Apparatus and method for producing labelled interconnected blister packages

Abstract: An apparatus (30) for the processing and segmenting of a cover-forming laminate web (70) or sheeting structure which is adapted to interconnect a plurality of containers (12), such as the base members of blister packages each of which is designed to contain a hydrophilic contact lens in a sterile aqueous solution. More specifically disclosed is an apparatus for the imprinting, perforating, slitting and cutting the laminated web structure (70) such that the severed laminate segments constitute printed covering label for an array of such containers, and whereby the laminated web or sheeting segment may be severed along weakening or perforation lines (106) so as to provide a separable packaging arrangement for individual of the containers which are subsequently adhered thereto.

Description: BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an apparatus and a method for producing labelled interconnected blister packages. Packaging apparatus such as that disclosed in DE 2 355 208 A is known. However, with the disclosed apparatus, individually labelling each package automatically is not possible. Labelling is required for many types of packages including contact lens packaging as indicated later. The packaging of hydrophilic contact lenses in a sterile aqueous solution is well known in the contact lens manufacturing technology. In particular, packaging arrangement of that type generally consist of so-called blister packages adapted to be employed for the storage and dispensing of the hydrophilic contact lenses for use by a medical practitioner or by a consumer who intends to wear the contact lenses. Such hydrophilic contact lenses, which may be disposable after a single wear or short-terms use, are inexpensively manufactured from suitable hydrophilic polymeric materials, for example, copolymers of hydroxyethylene methacrylate containing from about 20% to 90% or more of water, depending upon the polymer composition. These contact lenses are generally stored in a sterile aqueous solution, ordinarily consisting of an isotonic saline solution, in order to prevent dehydration and to maintain the lenses in a ready-to-wear condition. A container of the foregoing type, normally comprises a base member which is molded from a suitable injection-molded or thermoformed plastic material; for instance, such as polypropylene, and incorporates a cavity adapted to house the contact lens in the aqueous solution, and which is sealingly closed by a label-forming cover, preferably in the form of a flexible multi-layered laminated web or sheeting structure to provide a so-called blister package. This type of packaging arrangement has found widespread use in view of the inherently advantageous storing properties thereof and easy-to-dispense nature of the package by simply peeling the adherent cover from the base member, thereby enabling a user to gain ready access to the contact lens which is contained in the cavity of the base member. For example, a blister package which is adapted to provide a sterile sealed storage environment for a disposable, essentially single-use hydrophilic contact lens, which may normally be worn for a period of between about 8 to 16 hours during any 24-hour period, has the lens immersed in a sterile aqueous solution within the package, as is described in European Patent Application No. EP-A-0686563. In the above-mentioned European patent application, the blister package for storing and dispensing a hydrophilic contact lens includes an injection-molded or thermoformed plastic base portion or member incorporating a molded cavity which is surrounded by an outstanding planar flange extending about the rim of the cavity. A flexible cover sheet, such as a multi-layered laminated structure is adhered to the surface of the flange in order to sealingly enclose the cavity in a generally liquid-tight manner. The surface of the cover sheet may constitute a label and be imparted suitable printing indicia informative of the product stored in the blister package, the name and address of the manufacturer, incorporate various decorative designs and logos as desired; and also provide for changeable information, such as lot numbers, expiration dates, fitting parameters, lens power, and the like in addition to the foregoing, such as may be required by FDA regulations. Heretofore, such blister packages have been generally sold as individual or single units and the imprinted information provided thereon is completed for each blister package. However, when it is intended to sell arrays or multiples of such blister packages which are detachably interconnected, each containing respectively a single hydrophilic contact lens, the opportunity may arise for a diverter to pass off the relatively inexpensive disposable product contained in each of the respective detached blister packages as a more expensive single unit item. In essence, such single-use or disposable contact lenses could be conceivably passed off as more expensive reusable contact lenses, potentially causing significant economic losses to the manufacturer and sellers, while also raising the possibility of potential legal liabilities in the event that the product is not properly used or worn for extended periods of time so as to result in physical harm to a user. At this time, there has accordingly been addressed the concept of the development of new and unique packaging arrangements of the blister package type, particularly for the containment of hydrophilic contact lenses in a sterile aqueous solution, wherein a plurality of base members, each formed with a cavity for containing a hydrophilic contact lens in a sterile saline solution, are adapted to be positioned in a contiguous array and sealingly covered by a single or unitary flexible cover sheet, the latter of which is