Patent Publication Number: US-9415890-B2

Title: Device for opening and emptying filled two-piece capsules

Description:
BACKGROUND OF THE INVENTION 
     The invention concerns a device for opening and emptying filled two-piece capsules. For example, in the field of pharmacy and food supplements, so-called two-piece capsules are used in which an active ingredient preparation is contained and which are designed to be swallowed by the user. Such two-piece capsules are comprised, for example, of hard gelatine or of HPMC (hydroxypropyl methylcellulose) or the like, wherein the capsule material after having been swallowed will dissolve and release the active ingredient preparation. The two-piece capsules are formed of a capsule bottom part and a capsule top part, wherein first the capsule bottom part is filled and then subsequently a capsule top part is pushed onto the filled capsule bottom part. The plug connection is sufficiently strong so that the two parts will not accidentally detach from each other. 
     When filling two-piece capsules, specifications with regard to metering precision are stringent. However, these specifications are not always fulfilled. Due to the metering system, the quality of the metered material, and also other conditions, high reject rates may be produced. Particular in case of high-quality or high-priced filling material, there is the need in such a case to recover the filling material, if possible, without contaminations. 
     The invention has the object to provide a device for opening and emptying filled two-piece capsules with which a recovery, that is economic and gentle to the material, of the filling material from the filled and closed two-piece capsules is possible. 
     SUMMARY OF THE INVENTION 
     The object is solved by a device that comprises a separator block for separating capsule bottom part and capsule top part as well as a guide pusher for pushing an individual two-piece capsule into the separator block in a pushing direction. The separator block has a first clamping path for the capsule bottom part and a second clamping path for the capsule top part, wherein the clamping paths are designed such that they each have an advancing direction in which the capsule bottom part or the capsule top part can be moved by means of the guide pusher and, during this movement, are clamped perpendicularly thereto. The two clamping paths are slanted relative to each other such that their respective advancing directions relative to the pushing direction of the guide pusher diverge at an opening angle. 
     With the aforementioned clamping action, the capsule bottom part and capsule top part are forced into paths that are diverging relative to each other while they follow the advancing action of the guide pusher. As a result of the aforementioned clamping action, the diverging paths cause the capsule bottom part and the capsule top part, starting with their closed plug position, to move away from each other and to finally be completely separated. The precious filling material can be removed and can be supplied to a further filling process or another after-processing step. Opening of the two-piece capsule is realized with only minimal loading of the capsule material so that capsule damage and contamination of the filling material caused thereby are reliably avoided. High cycle rates are possible. A compact configuration results that enables installation of the device according to the invention in existing GMP (good manufacturing practice) rooms, for example, also in those rooms in which the filling and closing machine is located. 
     According to an advantageous further embodiment, the clamping paths each have a pair of at least approximately parallel clamping edges facing each other wherein the pair of parallel clamping edges of the first clamping path are positioned at the opening angle relative to the pair of parallel clamping edges of the second clamping path. In particular, the pairs of clamping edges are formed on pairs of clamping plates. The arrangement is constructively simple with respect to its configuration and is reliable with respect to its clamping guiding action. The capsule parts which are secured by clamping action between the clamping edges can be moved with minimal force expenditure and without excessive loading of the capsule material in the respective advancing direction. At the same time, the clamping edges prevent sliding of the capsule part secured therein perpendicular to the advancing direction, respectively, so that the two-piece capsule is reliably opened along the advancing path of the guide pusher. 
     In an advantageous embodiment, the separator block has upstream thereof a sorting device for oriented alignment and supply of an individual two-piece capsule to the separator block wherein the first clamping path is matched to the diameter of the capsule bottom part and the second clamping path to the diameter of the capsule top part. 
     The sorting device ensures that the two-piece capsules that are initially supplied unoriented are oriented such that, independent of their supply orientation, the capsule bottom part is always supplied to the correlated first clamping path and the capsule top part always to the correlated second clamping path. The individual adjustment to the capsule top and capsule bottom parts that differ with regard to their diameter enables a precisely predetermined clamping action on the capsule bottom part and the capsule top part without one of them being overloaded or subjected to a clamping action that is too low. The adjustment of the separator block to the diameter differences of the two-part capsule parts enables a safe and destruction-free opening of the capsule. 
