Method for Filing a Cavity with a Quantity of Particulate Material
A method for filling a cavity with a quantity of particulate material, comprising the steps of filling a chamber with its open side facing upwards with the quantity of particulate material, positioning the opening of the cavity opposite the opening of the filled chamber, and thereafter rotating the chamber and the cavity so that the cavity is positioned with its open side facing upwards and the chamber with its open side facing downwards, whereby the quantity of particulate material is emptied into the cavity. A corresponding device comprising a chamber, filling means for filling the chamber with the quantity of particulate material, operating means for positioning the opening of the cavity opposite the opening of the chamber, and conveyor belt for rotating the chamber and the cavity so that the cavity is positioned with its open side facing upwards and the chamber is positioned with its open side facing downwards.
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The present invention relates to a method and a device for filling a cavity with a quantity of particulate material, comprising the step of filling a chamber with its open side facing at least partially upwards with the quantity of particulate material. The method and device disclosed may be suitable for filling packs containing doses of powdered medicament, the doses being housed in cavities of the packs, which packs can be used in inhalation devices.
BACKGROUNDToday supply and distribution of medicament is accomplished in many different ways. Within health care more and more is focused on the possibility to dose and distribute medicaments in the form of powder directly to the lungs of a user by means of a dispensing device, for example an inhalation device, to obtain an efficient and user friendly administration of the specific medicament. In most cases, some form of dosing process is used for preparing the dose to be inhaled. Usually, the doses of medicament are provided in packs having several cavities for housing a dose of medicament. The cavities filled with a dose is subsequently sealed by a sealing sheet, for example a foil of aluminium. These packs are loaded into a dispensing device, in which the toil above the cavity is penetrated and the dose of medicament is released for inhalation by the user. By this sealing, the medicament is well protected before inhalation. There are also other cases where it is suitable to provide doses of medicament in packs having cavities for housing a dose of medicament, which cavities are sealed by a foil. The packs containing the doses of medicament can be in the form of blister packs or injection moulded discs provided with blisters and cavities, respectively, for housing the powdered medicament, the packs can have various shapes, and the cavities can be distributed in various patterns. The method for filling said cavities must provide an accurate and changeable dosing into the cavities, to provide packs containing accurate doses of medicament of different sizes.
EP 1 354 795 A2 discloses a method and apparatus for the metered transport of fine powders into receptacles. The apparatus is provided with a hopper having an opening. The hopper is adapted to receive fine powder. Further, the apparatus comprises a vibrating element vibrating within the powder, and a rotatable member provided with a plurality of chambers aligned about its periphery. The rotatable member may be rotated to align the chambers with said opening to allow powder to be transferred from the hopper and into the chambers. The rotatable member is rotated 180° to a dispensing position where the chambers are aligned with said receptacles, and the receptacles are filled with the powder.
U.S. Pat. No. 5,187,921 A describes a method and apparatus for filling a blind cavity with a quantity of powder, which comprises urging the cavity, with its open side facing a least partially downwards, into a reservoir of powder, withdrawing from the cavity having the quantity of powder therein while the open side continues to face at least partially downwards, and subsequently applying a lid to cover the cavity having the powder therein.
WO 03/066437 A1 discloses a method and apparatus for introducing powder into a pocket having an open side, including orientating the pocket with the open side facing at least partially upward, providing the pocket with a volume of powder greater than that of the pocket, compressing the volume of the powder to a predetermined bulk density, and removing excess powder so as to leave the pocket full of powder with the predetermined bulk density.
U.S. Pat. No. 6,035,905 A describes a method for introducing each of a plurality of doses of particulate material into a respective compartment of a container, the method comprising the steps of inserting a respective protuberance, preferably a conduit through which said particle material is introduced into said compartment, into each compartment so as to reduce the capacity thereof, and filling each compartment with said particulate material, with the respective protuberance inserted in said compartment, and removing said protuberance, wherein the volume of each dose of material is less than that of its respective compartment.
