it is lying askew on the conveyor belt (34), it is marked, for example, or ejected. The imprinting of the portion (95) can also be monitored by means of this inspection device (40).

The inspection of a portion (95) takes place, for example, in a stoppage interval during the cycle following its separation stoppage interval (105) Accordingly, the distance between the center line (45) of the inspection device (40) and the separating device (20) is the sum of the length of a packaging unit (80) and half the length of a portion (95) or the sum of the whole-number multiple of the length of a packaging unit (80) and half the length of a portion (95). The inspection device (40) can be adjusted in the lengthwise direction of the device (1) in order to adapt the latter to another length of packaging unit (80) or to another portion length (95).

It is also conceivable for the inspection to be carried out during the conveying of the intermediate conveyor device (30). In this case, the position of the inspection device (40) relative to the separating device (20) can be chosen freely.

As soon as the portions (95) conveyed by means of the intermediate conveyor device (30) have left the area of influence of the suction device (36), they lie only loosely on the load strand (35) of the conveyor belt (34). On reaching the driving drum (32), they are transferred, flat for example, onto the packaging device (50). The individual portions (95) reach the packaging device (50) in a clocked sequence. Here, the time intervals between the times of arrival of the individual portions (95) at the packaging unit (50) are constant. Since, in this illustrative embodiment, each portion (95) is received directly by the packaging device (50), without waiting time, there is no buffer and no waiting line.

The packaging device (50) comprises an upper packaging material web (51), a lower packaging material web (52), and an intermittent conveyor (58) with feeding pincers (59). The upper and lower packaging material webs (51, 52) are each wound in lengths of several hundred meters onto reels (53, 54) and each have a width of between 250 millimeters and 2500 millimeters depending on the number of packaging units (80) produced in parallel. The lower packaging material web (52) is guided from the reel (54) to the transfer site (57), e.g. via a guide roller (56). At a location offset from this in the conveying direction (5), the upper packaging material web (51) is guided via a guide roller (55) into the conveying direction (5) parallel to the lower packaging material web (52).

Next to the site of transfer to the packaging device (50), the individual portion (95) lies on the lower packaging material web (52). The feeding pincers (59), configured analogously for example to the feeding pincers (12) of the delivery device (10), convey the packaging material webs (51, 52), equipped with the portions (95), in the conveying direction (5). In this case, for example, an advance equal to the length of a packaging unit (80) takes place in each cycle. The feeding pincers (59) can also be configured such that the advance equal to the length of a packaging unit (80) takes place in two cycles or in several whole-number cycles. The length of a packaging unit (80) corresponds to the sum of the length of a portion (95) and of both protruding areas of the packaging material webs (51, 52), which protruding areas are oriented in the longitudinal direction of the device (1) shown in FIG. 1 and are used for sealing.

During stoppage of the intermittent conveyor (58), the feeding pincers (59) are moved back to their starting position in order to continue conveying. As soon as the conveying path corresponds to the length of a packaging unit (80), the sealing device (60) is closed. For example, by means of an upper part (61) and lower part (62) of the sealing device (60), the upper and lower packaging material webs (51, 52) are sealed together, for example with simultaneous heating, to form a moisture-tight and aroma-tight closure. In the illustrative embodiment, the sealing is carried out at four seams surrounding the individual portion (95), resulting in what is called a four-edge sealed bag. The latter is separated from the packaging material webs (51, 52) in a downstream separating station not shown here.

The position of the sealing device (60) relative to the device (1) can be adjusted, for example. In this way, the device (1) can be adapted to different portion and/or package lengths.

FIG. 4 shows a simplified path-time diagram of the packaging device (50). The scales of the abscissa and of the ordinates in this figure correspond, for example, to the abscissa and ordinates scales of FIGS. 2 and 3. The origin of the time axis in FIG. 4 corresponds, for example, to the origin of the time axis in FIGS. 2 and 3.

The transfer of a portion (95) between the packaging material webs (51, 52) at the transfer site (57) is described on the basis of the time interval (110-112) delimited by time points (122) and (126).