     In connection with the sorting device and the configuration of the clamping paths with clamping edges, a proper longitudinal guiding action and clamping action transversely thereto are achieved in that the spacing between the clamping edges of the first clamping path is smaller by a first clamping measure than the diameter of the capsule bottom part and in that the spacing between the clamping edges of the second clamping path is smaller by a second clamping measure than the diameter of the capsule top part. 
     The sorting device has advantageously a sorting block with an ejector passage for receiving two-piece capsules that are supplied unoriented as well as a sorting pusher for oriented turning within the ejector passage and for removing the turned and oriented two-piece capsules from the ejector passage. In this connection, the effect is utilized that the closed capsules have their maximum diameter and also their maximum stiffness in the area of the spherical top part. In this area, the two-piece capsule is secured in the ejector passage with minimal clamping action wherein the site of the clamping action determines an eccentric pivot axis. The laterally supplied sorting pusher that hits the two-piece capsule centrally causes first a turning movement of the two-piece capsule in such a way that its thinner capsule bottom part in the ejecting direction of the sorting pusher is pointing forwardly. This applies likewise to two-piece capsules with capsule top part positioned at the top or at the bottom. After completed turning, the two-piece capsule independent of its initial position is ejected, with the thinner capsule bottom part leading, and supplied to the separator block in correct position so that an unequivocal assignment of capsule bottom part and capsule top part to the respective clamping path is ensured. In particular, the clamping paths and the sorting block can be designed as so-called format parts so that, with otherwise identical configuration of the device according to the invention, all conventional and differently designed two-piece capsule sizes can be processed. 
     In a preferred further embodiment, the sorting device has a capsule supply for the sorting block that performs a lifting stroke. In this connection, the lifting movement of the guide pusher is coupled with the lifting movement of the capsule supply which advantageously can be achieved by a fixed attachment of the guide pusher at the capsule supply. Without additional control expenditure, it is ensured that the processes of capsule orientation and capsule opening will be performed synchronous to each other. This contributes to operational safety at high cycle rates. 
     For the opening angle between the clamping paths there is some freedom with respect to design. It has been found to be advantageous that the opening angle is within a range of including 10° to including 50° and preferably in a range of including 20° to including 40° and in particular at least approximately 30°. 
     In an expedient further embodiment of the invention, below the separator block a separating device for separating the opened capsule bottom parts and capsule top parts from the contents of the capsule is arranged. Preferably, the separating device is formed by a vibrating screen and a collecting container for the capsule contents that is arranged below the vibrating screen. The vibrating screen retains the opened two-piece capsules while the capsule contents fall through the mesh of the screen into the collecting container. For a sufficiently narrow mesh size, also fragments of accidentally destroyed capsule parts can be retained so that a high degree of purity of the recovered capsule contents is ensured. The vibrating screen ensures also due to its vibrating movement that the entire capsule contents is removed from the vibrated capsule top parts and capsule bottom parts and supplied through the screen to the collecting container. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       One embodiment of the invention will be explained in the following with the aid of the drawing in more detail. It is shown in: 
         FIG. 1  in a schematic partially sectioned side view a device according to the invention for opening and emptying filled two-piece capsules with a sorting block, with a separator block, and with a separating device for separating the capsule contents; 
         FIG. 2  a schematic cross-sectional illustration of the sorting block with introduced two-piece capsule according to  FIG. 1 ; 
         FIG. 3  the arrangement according to  FIG. 2  with two-piece capsule inserted in reverse arrangement; 
         FIG. 4  in a perspective schematic illustration a part of the separator block according to  FIG. 1  with clamped two-piece capsule; 
         FIG. 5  the arrangement according to  FIG. 1  at the beginning of the separating process. 
     
    
    
     DESCRIPTION OF PREFERRED EMBODIMENTS 
       FIG. 1  shows in a schematic partially sectioned side view one embodiment of the device according to the invention for opening and emptying filled two-piece capsules  1 . Each individual two-piece capsule  1  is comprised of a capsule bottom part  2  as well as a pushed-on capsule top part  3 . The two-piece capsules  1  or their capsule bottom parts  2  and capsule top parts  3  are comprised of hard gelatine, HPMC or the like, and contain an active ingredient preparation which is in particular in the form of a fine-grain powder. The illustrated device according to the invention is provided to recover the contents of the capsule in case of improper filling of the two-piece capsules  1  or for other reasons. The device comprises a capsule supply  23 , a sorting device  19 , a separator block  4 , as well as a separating device  24 . 