However, above-mentioned solutions have several drawbacks. Some of above-mentioned methods and apparatuses cannot distribute a specified dose of powder having a smaller volume than the volume of the cavity housing the dose, or cannot do this accurate enough. The methods and apparatus which are adapted to distribute a dose of powder having a smaller volume than that of the cavity are complicated in construction and can only be used to fill cavities in linear patterns or patterns consisting of several linear patterns, e.g. a matrix pattern, and cannot fill cavities arranged in various kinds of patterns of cavities, for example arbitrary and non-linear patterns. None of the above mentioned methods or apparatuses are able to simultaneously fill all cavities or blisters in a disc or pack, but require several repetitive filling operations.
SUMMARYAn object of the present invention is to provide a method and device for filling at least one cavity with a quantity of particulate material, which can fill cavities or blisters arranged in any kind of pattern in a pack or disc, for example arbitrary and non-linear patterns, are uncomplicated and manage to fill cavities with particulate material to a low cost, can distribute an accurate dose of powder having a smaller volume than that of the cavity housing the dose, are flexible and easy to adapt to new patterns of cavities, and can simultaneously fill all cavities or blisters in a disc or pack, thereby providing a high production capacity.
This may be achieved by positioning the opening of the cavity opposite the opening of the filled chamber, and thereafter rotating the chamber together with the cavity so that the cavity is positioned with its open side facing at least partially upwards and the chamber is positioned with its open side facing at least partially downwards, whereby the quantity of particulate material is emptied into the cavity, and by providing a device with operating means for positioning the opening of the cavity opposite the opening of the chamber, and guiding means for rotating the chamber together with the cavity so that the cavity is positioned with its open side facing at least partially upwards and the chamber is positioned with its open side facing at least partially downwards, whereby the quantity of particulate material is emptied into the cavity.
This method and device may be used to fill cavities or blisters arranged in any kind of pattern in a pack or disc, for example arbitrary and non-linear patterns. The cavities can be filled with an accurate dose of powder having a smaller volume than that of the cavity housing the dose. All cavities or blisters in a disc or pack can be tilled simultaneously thereby providing a high production capacity. Some embodiments may result in substantially no loss of excess formulation, and may provide a high operative safety and a small physical size of the device. Some embodiments may provide an uncomplicated filling and may manage to fill cavities with particulate material to a low cost. Advantageously, the chamber may be exchangeable to adapt to the size of the dose to be dosed in said cavity.
The quantity of particulate material is emptied into the cavity by the force of gravity, but the release of material from the chamber can be enhanced by knocking or vibrating the chamber when emptying the quantity of particulate material into the cavity, or by subjecting the particulate material to additional forces in the form of pressurized gas or vibrations, for example by way of ultra-sonic waves. Correspondingly, the device can be equipped with vibration means for vibrating the chamber when emptying the quantity of particulate material into the cavity, or other additional means for subjecting the particulate material to additional forces in the form of pressurized gas or vibrations, for example caused by ultra-sonic waves.
Some embodiments may be suitable for fill quantities above one mg. The filling accuracy increases with the flow ability and the weight of the particulate material. Further, some embodiments may be suitable for free flowing or moderately free flowing particulate material, e.g. carrier-based formulations. In one embodiment, the filling method has been tested in a bench-top set-up, where 8 mg of a carrier-based formulation was manually scrape filled into 100 chambers. The filling accuracy was established to 2.4% RSD.
Advantageously, the size and shape of the opening of the chamber may be equal to the opening of the cavity, or the opening of the chamber may be smaller than the opening of the cavity and enclosed by the boundary of the opening of the cavity, when the openings of the chamber and cavity are facing each other.
According to an advantageous embodiment, the cavity may be detachably locked to the chamber before said rotation, and then detached from said chamber when the cavity is filled.
According to a further advantageous embodiment the chamber may be filled by way of scrape filling, achieved by at least one rotating scraper.
According to another advantageous embodiment, the chamber may be filled with a quantity of particulate material forming a volume which is smaller than the volume of the cavity. Advantageously, some embodiments may be used for particulate material comprising powdered medicament.
According to an advantageous embodiment, the device may include locking means for detachably locking the cavity to the chamber before said rotation, and may include detaching means for detaching the cavity from the chamber when the cavity is filled.
According to a further advantageous embodiment, the filling means includes scraper means for scrape filling the chamber, and the scraper means may include at least one rotating scraper.
