Abstract:
Apparatus and methods are provided to enable the removal of tablet and capsule medication from bottles. The apparatus includes a bottle opener assembly that enables the removal of the medication from the base of the bottle. Removal of the medication from the base of the bottle bypasses the need for removal of the bottle cap, tamper-resistant seals, and any filler material. The present invention further includes an automated unpack/repack system for packing the medication in bulk and individual containers.

Description:
FIELD OF THE INVENTION 
     This invention pertains to apparatus and methods to enable the unpacking of tablet and capsule medications from bottles for subsequent repackaging. 
     BACKGROUND OF INVENTION 
     Medications, either in tablet or capsule form, are commonly bottled by the pharmaceutical producer in one or more standardized quantities suitable for dispensing to the public. Medications, though, are commonly prescribed by a physician to the patient in quantities not conforming to the producer&#39;s standardized quantities. Therefore, prescriptions deviating from the standardized quantities require the medications to be unpacked from their original containers and repackaged in the desired quantities. 
     With the advent of automated prescription dispensing equipment, such as those used in hospitals and mail-order pharmacies, there is a need to supply the medications in bulk quantities. Many pharmaceutical producers do not supply the medications in the bulk quantities required for these systems. Again, the tablet or capsule medications require unpacking and repackaging in order to supply these users. 
     Pharmaceutical producers commonly supply the tablet and capsule medications in polyethylene bottles, or bottles composed of other plastics. Once the medicines are deposited within the bottles, it is common that any remaining void within the bottle is filled with cotton filler and the like. The filler prevents the tablets or capsules from shifting during shipping and handling in an effort to prevent damage to the contents. The bottles are subsequently sealed with various tamper-resistant inner and outer seals as well as capped with child and/or tamper-resistant caps. 
     The current methods of unpacking and repackaging tablet and capsule medications are labor intensive and inefficient. The child and/or tamper-resistant cap, as well as any tamper resistant seals require removal to access the medications. Subsequently, the cotton filler requires removal; an operation not amenable to automated equipment. 
     There is a need for apparatus and methods to replace the labor intensive and inefficient process of unpacking and repackaging bottled tablet and capsule medications. In order to be economical and efficient, the system must operate at high volume throughput with minimal human intervention. 
     SUMMARY OF INVENTION 
     The present invention includes apparatus and methods for the efficient and economical removal of tablet and capsule medications from polyethylene and other plastic bottles. The inventive apparatus includes a bottle opener assembly that enables the removal of the medications from the base of the bottle. Removal of the medication from the base of the bottle bypasses the need for removal of the bottle cap, tamper-resistant seals, and any filler material. 
     The present invention further includes an automated unpack/repack system for packing the medications in bulk and individual containers. 
    
    
     BRIEF DESCRIPTION OF DRAWINGS 
     FIGS. 1A,  1 B and  1 C are exploded, partially assembled, and assembled perspective views, respectively, of a bottle opener assembly in accordance with the present invention. 
     FIGS. 2-5 are perspective views of the gripper assembly in accordance with the present invention. 
     FIG. 6 is an exploded perspective view of an embodiment of the gripper assembly in accordance with the present invention. 
     FIGS. 7A and 7B are exploded and assembled perspective views of the translate/rotate assembly in accordance with an embodiment of the invention. 
     FIGS. 8A and 8B are exploded and assembled perspective views of a slicer assembly in accordance with an embodiment of the present invention. 
     FIGS. 9A and 9B are exploded and assembled perspective views of a discharge chute traverse assembly in accordance with an embodiment of the invention. 
     FIGS. 10A,  10 B and  10 C are perspective, top and side views of an embodiment of a bottle unpack/repack system in accordance with an embodiment of the invention. 
     FIG. 11 is a perspective view of an embodiment of a bottle unpack/repack line in accordance with the invention. 
    
    
     DESCRIPTION 
     In the following detailed description, reference is made to the accompanying drawings which form a part hereof wherein like numerals designate like parts throughout, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope of the present invention. Therefore, the following detailed description is not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims and their equivalents. 
     FIGS. 1A,  1 B and  1 C are exploded, partially assembled, and assembled perspective views, respectively, of a bottle opener assembly  100 . The bottle opener assembly  100  provides the ability to access the contents  11  of a bottle  10 , as shown in FIG.  5  through an opening in the lower portion  12  of the bottle  10  adjacent the base  16  of the bottle  10 . The bottle opener assembly  100  may be a stand-alone apparatus or a component of a bottle unpack/repack system that opens the bottles  10  and directs the bottle&#39;s contents  11  to subsequent components of the system to repackage the contents  11  into a container, such as, but not limited to, a bulk container  262  and new bottles  20 . 