     By means of the capsule supply  23  in the form of a vertically oriented passage. filled two-part capsules  1  are supplied from a storage container, not illustrated, to the sorting device  19 . The vertical passage of the capsule supply  23  has for this purpose a cross-section that is slightly greater than the diameter of the two-piece capsules  1  so that the two-piece capsules  1  can fall in vertical alignment in a row atop each other through the passage into the sorting device  19 . The two-piece capsules  1  are unoriented within the capsule supply  23  such that randomly either a capsule bottom part  2  or a capsule top part  3  will be positioned facing downwardly. 
     The sorting device  19  comprises a sorting block  20  with a horizontally arranged and upwardly open ejector passage  21  as well as a sorting pusher  22  that is horizontally moveable in oscillation in accordance with a double arrow  29  and that has a tip  30  that is facing the ejector passage  21 . 
     The separator block  4  is provided for separation of capsule bottom part  2  and capsule top part  3 , beginning with the pushed-on state, and comprises a first clamping path  7  for an individual clamping bottom part  2  as well as a second clamping path  8  for an individual capsule top part  3 . The first camping path  7  has an advancing direction  9  while the second clamping path  8  has an advancing direction  10 . Moreover, a guide pusher  5  which is acting on an individual two-piece capsule  1  is provided which, in the illustrated embodiment, is rigidly connected to the capsule supply  23  and is movable in oscillation together with it in accordance with a double arrow  28  up and down in the vertical direction. Due to the rigid or fixed connection of the guide pusher  5  with the capsule supply  23 , the lifting movement of the guide pusher  5  is coupled with the lifting movement of the capsule supply  23  in accordance with double arrow  28 . However, a rigid connection between the two components can be omitted wherein then both lifting movements are driven separately and are coordinated or synchronized by means of a suitable control unit. 
     During the downward phase, the guide pusher  5  moves in pushing direction  6  and forces an individual two-piece capsule  1  into the separator block  4 . The two clamping paths  7 ,  8  are slanted relative to each other such that their advancing movements  9 ,  10  relative to the vertical pushing direction  6  of the guide pusher  5  diverge at an opening angle α. The opening angle α is expediently in a range of including 10° to including 50° and preferably in a range of including 20° to including 40°. In the illustrated embodiment, the opening angle α is at least approximately 30°. 
     Below the separator block  4 , the separating device  24  for separating the opened bottom parts  2  and capsule top parts  3  from their capsule contents is arranged. In the illustrated embodiment, the separating device  24  is formed by a vibrating screen  25  as well as by a collecting container  26  for the capsule contents arranged underneath the vibrating screen  25 . The vibrating screen  25  is oscillatingly movable in horizontal direction by means of a drive, not illustrated, in accordance with double arrow  27 . In addition or alternatively, a vertical oscillating movement can be provided also. 
       FIG. 2  shows in a schematic cross-sectional illustration the sorting block  20  according to  FIG. 1  with an individual two-piece capsule  1  which is upright within the ejector passage  21  and resting on its passage bottom  35 . In the illustrated case, the capsule bottom part  2  is positioned at the top while the capsule bottom part  3  is positioned at the bottom. The capsule top part  3  has a diameter D o  that is greater by such a measure than the diameter D u  of the capsule bottom part  2  that the capsule bottom part  2  can be inserted in a clamping fashion into the capsule bottom part  3 . The ejector passage  21  which is open in upward direction is laterally delimited by parallel extending passage walls  33  wherein their spacing relative to each other is somewhat smaller than the diameter D o  of the capsule top part  3  but greater than the diameter D u  of the capsule bottom part  2 . In this way, the two-piece capsule  1  is clamped between the passage walls  33  in the area of the capsule top part  3  such that at the site of maximum surface pressure, i.e., at the transition area of cylindrical section to the spherical section of the capsule top part  3 , a horizontal pivot axis  34  is formed. When looking jointly at  FIGS. 1 and 2 , it is apparent that the sorting pusher  22  with its tip  30  is adjusted in vertical direction such that the sorting pusher  22  with its tip  30  upon horizontal advancing movement will impinge on a contact point  32  which is approximately located at the center of the capsule, i.e., below the pivot axis  34 , on the two-piece capsule  1 . 