preferably in the form of a flexible multi-layered imprinted label-forming laminate. In this instance, the laminate is provided with weakening lines, such as micro-perforating, intermediate each of the respective base members so as to enable individual segments of the flexible laminate to be detached along the weakening lines or perforations without affecting the integrity of the sealed blister packages, and in conjunction with the therewith associated base member, to be separated from the array when it is desired to gain access to the single contact lens contained therein. In essence, the lines of perforations which are present in the laminate forming the unitary cover sheet for an array of interconnected blister packages provides an easy opening feature enabling a consumer to readily separate individual of the blister packages without damaging the sterile integrity of an adjacent blister package. Moreover, the perforations still provide adequate strength to remain for the laminate cover sheet material to enable automated material handling thereof; for instance, after post-hydration and shipment of the packages to the consumer. This type of array of multiple interconnected blister packages enables the compact packaging of a plurality of such arrays, each possessing a specified number of contact lens-containing base members interconnected by a single flexible cover sheet, within the confines of a suitable container, such as a rigid paperboard carton. In the carton there may be compactly stored a plurality of interleaved and superimposed layers of arrays of blister packages; for example, each array having five interconnected blister packages each with a single contact lens disposed therein. The carton may be designed to store six arrays of blister packages, positioned in three tiers each consisting of two inverted and interleaved arrays, for a total of thirty blister packages; in essence, containing a 30-day supply of contact lenses for respectively one eye of a user. A packaging arrangement for contact lenses of that type which is in the form of arrays of interconnected blister packages is disclosed in European Patent Application EP-A-0 650 676. The blister packages which are formed through the intermediary of this structure comprise a plurality of contiguously linearly arranged thermoformed or injection-molded base members each possessing a cavity for housing a hydrophilic contact lens in a sterile saline solution, and wherein the resultant array of such base members; for example, five (5) base members, is adapted to be sealingly covered and interconnected by a single flexible multi-layered laminated web segment which also forms a common printed label, preferably of the kind as disclosed in EP-A-0 646 471. In the foregoing disclosure, the multi-layered laminated web includes an outer layer of a plastic film material which is adhesively bonded to the surface of a supporting metallic foil, such as aluminum, or in lieu of the latter may be coated with silicon oxide, and in which the outer layer is illustrated as being double-side printed; in effect, on both opposite surfaces, although it is possible to contemplate imparting the printing to only one surface of the outer plastic film layer. The surface of the outer plastic film layer which faces towards and is adhered to the metallic foil (or coated with silicon oxide) is imprinted with suitable indicia and legends which may consist of permanent information regarding the manufacturer and the product, logos, instructive material, and decorative and advertising indicia relative the product in the blister package; whereas the opposite or exterior surface of the outer plastic film material layer may be imprinted with suitable variable information, such as expiration dates, lot/batch numbers, fitting parameters and other data specific to the packaged product. The interior surface of the outer plastic film material layer may be imprinted through the intermediary of suitable lithographic printing, either in single color or multi-colors and also provided with an appropriate printed background; whereas the variable information specific to the product which is imprinted on specific areas of the outwardly facing surface of the outer film layer, may be printed thereon through thermal transfer printing, although the foregoing is set forth by way of example only, and other printing methods may be readily employable. SUMMARY OF THE INVENTION Accordingly, in order to be able to provide the segments of the multi-layered laminate web or sheet which are dimensioned to be able to be adhesively positioned on an array of base members in order to form covers and printing labels for each of the resultingly interconnected blister packages containing the contact lenses, the invention contemplates the provision of an apparatus according to Claim 1 and a method according to Claim 23. Further advantageous features include conveying the transversely perforated web past a slitting station including a slitting blade for dividing the web in the longitudinal direction thereof into at least two widths each conforming to the transverse width of the blister packages onto which the laminate is to be placed. Incorporated is a novel structure for intermittently drawing the web of the laminate material in a precisely dimensioned advancing motion so as to correlate the accuracy in the advance thereof with a scanning of the indicia or characters imprinted on the laminated web. Since the graphic repeats on the foil web are not exact from the information, the sensors scan the preprinted indicia or the field on the foil web to determine the exact pull length for character printing, character verification by a vision system, perforating and cutting. This will ensure the exactness in the lengths of the severed segments which are adapted to be placed and adhesively fastened to contact lens-receiving base members