After a stoppage, the conveying operation of the packaging device (50) begins, for example, at time point (122). Starting from time point (123), a portion (95) is transferred to the packaging device (50) in the conveying interval (111). This transfer ends, for example, at time point (125). However, the intermittent conveyor (58) continues to convey throughout the subsequent time interval (112). The end position of the stroke of the intermittent conveyor (58) is reached at time point (126). The path covered by the packaging webs (51, 52) throughout this conveying interval (110-112) corresponds to the length of a packaging unit (80). The paths traveled in the time intervals (110) and (112) in the illustrative embodiment correspond to the length of the forward and rear sealing areas (81, 82) in the conveying direction (5). The path traveled in the time interval (111) by the packaging material webs (51, 52), which are moved in synchrony, for example with a constant conveying speed, corresponds to the length of a portion (95).

The time point (126) is followed by a stoppage interval whose length corresponds to the stoppage interval (109). The sealing of the packaging material webs (51, 52) and the return stroke of the intermittent conveyor (58) take place, for example, during this stoppage interval (109). This stoppage interval (109) is not identical to the stoppage interval (102) of the delivery device (10). It is shorter in the illustrative embodiment. A new cycle of the packaging device (50) begins after the stoppage interval (109).

The transfer of the portion (95) at the transfer site (57) can also be interrupted by a stoppage of the conveyor devices (30, 58).

The distances (99) between the portions (95) on the intermediate conveyor device (30) correspond to the length of two sealing areas (81, 82), which is the difference between the length of the packaging unit (80) and of an individual portion (95). A sealing area (81; 82) comprises the sealing seam and the protruding area of the corresponding packaging materials (51, 52). In relation to the delivery device (10), this means that the stoppage interval (102) of the delivery device (10) is equal to the sum of the stoppage interval (109) of the packaging device (50) and the quotient of the distance (99) and the conveying speed of the intermediate conveyor device (30). The conveying speed of the intermediate conveyor device (30) corresponds in the illustrative embodiment to the conveying speed of the packaging device (50). These two speeds can differ from each other, e.g. by ±3 percent. They are therefore at least approximately the same.

To control the device, the packaging device (50) comprises, for example, an incremental sensor (not shown here). By means of this incremental sensor, for example, a clock signal of the packaging device (50), e.g. the end of the sealing operation, is forwarded to an evaluation device. From this signal, it is then possible to derive a control signal, for example, for the servomotor of the intermediate conveyor device (30). This signal can also be used to control the ratio between stoppage interval (102) and conveying interval (101; 103) of the delivery device (10). Exact positioning of the individual portion (95) between the packaging material webs (51, 52) is thus ensured.

The intermediate conveyor device (30) can comprise a buffer. For example, the suction device (36) then covers only a partial area of the load strand (35). A catch arranged outside the area of action of the suction device (36), and controlled by the packaging device (50) for example, then releases in each case one portion (95) for further processing.

It is also conceivable for the individual conveyor devices (10, 30, 50) to operate at different heights. For example, the separating device (20) is then arranged above the intermediate conveyor device (30) and the intermediate conveyor device (30) is arranged above the lower packaging material web (52). In such an embodiment, the separated portion (95) then falls onto the intermediate conveyor device (30) and from the latter onto the lower packaging material web (52). In such an embodiment, the conveying speeds of the individual conveyor devices (10, 30, 50) can be different. For example, the stoppage interval (109) of the packaging device (50) can be greater than the stoppage interval (102) of the delivery device (10). However, the cycle interval—the sum of the respective conveying interval and of the respective stoppage interval—at least of the packaging device (50) and of the delivery device (10) is approximately equal. Variations can be compensated, for example, by means of the buffer described above.

If appropriate, the inspection device (40) can also control the packaging device (50). In such an embodiment, for example, the detection of a portion (95) by means of the inspection device (40) triggers a new cycle of the packaging device (50). Combinations of the described illustrative embodiments are also conceivable.

The following is a list of reference signs used herein:

• 1 device
• 5 conveying direction
• 10 delivery device
• 11 intermittent conveyor
• 10 12 feeding pincers
• 13 compression spring
• 20 separating device
• 21 knife, top
• 15 22 knife, bottom
• 30 intermediate conveyor device
• 31 continuous conveyor
• 32 driving drum
• 20 33 guide drum
• 34 conveyor means, conveyor belt
• 35 load strand
• 36 suction device
• 25 40 inspection device
• 41 camera
• 45 center line
• 30 50 packaging device
• 51 upper packaging material web
• 52 lower packaging material web
• 53 reel
• 54 reel
• 35 55 guide roller
• 56 guide roller
• 57 transfer site
• 58 intermittent conveyor
• 59 feeding pincers
• 60 sealing device
• 61 upper part of (60)
• 62 lower part of (60)
• 80 packaging units
• 81 seal area, forward
• 82 seal area, rear
• 90 web-like material
• 95 portions, transdermal therapeutic systems, wafers, items to be packaged
• 96 surface
• 99 distances
• 101 time interval, conveying interval
• 102 stoppage interval
• 103-104 time interval, conveying interval
• 105 stoppage interval
• 106-108 time interval, conveying interval
• 109 stoppage interval
• 110-112 time interval, conveying interval
• 121-126 time points
• s path
• t time

Claims

1. An interlinked device (1) for producing sealed packaging units (80), the device (1) including a clocked delivery device (10) adapted to carry a web-like material (90), the clocked delivery device (10) having at least one stoppage time interval (102) per cycle, a separating device (20) operatively connected to the clocked delivery device (10) and adapted to separate in each case at least one portion (95) of the web-like material (90), a clocked packaging device (50) operatively connected to the clocked delivery device (10) and adapted to place an upper packaging material web (51) and a lower packaging material web (52) on the at least one portion (95) of the web-like material (90), the clocked packaging device (50) having at least one stoppage time interval (109) per cycle, a sealing device (60) operatively connected to the clocked packaging device (50) and adapted to seal the upper packaging material web (51) and the lower packaging material web (52) on to the at least one portion (95) of the web-like material (90), the sum of the time of the stoppage intervals (102) per cycle of the delivery device (10) differing from the sum of the time of the stoppage intervals (109) per cycle of the packaging device (50), an intermediate conveyor device (30) adapted to carry the at least one portion (95) of the web-like material (90), the intermediate conveyor device operatively arranged between the delivery device (10) and the packaging device (50), and an inspection device (40) adapted to inspect the surface (96) of the at least one portion (95) of the web-like material, the inspection device (40) operatively arranged with the intermediate conveyor device (30) for at least geometric inspection of the at least one portion (95) of the web-like material (90).

2. The device as claimed in claim 1, wherein the delivery device (10), the intermediate conveyor device (30) and the packaging device (50) are all adapted to have conveying speeds at least approximately the same outside of the stoppage intervals (102, 109).

3. The device as claimed in claim 1, wherein the delivery device (10) further comprises an intermittent conveyor (11).

4. The device as claimed in claim 1, wherein the sum of the time of the stoppage intervals (102) per cycle of the delivery device (10) is greater than the sum of the time of the stoppage intervals (109) per cycle of the packaging device (50).

5. The device as claimed in claim 1, wherein the inspection device (40) comprises a camera (41).

6. The device as claimed in claim 1, wherein the intermediate conveyor device (30) further comprises a conveyor belt (34) and a suction device (36) in operative relationship with the conveyor belt (34).

7. The device as claimed in claim 1, wherein the packaging device (50) further comprises an incremental sensor adapted to control at least the delivery device (10) and/or the intermediate conveyor device (30).

8. A method for producing sealed packaging units (80) in an interlinked device (1), said method comprising:

delivering a web-like starting material (90) in a clocked manner,

separating portions (95) of the web-like starting material (90) from the web-like starting material (90) by means of a separating device (20) during a stoppage time interval (102) of the delivery device (10),

inspecting the portions (95) with an inspection device (40) at least geometrically on an intermediate conveyor device (30) arranged downstream of the separating device (20) in the material flow,

delivering a lower packaging material web (52) and an upper packaging material web (51) to the portions (95) by a clocked packaging device (50),

transferring the portions (95) by the intermediate conveyor device (30) between the packaging material webs (51, 52), and

sealing the packaging material webs (51, 52) onto each other in a sealing device (60) such that the packaging unit (80) is closed in a moisture-tight and aroma-tight manner during a stoppage time interval (109) of the packaging device (50).

9. The method as claimed in claim 8, wherein conveying speeds of the delivery device (10), of the intermediate conveyor device (30) and of the packaging device (50) are at least approximately the same outside of the stoppage intervals (102, 109).

10. The method as claimed in claim 8, wherein the stoppage time interval (109) per cycle of the packaging device (50) is shorter than the stoppage time interval (102) per cycle of the delivery device (10).