According to another advantageous embodiment, the volume of the chamber may be smaller than the volume of the cavity. By this embodiment, the cavity can be accurately and easily filled with a quantity of particulate material having a volume smaller than the volume of the cavity.
According to yet another advantageous embodiment, the device may include at least one filling element provided with each chamber, and the device may be adapted for at least one cavity provided in a disc. Advantageously, the element may be interchangeable with other elements having chambers of others sizes and distributed in other patterns, to adapt to the other sizes of doses and to other patterns of the cavities.
According to an advantageous embodiment, the filling element may include several chambers, the amount of which is the same as the amount of cavities, and the positions of the chambers corresponding to the positions of the cavities in the disc, whereby the opening of each chamber is facing an opening of a cavity when the filling element is locked to a disc. Advantageously, the device may include several filling elements.
According to another advantageous embodiment, the guiding means may include a conveyor belt to which the element is attached. Advantageously, the device may be adapted for a particulate material comprising powdered medicament.
Further, some embodiments may provide a method for producing packs containing doses of medicament.
Some embodiments also provide an apparatus for producing packs containing doses of medicament.
The invention will now be described, for exemplary purposes, in more detail by way of embodiments and with reference to the enclosed drawings.
Claims
1-24. (canceled)
25. A medicament filling station for filling a medicament pack that defines a plurality of medicament cavities, each cavity defining an opening at an outer surface of the pack, the medicament filling station comprising:
- a transfer device with an upper surface defining a plurality of chambers each having an opening at the upper surface;
- a dosing device operable to deposit a portion of powdered medicament on the upper surface of the transfer device; and
- a scraping element that scrapes the deposited portion of powdered medicament across the upper surface of the transfer device and into the plurality of chambers to fill each chamber with a respective dose of the deposited portion of powdered medicament;
- wherein the filling station is operable to place the medicament pack over the transfer device with the cavities of the medicament pack aligned with the chambers of the transfer device and the outer surface of the medicament pack against the upper surface of the transfer device and to, while the transfer device and medicament pack are held together, flip the medicament pack and transfer device over to position the transfer device over the medicament pack, such that the dose of powdered medicament in each of the chambers of the transfer device is transferred to a respective one of the cavities in the medicament pack.
26. The medicament filling station of claim 25, further comprising
- a conveyor belt to which the transfer device is attached and that moves and guides the transfer device between multiple process steps and that flips the transfer device.
27. The medicament filling station of claim 25, further comprising:
- a holding device connected to the transfer device and configured to hold the medicament pack against the transfer device.
28. The medicament filling station of claim 25, further comprising:
- a first monitor that scans the transfer device to confirm filling prior to flipping of the transfer device;
- a cleaner that cleans residual medicament from the transfer device after the medicament is transferred to the medicament pack; and
- a second monitor that scans the cleaned transfer device and confirms that the transfer device has been cleaned.
29. The medicament filling station of claim 25, wherein each chamber of the transfer device is of a smaller volume than a respective cavity of the medicament pack.
30. The medicament filling station of claim 25 further comprising an additional transfer device of a different chamber pattern, the transfer devices being selectable for use with correspondingly differing medicament pack cavity patterns.
31. A method of filling a medicament pack defining a plurality of cavities in an outer surface of the pack, the method comprising:
- depositing a portion of powdered medicament on a top surface of a transfer device defining a plurality of chambers;
- filling the chambers by dragging the deposited portion of powdered medicament across the top surface of the transfer device;
- positioning the medicament pack upside down on the transfer device, such that the outer surface of the medicament pack is adjacent the top surface of the transfer device and each cavity is aligned with a respective chamber;
- flipping the transfer device together with the medicament pack to place the medicament pack under the transfer device, whereby the powdered medicament in the chambers is simultaneously emptied into the respective cavities.
32. The method of claim 31 further comprising:
- holding the medicament pack against the transfer device prior to and after flipping the transfer device; and then
- releasing the medicament pack from the transfer device after the medicament is transferred to the medicament pack.
33. The method of claim 31, further comprising:
- scanning the chambers of the transfer device to confirm that the chambers are filled prior to positioning the medicament pack upside down on the transfer device;
- cleaning the residual medicament from the transfer device after the medicament is transferred to the medicament pack; and then
- scanning the cleaned transfer device to confirm that the transfer device has been cleaned.