for forming the array of blister packages. More specifically, the invention contemplates the provision of an apparatus as described herein, which incorporates sensors for scanning indicia or characters imprinted on the laminated web so as to provide control over the intermittent advance and exactness thereof by the laminated web so as to enable severing of the web into accurately dimensioned segments prior to placement of the segments on an array of base members. The invention also contemplates the provision of an apparatus as described herein whereby the perforations transversely extending across the laminated web are implemented through a plurality of rotatable perforating elements contacting the surface of the laminate web and which are spaced from each other in the direction of advance of the web so as to define the widths of each of the blister packages which are to be formed upon being covered by the segments of the laminated web material. Another aspect of the invention resides in the provision of an apparatus as described herein, wherein sensors operatively scanning indicia on the web correlate the incremental forward advance of the laminated web with the imprinted indicia or characters thereon, and whereby the sensors in response to the scanned characters imparted to the surface of the web by the printing device at the printing station, control the advance of the web and the precision thereof. Still another aspect of the invention resides in the provision of a method for printing, imparting perforations, longitudinal slits and subsequent severing into segments of precise locations and lengths from a continuous web supply so as to produce severed segmented and perforated portions from the web which are adapted to be placed in an accurate alignment over contiguously positioned base members each containing a contact lens in order to form the array of interconnected blister packages which are adapted to be separated into individual blister packages along the transverse perforations extending therebetween without affecting the integrity of the contents of the blister packages. BRIEF DESCRIPTION OF THE DRAWINGS Reference may now be had to the following detailed description of exemplary embodiments of the invention, taken in conjunction with the accompanying drawings; in which: Figure 1 illustrates a generally diagrammatic side elevational view of an installation for the assembly of blister packages for the containment of contact lenses; Figure 2 illustrates a top plan view of the installation of Figure 1; Figure 3 illustrates a side elevational view of the apparatus pursuant to the invention for imprinting, perforating, slitting and cutting into segments a continuous web of a laminated material preparatory to placement thereof on a plurality of contact lens-containing base members so as to form an array of blister packages commonly interconnected by the severed segment; Figure 4 illustrates a plan view of the apparatus of Figure 3; Figure 5 illustrates, generally diagrammatically, an elevational sectional view of the apparatus taken along line 5-5 in Figure 3; Figure 6 illustrates, on an enlarged scale, a diagrammatic sectional view through the perforating knife assembly for perforating the laminated web taken along line 6-6 in Figure 3; Figure 7 illustrates, generally diagrammatically, a plan view of the laminated web utilized for forming the cover structure and printed labels for the array of blister packages; Figure 8 illustrates a portion of the web of Figure 7 shown subsequent to the imprinting, perforating, slitting and severing into segments thereof; and Figure 9 illustrates the placement of a pair of segmented web portions as shown in Figure 8 in side-by-side relationship onto a plurality of base members for the formation of arrays of blister packages containing the contact lenses. DETAILED DESCRIPTION Referring specifically to Figures 1 and 2 of the drawings, there is diagrammatically disclosed an installation 10 for the packaging of contact lenses in arrays of so-called blister packages 12 comprising base members which are sealingly covered and connected by a single laminated flexible cover or sheet 14 adapted to constitute printed labels for each of the blister packages, as shown in Figure 9 of the drawings. The installation 10 is described in detail in the disclosure of European Patent Application No EP-A-0 686 558. In essence, in the installation 10, the contact lenses are each respectively immersed in a sterile saline solution contained in the cavity of a base member of a blister package 12, the latter of which is described in detail in the disclosure of European Patent Applications Nos. EP-A-0 686 563 and EP-A-0 650 676 referred to above. Briefly, each of the base members is adapted to be positioned in a recess formed in transfer pallet 18, whereby each pallet may be provided with ten (10) recesses, such as in two rows each of five (5) recesses, each adapted to house respectively one base member containing a contact lens in the sterile saline solution. The process for equipping such pallets with contact lens-filled base members may be implemented through a suitable dial arrangement 20 in which a turntable 22 is rotationally indexed to come into alignment with a placement device for positioning segments of a flexible laminate material over each of the arrays of base members containing the contact lenses so as to interconnect a linear array of five base members and form the arrays of blister packages as shown in Figure 3. The apparatus for preparing the laminated material segments which essentially forms the printed-label cover for each of the blister packages 12 and which also provides for the formation of two parallel rows each of five such blister package arrays, for instance, as shown in Figure 9 of the present application and as discussed in detail hereinbelow, is now elucidated