     One embodiment of the bottle opener assembly  100  in accordance with the present invention comprises a gripper assembly  120 , a translate/rotate assembly  140 , a bottle slicer assembly  160 , a discharge chute traverse assembly  180 , and a second discharge chute  190 . The gripper assembly  120  is adapted to firmly grip a bottle  10  standing in a vertical position as shown in FIG.  2 . The gripper assembly  120  provides that the lower portion  12  of the bottle  10  remains unobstructed. The gripper assembly  120  is coupled to the translate/rotate assembly  140 . The translate/rotate assembly  140  is adapted to lift the gripper assembly  120  and attached bottle  10  away from a bottle  10  pick-up location  102 , as shown in FIG.  1 B. In addition, the translate/rotate assembly  140  is adapted to rotate the gripper assembly  120  to position the bottle  10  in a horizontal position. 
     Adjacent the translate/rotate assembly  140  is the bottle slicer assembly  160 . The translate/rotate assembly  140  positions the bottle  10  such that the bottle sidewall  14  proximal the base  16  of the bottle  10  makes contact with a cutting blade  162  of the bottle slicer assembly  160  as shown in FIG.  3 . This contact provides for the cutting blade  162  of the bottle slicer assembly  160  to pierce the sidewall  14  of the bottle  10 . The gripper assembly  120  is adapted to spin the bottle  10  about an axis  18  of the bottle  10  while held in a horizontal position. The rotation enables the cutting blade  162  to slice the bottle sidewall  14  circumferentially about the base  16  of the bottle  10 . The bottle sidewall  14  is sliced such that the base  16  of the bottle  10  remains attached to the bottle  10  by a tab  13  of material as shown in FIG.  4 . 
     The base  16  of the bottle  10  is subsequently pivoted away from the bottle sidewall  14  about the tab  13  connecting the base  16  of the bottle  10  with the bottle sidewall  14 . The bottle  10  is rotated in a downward direction as shown in FIG. 5 such as to cause the contents  11  of the bottle  10  to be discharged into the first discharge chute  182  of the discharge chute traverse assembly  180 , as shown in FIG.  1 B. The first discharge chute  182  directs the contents  11  of the bottle  10  to a secondary discharge chute  190  such that the contents  11  are directed out of the bottle opener assembly  100 . The discharge chute traverse assembly  180  is adapted to translate in a horizontal direction away from the bottle  10  to expose the bottle discharge chute  184  below. The gripper assembly  120  releases the empty bottle  10  into the bottle discharge chute  184  where the empty bottle  10  is further processed or discarded. The gripper assembly  120  returns to the bottle pick-up location  102  to start the process again. 
     FIG. 6 is an exploded perspective view of an embodiment of the gripper assembly  120  in accordance with the present invention. The gripper assembly  120  is adapted to firmly grip bottles of various shapes and sizes standing in a vertical position. The gripper assembly  120  comprises at least two elongated members or gripping tangs  122 . The gripping tangs  122  are held in parallel relationship with each other and are adapted to translate together and away from each other. The tangs  122  are positioned a distance apart from each other such that the tangs  122  can be brought down from above the bottle  10  to be positioned adjacent to and on opposite sides of the bottle sidewall  14 . Each gripping tang is shaped to enable the tangs  122  to firmly grip bottles of various shapes and sizes, including round, oval, and square shapes. In the embodiment of FIG. 6, each of the two tangs  122  has a vee-shaped cross-section with serrated edges  124 . 
     The tangs  122  are assembled in a camming assembly  128  employing a motor  130  to move the tangs  122  toward and away from each other in a linear and parallel fashion. The trough  126  of each tang  122  is positioned facing the bottle sidewall  14  as shown in FIG.  2 . 
     In an embodiment of the method of the invention as shown in FIGS. 2-5, the gripper assembly  120  is positioned above a standing bottle  10 . The gripper assembly  120  is lowered onto the bottle  10  such the tangs  122  are positioned on either side of the bottle sidewall  14 , while positioned a distance from the base  16  of the bottle  10 . The motor  130  is used to drive the camming assembly  128  to bring the tangs  122  together and in contact with the bottle sidewall  14 . The gripper assembly  120  provides a secure grip to the bottle  10  sufficient to hold the bottle  10  as it is lifted into position and rotated against a cutting blade  162 , as shown in FIG.  3 . The distance of the gripping tangs  122  above the base  16  of the bottle  10 , defining the lower portion  12 , provides that the lower portion  12  of the bottle sidewall  14  remains uncovered around the circumference to allow access by the cutting blade  162 . 
     FIGS. 7A and 7B are exploded and assembled perspective views of the translate/rotate assembly  140  in accordance with an embodiment of the invention. The translate/rotate assembly  140  comprises two parallel rods  142  upon which a carriage assembly  144  is attached. A belt-driven drive assembly  146  translates the carriage assembly  144  vertically along the rods  142 . A dust belt  148  between two rollers  149  is provided. The belt  148  is attached to one side of the carriage assembly  144 , such that as the carriage assembly  144  is translated along the rods  142 , the belt  148  moves with the carriage assembly. The belt  148  provides protection to the rods  142  and other components from dust and the like. 