34. The method of claim 31, further comprising:
- selecting the transfer device to have a chamber pattern corresponding to a cavity pattern of the medicament pack to be filled; and then
- attaching the selected transfer device to a conveyor belt that moves and guides the transfer device between multiple process steps.
35. A method of producing a medicament pack defining a plurality of cavities at an outer surface of the pack, the method comprising:
- depositing a portion of powdered medicament on a top surface of a transfer device defining a plurality of chambers;
- filling the chambers by dragging the deposited portion of powdered medicament across the top surface of the transfer device;
- disposing of the excess powder on the surface of the transfer device;
- positioning the medicament pack upside down on the transfer device such that the outer surface of the medicament pack is adjacent the top surface of the transfer device and each cavity is aligned with a respective chamber;
- flipping the transfer device together with the medicament pack to place the medicament pack under the transfer device, whereby the powdered medicament in the chambers is emptied into the respective cavities; and then
- sealing the cavities with a sealing sheet.
36. The method of claim 35, further comprising:
- holding the medicament pack against the transfer device prior to flipping the transfer device; and then
- removing the medicament pack from the transfer device after the medicament is transferred to the medicament pack.
37. The method of claim 35, further comprising:
- confirming that the chambers of the transfer device are filled prior to positioning the medicament pack upside down on the transfer device;
- cleaning, the residual medicament from the transfer device after the medicament is transferred to the medicament pack; and then
- confirming that the transfer device has been cleaned.
38. The method of claim 35, further comprising:
- selecting the transfer device to have a chamber pattern corresponding to a cavity pattern of the medicament pack to be filled; and then
- attaching the transfer device to a conveyor belt that moves and guides the transfer device between multiple process steps.
39. An apparatus for producing a medicament pack that contains multiple discrete doses of medicament and defines a plurality of medicament cavities, each cavity defining an opening at an outer surface of the pack, the apparatus comprising:
- a transfer device with an upper surface defining a plurality of chambers each having an opening at the upper surface;
- a dosing device operable to deposit a portion of powdered medicament on the upper surface of the transfer device;
- a scraping element that scrapes the deposited portion of powdered medicament across the upper surface of the transfer device and into the plurality of chambers to fill each chamber with a respective dose of the deposited portion of powdered medicament; and
- means for disposing of any excess powdered medicament remaining on the upper surface of the transfer device;
- wherein the apparatus is operable to place the medicament pack over the transfer device with the cavities of the medicament pack aligned with the chambers of the transfer device and the outer surface of the medicament pack against the upper surface of the transfer device and to, while the transfer device and medicament pack are held together, flip the medicament pack and transfer device over to position the transfer device over the medicament pack, such that the dose of powdered medicament in each of the chambers of the transfer device is transferred to a respective one of the cavities in the medicament pack.
40. The apparatus of claim 39, wherein each chamber of the transfer device is of a smaller volume than a respective cavity of the medicament pack.
41. The apparatus of claim 39, further comprising a conveyor belt to which the transfer device is attached and that moves and guides the transfer device between multiple process steps and that flips the transfer device.
42. The apparatus of claim 39 further comprising an additional transfer device of a different chamber pattern, the transfer devices being selectable for use with correspondingly differing medicament pack cavity patterns.
43. The apparatus of claim 39, further comprising a holding device connected to the transfer device for holding the medicament pack against the transfer device prior to and after flipping the transfer device.
44. The apparatus of claim 43, further comprising:
- a first monitor that scans the transfer device to confirm filling prior to flipping of the transfer device;
- a cleaner that cleans residual medicament from the transfer device after the medicament is transferred to the medicament pack; and
- a second monitor that scans the cleaned transfer device and confirms that the transfer device has been cleaned.
Type: Application
Filed: Apr 28, 2006
Publication Date: Aug 14, 2008
Applicant: ASTRAZENECA AB (SE-151 85 Sodertalje)
Inventors: Lars Arvidsson (Lund), Orest Lastow (Lund), Vesna Akerberg (Lund)
Application Number: 11/913,403
International Classification: B65B 3/04 (20060101);