with regard to Figures 3 through 6 of the drawings. Referring particularly to Figures 3 through 5, there is diagrammatically illustrated an apparatus 30 processing a multi-layered flexible laminate to produce the printed label covers for the array of blister packages, with such laminate being preferably of the type disclosed in Application EP-A-0 686 563 referred to above, and which is supplied from a continuous supply roll of the laminate material. The apparatus 30 which is designed to provide specific product-identifying printing on the laminate material, perforations, slitting and cutting operations to provide for the separated cover segments for placement on the arrays of base members in the installation 10, as mentioned hereinbefore, basically includes a stationary frame structure 32 of rigid construction including a plurality of horizontally extending support beams 34 interconnecting uprights 36 possessing leg sections 38 for firmly supporting the apparatus on a base or floor surface. On a horizontal beam extension 40, there is located a rotatably journaled shaft and pulley unit 42 on which there is adapted to be rotatably mounted a continuous supply roll 44 of the flexible laminate material, the latter being of a width which corresponds to the width A of two parallel rows of base members of blister packages located in contacting end-to-end position, as shown in Figure 9 of the drawings, as would be the orientation thereof on the pallets 18 in installation 10. The web of laminate material which is unwound from the supply roll 44 for transport through apparatus 30 is entrained over a plurality of idler rollers collectively designated by 50, including a tension member in the form of a device 52 which is intended to maintain a predetermined variable tension on the web 70 of laminate material dispensed from the supply roll 44 as the material enters the apparatus 30. Alternatively, a weighted roller device or a constant tensioner device may be substituted for the illustrated variable tensioner member 52 which is in the form of a roller unit. The laminate web 70 is conducted through a printing unit 60 which is mounted on an upper support beam structure 62 of the apparatus 30, such that suitable indicia, characters or legends, preferably, although not necessarily, by thermal printing, are adapted to be imprinted on the upper surface 72 of the laminate web 70 at specific spaced intervals within designated areas 74, 76, 78 on each segment of the laminate web source to define lots, batch numbers, expiration dates, and fitting parameters, such as the power of the contact lens, for each respective blister package which is to be produced in the installation 10. Fixedly mounted in the apparatus 30 is a smooth-surfaced perforating drum 80 located downstream of a set of idler rollers, collectively identified by 82, and a dancer roller arrangement 84 for maintaining a predetermined longitudinal tension on the imprinted laminate web 70 as the latter is conveyed from the printing unit 60. The laminate web 70 is entrained about the lower portion of the circumferential surface 86 of the perforating drum 80 so as to be transported in slidable surface-contact therewith. Positioned on a support structure 90 of the framework of the apparatus 30 which supports idler rollers 82 is a sensor arrangement 92, such as a camera unit, which is adapted to scan characters imprinted onto the surface 72 of laminate web 70 by the printing unit 60, as well as sensors (not shown) in the surface 86 of stationary drum 80, for a purpose as elucidated hereinbelow. Located in close proximity with the lower circumferential surface portion 86 of the drum 80 are a plurality of perforating knives 100, which may be serrated or toothed disc-shaped blades, as shown schematically in Figure 6, oriented coaxially with the longitudinal center axis the drum 80, and which are adapted to be reciprocated longitudinally therealong through the intermediary of displacements being imparted thereto through a pneumatically-operated piston and cylinder device 104, to be able to cause the teeth or serrations on the perforating knife or blade surfaces to cut into the laminated web and produce perforation lines 106 in the laminate web, as shown in Figures 7 through 9, in a direction extending transversely of the longitudinal or machine direction of the laminate web. A unique feature of the blades perforating the foil web against a hard surface 86 resides in that as particles are generated by this process, enhancing and ensuring a clean environment for the perforations. The perforating knives or blades for forming the perforation, in this case four in number, are oriented so as to be angled radially towards the longitudinal center axis of the perforating drum 80, and their cutting edges are spaced with regard to each other so as to produce lines of perforations at mutually predetermined spaced intervals along the length of the laminate web 70, as described hereinbelow. Arranged downstream of the perforating drum 80 in the direction of conveyance of the laminate web in the apparatus and mounted stationarily on an upper support 110 is a web slitting unit 112 equipped with a rotatable disc-shaped slitting blade or knife 114 oriented in the direction of conveyance for the web. Alternatively, instead of a rotary blade, the slitting may be effected by means of a "scissors-type" cutter or straight slitting blade. The slitting blade 114, during the conducting of the laminate web therepast, is intended to separate the web into two equally-sized continuous strips 70a and 70b, as shown in Figure 7 of the drawings. The slitting knife unit 112, is fixedly located at a predetermined distance downstream of the perforating knives 100 and drum 80 and includes a sensor arrangement for scanning the characters on the laminate web surface imprinted thereon by the printing unit 60. Supported