       FIG. 3  shows the arrangement according to  FIG. 2  in the situation in which an individual two-piece capsule  1  with its capsule top part  3  pointing downwardly is resting in upright position in the ejector passage  21  on its passage bottom  35 . As in the arrangement according to  FIG. 2 , the horizontal pivot axis  34  is formed at the top capsule part  3  wherein however due to the reverse position of the two-piece capsule  1  the horizontal pivot axis  34  is now below the contact point  31 . In respect to other features and reference characters, the arrangement according to  FIG. 3  is identical to that of  FIG. 2 . Details to the effect of the illustrated arrangement will be explained infra. 
       FIG. 4  shows in a perspective schematic illustration a part of the separator block  4  according to  FIG. 1  with an individual two-piece capsule  1  having been pushed in from above. The first clamping path  7  has a pair of clamping edges  11 ,  12  that are at least approximately parallel and are facing each other while the second clamping path  8  has a further pair of clamping edges  13 ,  14  that are at least approximately parallel and are facing each other. For configuring the pairs of clamping edges  11 ,  12  or  13 ,  14 , a first pair of clamping plates  15 ,  16  as well as a second pair of clamping plates  17 ,  18  are provided. The first clamping path  7  is matched to the diameter D u  of the capsule bottom part  2  ( FIGS. 2, 3 ) while the second clamping path  8  is matched to the diameter D o  of the capsule top part  3  ( FIGS. 2, 3 ). In this connection, the clamping plates  15 ,  16  of the first clamping path  7  have between their facing clamping edges  11 ,  12  a spacing a 1  that is smaller by a certain clamping measure than the diameter D u  of the capsule bottom part  2 . The same applies also to the spacing a 2  between the two clamping plates  17 ,  18  or their facing clamping edges  13 ,  14  of the second clamping path  8  wherein the aforementioned spacing a 2  is smaller by a certain clamping measure than the diameter D o  of the capsule top part  3 . Since the diameter D u  of the capsule bottom part  2  is smaller than the diameter D o  of the capsule top part  3 , the spacing a 1  between the clamping edges  11 ,  12  of the first clamping path  7  is smaller than the spacing a 2  between the clamping edges  13 ,  14  of the second clamping path  8 . In any case, the spacings a 1 , a 2  or their clamping measures are adjusted such that the respective capsule bottom part  2  or capsule top part  3  secured by clamping therebetween can be moved parallel to the clamping edges  11 ,  12  or the clamping edges  13 ,  14  but not in a direction perpendicular thereto. Accordingly, the clamping edges  11 ,  12 , due to their spatial orientation, determine the aforementioned first advancing direction  9  of the first clamping path  7  while, in the same way, the clamping edges  13 ,  14 , due to their spatial orientation, determine the second advancing direction  10  of the second clamping path  8 . Coinciding with the illustration according to  FIG. 1 , the first pair of clamping plates  15 ,  16  is slanted relative to the second pair of clamping plates  17 ,  18  such that the pair of parallel clamping edges  11 ,  12  of the first clamping path  7  and thus the first advancing direction  9  is positioned at an opening angle α relative to the pair of parallel clamping edges  13 ,  14  of the clamping path  8  or relative to its second advancing direction  10 . 
     The device according to the invention is operated with the following method steps.  FIG. 1  shows the arrangement in the first method step according to which the capsule supply  23  is lowered onto the sorting block  20 . At the lower end of the capsule supply  23  a retaining spring is arranged for the two-piece capsules  1  that are aligned in the capsule supply  23  and is retracted. As a result, the row of two-piece capsules stacked on each other will drop downwardly until an individual two-piece capsule  1  is positioned upright within the ejector passage  21  of the sorting block  20  in accordance with the illustration of  FIG. 2 . The sorting pusher  22  is positioned in a horizontally retracted position in which its tip  30  is positioned at a spacing relative to the two-piece capsule  1  standing in the ejector passage  21 . 