     The carriage assembly  144  comprises an anchor  150  for coupling the gripper assembly  120  to the carriage assembly  144 . The gripper assembly  120  is raised and lowered as the carriage assembly  144  is raised or lowered. The anchor  150  is adapted to rotate, such that the attached gripper assembly  120  and bottle  10  may be rotated from a vertical position to a horizontal position. 
     FIGS. 8A and 8B are exploded and assembled perspective views of a slicer assembly  160  in accordance with an embodiment of the present invention. The slicer assembly  160  comprises a blade  162 , a blade guide  164 , and a nesting frame assembly  166 . The nesting frame assembly  166  comprises first portion  168  and a second portion  169  adapted to telescopically nest one within the other. The first portion  168  and the second portion  169  are coupled together with a pair of spring-biased rods  170 . The rods  170  guide the first portion  168  and the second portion  169  in linear translation with respect to each other. The springs  172  provide a bias force to hold the first portion  168  and the second portion  169  apart. 
     A blade guide  164  is provided either as a component of the first portion  168  of the nesting frame assembly  166  and/or as a component of a blade-coupling element  174 . The blade guide  164  is adapted to allow the blade  162  to penetrate the bottle sidewall  14  but to prevent the blade  162  from extending into the bottle  10  a distance that could damage the bottle&#39;s contents  11 . The blade  162  is coupled to the first portion  168  by the a blade-coupling element  174 . The blade-coupling element  174  provides for easy and quick blade  162  replacement. 
     In accordance with an embodiment of the method of the present invention, during a piercing and slicing operation, the bottle  10  is placed in contact with the blade  162  with the blade  162  piercing the bottle sidewall  14  and the sidewall  14  abutting the blade guide  164 . The bottle  10  is urged against the blade guide  164  with sufficient force to move the first portion  168  and partially compress the springs  172 . The spring bias force on the blade guide  164  against the bottle sidewall  14  is sufficient to enable full contact between the blade  162  and the bottle sidewall  14  while the bottle  10  is rotated against the blade  162 . The spring bias force provides for full blade  162  contact with the bottle sidewall  14  as the blade guide  164  follows the contour of bottle  10 . In this manor, bottles  10  of various contours, such as oval and square, are accommodated. 
     In one embodiment in accordance with the invention, the blade  162  is coupled to the first portion  168  of the nesting assembly  166  at an angle to the bottle sidewall  14  to facilitate the piercing and slicing of the bottle sidewall  14 . 
     FIGS. 9A and 9B are exploded and assembled perspective views of a discharge chute traverse assembly  180  in accordance with an embodiment of the invention. The discharge chute traverse assembly  180  comprises two parallel rods  186  upon which a discharge chute carriage assembly  192  is attached. A first discharge chute  182  is coupled to the discharge chute carriage assembly  192  as shown in FIG. 1B. A belt-driven drive assembly  194  translates the first discharge chute  182  horizontally along the rods  186 . A belt  196  stretched between two rollers  197  is provided between the parallel rods  186  and the first discharge chute  182 . The belt  196  is attached to one side of the discharge chute carriage assembly  192 , such that as the discharge chute carriage assembly  192  is translated horizontally along the rods  186 , the belt  196  moves with the discharge chute carriage assembly  192 . The belt  196  provides protection to the rods  186  and other components from dust and the like. 
     The discharge chute traverse assembly  180  is adapted to position a first discharge chute  182  below the bottle  10  when the bottle  10  is positioned against the bottle slicer assembly  160 . After the bottle slicing operation, the contents  11  of the bottle  10  is allowed to drop into the first discharge chute  182 , which directs the contents  11  to a second discharge chute  190  and out of the bottle slicer assembly  160  as shown in FIG.  1 B. The gripper assembly  120  is adapted to rotate the bottle  10  in a downward direction to facilitate the discharge of the contents  11  of the bottle  10  into the first discharge chute  182 . When the bottle  10  is empty, the discharge chute traverse assembly  180  is adapted to translate the first discharge chute  182  horizontally out from under the bottle  10  to expose the bottle  10  to the bottle discharge chute  184  below. The gripper assembly  120  subsequently releases the bottle  10  into the bottle discharge chute  184  for processing or disposal. 