for movement along a guide rail structure 120 of the apparatus 30 is a carriage 122 possessing spaced upright supports 124, 126 and mounting a cutting knife 128 movable transversely of the direction of conveyance of the laminated web through apparatus 30, enabling the cutting knife 128 to sever the perforated and longitudinally slit laminate web portions 70a, 70b into segments of predetermined length commensurate with the number of adjacently located base members of arrays of blister packages to be produced which are to be jointly covered thereby as a unitary printed label covering. The movable carriage 122 for the transverse cutting knife 128 is equipped with openable and closable slide grippers 130 for selectively engaging opposite side edges of the laminate web portions 70a, 70b. Movable vacuum devices 140 possessing suction units 142 are adapted to be reciprocated vertically proximate the downstream outlet end of apparatus 30 so as to be able of engaging severed laminated web segments and transporting them towards the dial mechanism of the installation 10 for placement on the plurality of base members which are located in the pallets 18 so as to produce completed arrays of blister packages 12 as shown in Figure 9, upon being adhered or sealed to each other. The graphics or indicia grouping position on the laminate web 70 is verified by a photoelectric sensor mounted just above the foil surface. Each time the web is pulled and is ready for cutting, the sensor state is tested to verify that diagonal stripes printed on the web have been positioned properly prior to cutting to ensure proper graphic grouping in the web. OPERATION OF THE APPARATUS The operation of the apparatus 30 which is employed to produce the unitary printed label cover structure for arrays of blister packages is now described as being essentially as follows: A supply roll 44 consisting of a continuous web of flexible multi-layered laminated material as described hereinabove which; for example may be of a construction as disclosed in Application EP-A-0 686 563 referred to above, is mounted on the shaft and rotatable pulley unit 42, and the web is entrained over the idler and tension rollers 50, 52 so as to be conducted into and through the printing unit 60. In connection with the foregoing, reference may be had to Figure 7 illustrating, for purposes of clarity only, the web of material 44 being conveyed through the apparatus 30 in an imaginary generally flat planar motion. The forward or advancing motion to the laminated web 44 is effected through released sliding along the edges of the web by the sliding grippers 130 of the movable carriage 122 when the latter is displaced rearwardly along the direction of double-headed arrow C towards the web slitting unit 112; the edges of the web 44 thereafter being engaged by the sliding grippers 130, and the web then drawn forwardly upon advance of the carriage 122 in the opposite direction along arrow C towards the outlet end of the apparatus 30. This, in effect, will impart an intermittent or indexed advance or forward movement to the laminated web 70 through the apparatus 30. During intervals when the edges of the laminated web 70 are not clampingly engaged by the sliding grippers 130, stationary grippers 113 proximate the slitting unit 112 may be adapted to engage the laminated web 70 so as to prevent any longitudinal shifting or possible flexing or bowing of the web which would negate the accurate or precisely measured indexed advance thereof and prevent the formation of the desired printed label covers for the blister packages. In the printing unit 60, the laminated web 70 is imprinted, for example through thermal printing, with suitable content identifying characters, representative of lot and batch number, and fitting parameter, such as lens power of the contact lens which is to be contained in each subsequently to be formed blister package. As illustrated, the laminated web 70 is approximately twice the width of a single length of a base member of a blister package 12 and; in effect comprises the width A of the two base members in a contacting end-to-end relationship, as shown in Figure 9 of the drawings. As the laminated web is conveyed from the printing unit 60 over a further series of idler rollers and dancer rollers 82, 84 which impart the necessary tension to the laminated web 70, it is passed about rotatable drum structure 80 of perforating knife arrangement 100. In this case, the web is directed to extend about the lower circumferential surface portion 86 of the drum as the perforating knives are adapted to pass transversely across the width of the laminated web 70 during the period when the web is stationary. As the perforating knives 100 are displaced transversely across the bottom of the drum 80 by the piston and cylinder device 104, the serrated or toothed edges 101 cut into the laminated web 70 so as to produce lines of microperforations, as shown in Figures 7 through 9, which are spaced apart 30 mm; in essence, the width of a respective base member of a blister package 12. Herein, there are provided four (4) perforating knives 100 to form four perforation lines in parallel spaced relationship, with a total distance between the perforating knives 100 of 90 mm. Suitable air cylinders (not shown) may also be provided to control the depth of the perforations being imparted to the laminated web 44 by the perforating knives 100. As leading end of the laminated web 70 is engaged by the sliding grippers 130 of the reciprocable carriage 122, upon being in the position in which the carriage is retracted towards the slitting knife unit 112, with the edge grippers 130 engaging the web, the carriage 122 is displaced forwardly towards the outlet end of the apparatus 30, drawing the web forwardly by a precise distance, in this instance by 150 mm, so as to provide a web length of 60 mm