       FIG. 5  shows the arrangement according to  FIG. 1  in the next method step, according to which the capsule supply  23  relative to the position of  FIG. 1  is lifted. In this context, the retaining spring  31  projects into the passage of the capsule supply  23  so that the row of two-piece capsules  21  positioned therein is lifted together with the capsule supply  23  while only an individual two-piece capsule  1  is located within the sorting block  20 . The sorting pusher  22 , starting from the position according to  FIG. 1 , has moved horizontally into the ejector passage  21  of the sorting block  20 . When looking jointly at  FIGS. 1, 2 and 5 , it is apparent that the sorting pusher  22  hits thereby with its tip  30  the contact point  32  of the two-piece capsule  1  and, as a result of its eccentricity to the horizontal pivot axis  34 , causes a pivot movement of the two-piece capsule  1  in such a way that the two-piece capsule  1  with its capsule bottom part  2  pointing forwardly in the advancing or ejecting direction of the sorting pusher  22  is ejected from the ejector passage  21  and is positioned above the separator block  4 . With additional attention to the illustration of  FIG. 3 , it is apparent that the same orientation of a two-piece capsule  1  is achieved even when it is resting with its capsule top part  3  pointing downwardly on the passage bottom  35  of the ejector passage  21 . In this case, the contact point  32  is above the horizontal pivot axis  34  so that the sorting pusher  22  upon hitting the contact point  32  also causes turning of the two-piece capsule  1  in such a way that the two-piece capsule  1  with its capsule bottom part  2  pointing forwardly is ejected from the ejector passage  21  and will be positioned with the same orientation above the separator block  4 . 
     Starting with the position of  FIG. 5 , in the next method step the capsule supply  23  together with the guide pusher  5  is lowered in the pushing direction  6  according to  FIG. 1 , wherein the guide pusher  5  will force the individual two-piece capsule  1 , having been oriented with respect to the capsule bottom part  2  and capsule top part  3 , into the separator block  4 . 
     At the beginning, the initially closed two-piece capsule  1  is forced into the separator block  4  in the way illustrated in  FIG. 4 . In this context, the capsule bottom part  2  is secured with clamping action in the first clamping path  7  between the clamping edges  11 ,  12  while the capsule top part  3  is secured with clamping action in the second clamping path  8  between the clamping edges  13 ,  14 . During the course of the further advancing stroke of the guide pusher  5  beginning with the position of  FIG. 5  up to the end position according to  FIG. 1  in the pushing direction  6 , the two-piece capsule  1  is also pushed downwardly in the pushing direction  6 . As a result of the afore described clamping and guiding action, the capsule bottom part  2  follows the first advancing direction  9  of the first clamping path  7  while the capsule top part  3  follows the second advancing direction  10  of the second clamping path  8 . Since the two advancing directions  9 ,  10  relative to the pushing direction  6  ( FIG. 1 ) are diverging at the opening angle α, the capsule bottom part  2  which is moved in the first advancing direction  9  and the capsule top part  3  which is moved in the second advancing direction  10  are pulled apart so far that finally the capsule bottom part  2  and the capsule top part  3  are separated from each other in accordance with the illustration of  FIG. 1 . 
     At the same time, the capsule supply  23  is also lowered again in accordance with the illustration of  FIG. 1  onto the sorting block  20  and the retaining spring  31  is retracted so that the next two-piece capsule  1  can drop into the ejector passage  21  of the sorting block  20  whereupon the afore described cycle will begin anew. 
     The illustration according to  FIG. 1  also illustrates that the separated capsule bottom parts  2  and capsule top parts  3  fall onto the vibrating screen  25  arranged underneath the separator block  4  and remain thereon. As a result of the vibrating movement of the vibrating screen  25  in accordance with double arrow  27 , the capsule contents, for example, in the form of the aforementioned fine-grain powder is shaken out of the capsule bottom parts  2  and capsule top parts  3  and passes through the vibrating screen  25  into the collecting container  26  arranged underneath. The vibrating screen  25  is of such a fine-mesh configuration that the capsule contents can pass through and is caught by the collecting container  26  while the capsule bottom parts  2  and capsule top parts  3  that have been ejected from the separator block  4  as well as possibly chipped-off capsule fragments are however retained. The capsule contents that is collected in the collecting container  26  is therefore free of any foreign material and can be subjected to further processing or used for refilling two-piece capsules  1 .