     In one embodiment in accordance with the present invention, the bottle discharge chute  184  further comprises a bottle guide  198 , as shown in FIG.  1 A. The bottle guide  198  is coupled to the bottle discharge chute  184  with a hinge  199 . The bottle guide  198  is adapted to flex out of the way in one direction when contacted by the bottle  10  as the gripper assembly  120  positions the bottle  10  from a vertical position to the horizontal position, and to subsequently return back into position when contact is released. The bottle guide  198  keeps the empty bottle  10  directed into the bottle discharge chute  184  when released by the gripper assembly  120 . The bottle guide  198  further comprises two cutouts  195  to allow the gripper tangs  122  to pass through the bottle guide  198  when returning to the bottle pickup position  102 . 
     FIGS. 10A,  10 B and  10 C are perspective, top and side views of an embodiment of a bottle unpack/repack system  200  in accordance with an embodiment of the present invention. The bottle unpack/repack system  200  comprises a bottle feed assembly  220 , the bottle opener assembly  100  as previously presented, an inspection tray conveyor assembly  240 , a bulk container assembly  260 , and a control assembly  280 . The bottle feed assembly  220  is adapted to convey a plurality of bottles  10  in an upright position in single file fashion to the gripper assembly  120 . The bottle feed assembly  220  may be of any type suitable for the intended purpose and are commonly known in the art. One embodiment of a bottle feed assembly  220  comprises a hopper  222 , a turntable  224 , and a bottle feed discharge chute  228 . The hopper  222  commonly has spiral-shaped waIls  226  with the turntable  224  as the floor. The spiral-shaped walls  226  are of a height that can contain the bottles  10  while the turntable  224  rotates beneath the bottles  10 . The rotation of the turntable  224  feeds the bottles  10  into the narrow end of the spiral-shaped walls  226  such that the bottles  10  are forced into a single-file configuration. The bottles  10  are then fed into a bottle feed discharge chute  228  for processing. 
     In an embodiment of the present invention, the end of the bottle feed discharge chute  228  is coincident with the gripper assembly  120  bottle pickup location  102 . The gripper assembly  120  picks up the waiting bottle  10  to be processed. As the bottle  10  is removed, the next bottle  10  is moved into place. 
     The second discharge chute  190  is positioned adjacent an inspection tray conveyor assembly  240 . The inspection tray conveyor assembly  240  is adapted to convey the bottle&#39;s contents  11  past an inspection area  242 . The conveyance may be driven by various means, such as by a belt or by vibratory conveyance. As the contents  11  are conveyed past the inspection area  242 , the contents  11  may be inspected for quality. For example, contents  11  comprising damaged or broken tablets or capsules (debris) can be removed during the inspection process by directing the debris through a debris bin  244 . The inspection tray conveyor assembly  240  further comprises an air handling system  246  to contain airborne dust particles. After the inspection process, the inspected contents  11 , such as tablets or capsules are conveyed to the bulk container assembly  260  that comprises a slide  264  and bulk container  262 . The tablets or capsules are subsequently discharged down the slide  264  into the a bulk container  262 . 
     In one embodiment of the invention, a control assembly  280  is used to control the operations of the various components of the bottle opener assembly  100 . In one embodiment, an attendant can regulate the speed of the operation using a foot controller. The control assembly  280  changes the speed of the bottle unpack/repack system  200  based on the input of the operator. 
     FIG. 11 is a perspective view of an embodiment of a bottle unpack/repack line  300  in accordance with the invention, wherein the tablets or capsules are repackaged into new bottles  20 . The bottle unpack/repack line  300  comprises the bottle unpack/repack system  200  in addition to a bottle handling apparatus  302 . The bottle handling apparatus  302  comprises a bottle unscrambler  340 , a bottle conveyor  350 , a bottle capper  370  and a cartoner  390 . Empty, uncapped new bottles  20  are loaded into a hopper  342  of the bottle unscrambler  340 . The bottle unscrambler  340  correctly orients the new bottles  20  for conveyance to a tablet counter/bottle filling apparatus  320 . The tablet counter/bottle filling apparatus  320  couples to the slide  264  of the inspection tray conveyor assembly  240 , as shown in FIG.  10 A. The tablet counter/bottle filling apparatus  320  elevates the contents  11 , comprising tables/capsules using a tablet/capsule elevator assembly  322  and subsequently counts the tablets/capsules and deposits them into the new bottles  20 . The new bottles  20  are conveyed to the bottle a capper  370  that places a bottle cap on the new bottle  20 . The new bottles  20  are conveyed to a labeler  380  and subsequently to a cartoner  390 . 
     Although specific embodiments have been illustrated and described herein for purposes of description of the preferred embodiment, it will be appreciated by those of ordinary skill in the art that a wide variety of alternate and/or equivalent implementations calculated to achieve the same purposes may be substituted for the specific embodiment shown and described without departing from the scope of the present invention. Those with skill in the construction arts will readily appreciate that the present invention may be implemented in a very wide variety of embodiments. This application is intended to cover any adaptations or variations of the embodiments discussed herein. Therefore, it is manifestly intended that this invention be limited only by the claims and the equivalents thereof.