between each set of four lines of perforations so as to ultimately provide for the 30 mm widths of five adjoiningly connected base members for an array of blister packages. The carriage 122 upon being moved forwardly, causes laminated web 70 to be drawn through the web slitting unit 112 such that the rotary blade 112 slits the web into two continuous web portions 70a, 70b, each one-half the width A shown in Figures 7 and 9. Upon the carriage 122 having completed the forward advance along guide rail structure 120, the transversely oriented cutting knife 128 located between upright supports 124 and 126 is actuated so as to sever the perforated and longitudinally slit laminated web portions 70a and 70b into the 150 mm lengths at precisely the middle of the 60 mm unperforated distance between the successive sets of four perforation lines. This resultingly produces five interconnected printed label covers from each severed web segment 44a and 44b. Subsequent to the severing of the laminated web portions 70a, 70b into the required segments each of 150 mm in length, the carriage 122 is retracted part of the distance towards the slitting knife device 112 so as to enable suitable vacuum structures 160 to each engage respectively one of the severed web segments and to transport them to the dial mechanism of installation 10 for placement over ten base members on a pallet 18 so as to form two arrays each of five interconnected blister packages 12, as shown in Figure 9. The extent and accuracy in the forward indexed movement and displacement of the laminated web 70, as shown in Figure 7, is controlled through the intermediary of suitable sensors 92, such as camera devices, located adjacent the infeed end of the stationary drum 80 of the perforating knife structure 100, as sensors (not shown) in the drum facing the web 70, and whereby the indexed displacement of the cutting knife-mounting carriage 122 along the longitudinal extent of the apparatus 30 is also calibrated by sensors 172 located at the slitting device 112 which will read the precision in the positioning of characters imprinted on the laminated web by the printing unit 60 in correlation with the location of the characters entering the perforating station so as to ensure that the distance the web has been indexed forwardly within predetermined parameters or variances, such as ± 0.2 mm for each intermittent advance of 150 mm for the laminated web. This is measured by the sensors 172 through scanning of the indicia or characters imprinted on the laminated web structure downstream of the slitting knife arrangement and also the calibration in relation thereto by the sensors 92 scanning the positioning of the printed character in each of an appropriate printing field on the web. In the event that the displacement is inaccurate, in effect, exceeds the ± 0.5 or preferably 0.2 mm variation allowed for each 150 mm of web advance, the apparatus 30 may include suitable structure for ejecting the incorrectly severed segments of the laminated web, and concurrently provide for an adjustment in the web feed mechanism of the apparatus, i.e. the displacement of carriage 122, so as to correlate the printed characters on the web 70 being scanned by the sensors 92, 172 with the extent of forward displacement of the laminated web. Reverting to the web perforating arrangement, the latter of which includes perforating knives 100 in the form of four rotary cutting blades, each having perforating teeth extending about the circumference of the disk-shaped blade member, for example 40 blades per inch of circumference to form microperforations, as shown in Figure 6, the blades are supported in a housing 103 which is reciprocable across the width of the laminated web 70 along the lower surface 86 of the drum 80, upon the web being intermittently advanced into a stationary period at the drum, the four perforating blades as illustrated being spaced with respect to each other at the points of perforating contact with the laminated web so as to define a longitudinal spacing between perforation lines of 30 mm, four such perforations lines being formed, and thereafter the laminated web being advanced by the apparatus to produce a double spacing of 60 mm between sets of perforation lines; in effect, skipping one perforation line which, in lieu thereof becomes the transverse severing or cutting edge for the transverse cutting knife 128 to form the web segments for conveyance to the dial mechanism of installation 10. From the foregoing, it becomes readily apparent that the apparatus and method provides for a unique and highly precise system of imparting suitable printing, perforations, slitting and severing of the laminated web to produce segments prior to placement thereof onto the base members containing the contact lenses in order to form the required printed label covers for arrays of interconnected blister packages. Other aspects of the invention may provide imparting pneumatic pressure to the perforating blades or knives which, as required, may exert increased pressure of the knife cutting edges against the laminated web so as to force the knives deeper into the web during any sense the dulling of the knife edges. This may, of course, be implemented through suitable sensors (not shown) which determine the depth of the either partially deep or through microperforations in the laminated web at the web perforating arrangement. While there has been shown and described what are considered to be preferred embodiments of the invention, it will, of course, be understood that various modifications and changes in form or detail could readily be made without departing from the the invention. It is, therefore, intended that the invention be not limited to the exact form and detail herein shown and described, nor to anything less than the whole of the invention herein disclosed as hereinafter claimed.

Claims: An apparatus (30) for producing blister packages (12), the packages (12) comprising printed labels forming covers (14) that interconnect a plurality of blister packages (12), said covers (14) each being a segment severed from a continuous length of a laminated web, said apparatus (30) including a framework (34, 36) for supporting a laminated web (70) along a predetermined path of movement, comprising: a) a movable carriage (122) including grippers (130) for engaging said laminated web (70) and for intermittently advancing said web (70) along said path of movement; b) a printing arrangement (60) for imprinting indicia on said laminated web (70) at a first station along said path of movement; c) a perforating device (80) for imparting a plurality of spaced lines of perforations (106) to said laminated web (70) at a second station, said lines 106) of perforations (106) extending transversely across the width of said laminated web (70); d) a cutting structure (128) being mounted on said movable carriage (122) or severing said web (70) into segments to produce printed label-forming covers; and e) means for engaging said severed segments for placement on pluralities of base members for forming arrays of blister packages individually detachable along said lines of perforation. An apparatus (30) as claimed in Claim 1, wherein said perforating device (80) comprises a stationary drum (80) mounted on said framework (34, 36), said laminated web (70) being conveyable in sliding contact with at least a portion of the circumferential surface (86) of said drum (80), and a plurality of perforating knives (100) being engagable with said laminated web (70) in spaced relationship along said drum surface portion (86) for imparting said lines of perforations to said web (70). An apparatus (30) as claimed in Claim 2, wherein each perforating knife (100) comprises a rotatable disc-shaped blade having perforating serrations extending about the circumference thereof. An apparatus (30) as claimed in Claim 2, wherein a pneumatically-actuated piston and cylinder means (104) is operatively connected with each perforating knife (100) or reciprocating said perforating knives (100) across the width of said laminated web (70). An apparatus (30) as claimed in Claim 4, wherein said perforating knives (100) include a structure for adjusting the depth of the perforations (106) formed in said laminated web (70). An apparatus (30) as claimed in Claim 1, wherein sensor means (92) are operatively associated with said perforating device (80) for correlating the location of said lines of perforations (106) in said laminated web (70) with indicia imprinted on said web (70) by said printing arrangement (60). An apparatus (30) as claimed in Claim 6, wherein said sensor means (92) comprises a camera for scanning the indicia imprinted on said laminated web (70). An apparatus (30) as claimed in Claim 6, wherein said sensor means (92) are located proximate the infeed of said laminated web (70) to said perforating device (80). An apparatus (30) as claimed in Claim 1, wherein a slitting arrangement (112) is located at a third station downstream of said perforating device (80) in the direction of conveyance of the laminated web (70) for slitting said web (70) into at least two longitudinally extending continuous web portions (70a, 70b). An apparatus (30) as claimed in Claim 9, wherein said slitting arrangement (112) includes a disc-shaped slitting blade (114) for imparting a continuous slit to said laminated web (70) in the direction of advance of said web (70) for severing said web (70) into at least two continuous web strips (70a, 70b) of substantially equal widths. An apparatus (30) as claimed in Claim 10, wherein said slitting arrangement (112) includes a stationary support for said slitting blade (114), and gripping means for clamping said laminated web (70) during intervals when the grippers (130) on said movable carriage (122) are disengaged from said laminated web (70). An apparatus (30) as claimed in Claim 1, wherein said movable carriage (122) comprises a pair of spaced uprights (124, 126), said cutting structure (128) being located between said uprights (124, 126), and actuating means being operatively connected to said cutting structure (128) for placing said cutting structure (128) into a web-severing condition upon the carriage (122) reaching the forward advanced position thereof in said apparatus (30). An apparatus (30) as claimed in Claim 12, wherein said cutting structure (128) comprises a cutter blade (128) for severing said web (70) into segments of predetermined lengths. An apparatus (30) as claimed in Claim 13, wherein said actuating means comprises a pneumatically-operated piston and cylinder arrangement. An apparatus (30) as claimed in Claim 6, wherein said movable carriage (122) includes sensors for scanning the extent of displacement of said carriage (122) upon the rearward movement of said carriage (122) towards said slitting arrangement (112), said sensors being operatively connected with sensor means at said perforating device (80) for calibrating the accuracy of the forward displacement of said laminated web (70). An apparatus (30) as claimed in Claim 1, wherein vacuum suctioning devices (142) engage said severed segments proximate the outlet end of said apparatus (30) downstream of said movable carriage (122) for placement on pluralities of base members for forming arrays of blister packages (12). An apparatus (30) as claimed in Claim 1, wherein said movable carriage (122) advances said laminated web (70) a distance of 150 mm during each indexed forward motion of the carriage (122). An apparatus (30) as claimed in Claim 1, wherein photoelectric sensor means verify the position of indicia on said laminated web (70) prior to actuation of said cutting structure (128) to ensure proper web indicia grouping. An apparatus (30) as claimed in Claim 18, wherein said advance of 150 mm forms segments upon cutting said web (70) each having a length of 150 mm and four spaced transverse perforation lines to produce printed label covers each conveying a linear array of blister packages (12) of respectively each 30 mm in width. An apparatus (30) as claimed in Claim 18, wherein said carriage advance of 150 mm is maintained at a degree of accuracy of within ± 0.50 and preferably 0.20 mm. An apparatus (30) as claimed in Claim 1, wherein a tension device (52) imparts a predetermined variable tensile force to said laminated web (70) during conveyance through said apparatus (30). An apparatus (30) as claimed in Claim 21, wherein said tension device (52) comprises a weighted roller device or a constant tensioner unit. A method for producing blister packages (12) said packages comprising printed labels forming covers that interconnect a plurality of blister packages (12), said covers each being a segment severed from a continuous length of a laminated web 70, the method comprising the steps of: a) actuating a movable carriage (122) including grippers (130) for engaging a laminated web (70) and for intermittently advancing said web (70) along a path of movement; b) imprinting indicia on said laminated web (70) at a first station (60) along said path of movement; c) imparting a plurality of spaced lines of perforations (106) to said laminated web (70) at a second station (80), said lines of perforations (106) extending transversely across the width of said laminated web (70); d) severing said web (70) into segments to produce printed label-forming covers; and e) engaging said severed segments for placement on pluralities of base members for forming arrays of blister packages individually detachable along said lines of perforations. A method as claimed in Claim 23, wherein said laminated web (70) is conveyable in sliding contact with at least a portion of the circumferential surface (86) of a stationary drum (80), and engaging a plurality of perforating knives (100) with said laminated web (70) in spaced relationship along said drum surface portion (86) for imparting said lines of perforations (106) to said web (70). A method as claimed in Claim 24, wherein each perforating knife (100) comprises a rotatable disc-shaped blade having perforating serrations extending about the circumference thereof. A method as claimed in Claim 24, wherein a pneumatically-actuated piston and cylinder means (104) is operatively connected with each perforating knife (100) for reciprocating said perforating knives (100) across the width of said laminated web (70). A method as claimed in Claim 26, wherein said perforating knives (100) adjust the depth of the perforations formed in said laminated web (70). A method as claimed in Claim 23, wherein sensors (92) are operatively associated with said perforating device (80) for correlating the location of said lines of perforations (106) in said laminated web (70) with indicia imprinted on said web (70). A method as claimed in Claim 28, wherein said sensors (92) comprise a camera for scanning the indicia imprinted on said laminated web (70). A method as claimed in Claim 28, wherein said sensor means (92) are located proximate the infeed of said laminated web (70) to said perforating device (80). A method as claimed in Claim 23, wherein said laminated web (70) is slit into at least two longitudinally extending continuous web portions (70a, 70b) at a third station (112) downstream of the perforating step in the direction of web conveyance. A method as claimed in Claim 31, wherein said slitting is implemented by a rotatably journaled disc-shaped slitting blade (114) for imparting a continuous slit to said laminated web (70) in the direction of advance of said web (70) for severing said web (70) into at least two continuous web strips (70a, 70b) of substantially equal widths. A method as claimed in Claim 32, wherein said slitting step includes grippingly clamping said laminated web (70) during intervals when the grippers (130) on said movable carriage (122) are disengaged from said laminated web (70). A method as claimed in Claim 23, wherein said movable carriage (122) comprises a pair of spaced uprights (124, 126), cutting said web (70) into segments being affected between said uprights (124, 126) and actuating a web cutting and severing condition upon the carriage (122) reaching a specified advanced position. A method as claimed in Claim 34, wherein web severing is implemented by a linear cutting blade (128) for severing said web strips (70a, 70b) into segments of predetermined lengths. A method as claimed in Claim 35, wherein said cutting blade (128) is reciprocated across said web (70) by a pneumatically-operated piston and cylinder arrangement. A method as claimed in Claim 29, wherein said movable carriage (122) includes sensors for scanning the extent of displacement of said carriage (122) upon a rearward movement of said carriage (122) towards a web slitting arrangement (112), said sensors being operatively connected with sensors at said perforating device (80) for calibrating the accuracy of the forward displacement of said laminated web (70). A method as claimed in Claim 23, wherein said severed segments are engaged by suctioning devices (142) proximate the outlet end of said apparatus (30) downstream of said movable carriage (122) for placement on pluralities of base members for forming arrays of blister packages (12). A method as claimed in Claim 23, wherein said movable carriage (122) advances said laminated web (70) a distance of 150 mm during each indexed forward motion of the carriage (122). A method as claimed in Claim 39, wherein said advance of 150 mm forms segments upon cutting said web (70) each having a length of 150 mm and four spaced transverse perforation lines to produce printed label covers each conveying a linear array of blister packages (12) of respectively 30 mm in width for each package (12). A method as claimed in Claim 39, wherein said carriage advance of 150 mm is maintained at a degree of accuracy of within ± 0.50 and preferably 0.20 mm. A method as claimed in Claim 23, wherein a predetermined variable tensile force is maintained on said laminated web (70) during the path of movement thereof.

Inventors: ABRAMS RICHARD WAYNE, EDWARDS RUSSEL JAMES, GUNDERSEN BORGE PETER, HOLLEY WILLIAM EDWARD, RAVN THOMAS CHRISTIAN, SCHLAGEL MARK EDWARD, WANG DANIEL TSU-FANG, ABRAMS, RICHARD WAYNE, EDWARDS, RUSSEL JAMES, GUNDERSEN, BORGE PETER, HOLLEY, WILLIAM EDWARD, RAVN, THOMAS CHRISTIAN, SCHLAGEL, MARK EDWARD, WANG, DANIEL TSU-FANG
Applicants: JOHNSON & JOHNSON VISION PROD, JOHNSON & JOHNSON VISION PRODUCTS, INC.
Application year: 1995
Main classification: B65C1
IPC codes: B65B7, B65C9, B65B25, B65B61, B31D1