Semi-automatic vial closing apparatus

Abstract

A vial closing machine includes an indexed mechanism to facilitate movement of vial fixtures between a plurality stations—loading, filling, sealing, and unloading; integration of a filler and manifold system, to dispense a pharmaceutical product equally into each of the vials; an electrical enclosure containing a programmable logic controller or a series of timers to control filler, sealing mechanism, indexer movement; a moveable heat sealing device providing pressure against an opposing respective device which creates pressured system required for sealing process; a material flattener, attached to the moveable heat sealing device, used to pre-flatten a vial below a sealing area in order to create a reliable seal without damaging the integrity of the vial material; and a means for removing filled and sealed vials from vial fixture. The vial closing machine may be one of two types—a Ferris wheel design type or a stadium design type.

What is claimed is:  
     
         1 . An apparatus for filling and sealing vials, the apparatus comprising: 
 one or more vial fixtures for holding one or more vials to be filled with a substance;    an indexed mechanism to facilitate movement of one or more vial fixtures between a plurality stations, the plurality of stations including: 
 a filler station comprising a filler mechanism and manifold system, attached to the indexed mechanism, to dispense a substance into at least one of the vials;  
 a sealing station comprising a sealing device for providing pressure against an opposing sealing device for creating the necessary force to seal one or more vials, wherein at least one of the sealing device and the opposing sealing device are movable so as to pinch the one or more vials while sealing to create a reliable seal without damaging the vial; and  
 an unloading station for removing filled and sealed vials from vial fixture; and  
   a control system electrically coupled to one or more of the stations and the index mechanism in order to control the movement of the vial fixtures between the plurality of stations.    
     
     
         2 . The apparatus of  claim 1 , wherein the indexed mechanism comprises a Ferris wheel design so as to move the vial fixtures in an orbital path from station to station.  
     
     
         3 . The apparatus of  claim 2 , wherein the plurality of stations further includes: 
 a loading station connected to a trough to hold vial fixtures to be loaded onto the indexed mechanism.    
     
     
         4 . The apparatus of  claim 1 , wherein the indexed mechanism comprises a stadium design so as to move vial fixtures along a conveyor track from station to station.  
     
     
         5 . The apparatus of  claim 4 , wherein the stadium design type includes one or more levels of indexed mechanisms and stations such that each level is positioned tandemly to prevent interference.  
     
     
         6 . The apparatus of  claim 1 , wherein the sealing station includes a material flattener, attached to at least one of the sealing device and the opposing sealing device, so as to pre-flatten one or more vials below a sealing area to facilitate sealing the vials in order to create a reliable seal without damaging the vial  
     
     
         7 . The apparatus of  claim 1 , wherein the moveable sealing device comprises at least one of a stack, anvil and flattener.  
     
     
         8 . The apparatus of  claim 1 , wherein the opposing respective device comprises at least one of a stack, anvil and flattener.  
     
     
         9 . The apparatus of  claim 1 , wherein the means for removing filled and sealed vials from vial fixture comprises one of a mechanical cam and a second level return.  
     
     
         10 . The apparatus of  claim 1 , wherein the moveable sealing device is a heat sealer using at least one of an impulse heat sealing, an ultrasonic heat sealing, a high frequency heat sealing device and a wedge sealing device.  
     
     
         11 . The apparatus of  claim 1 , wherein the sealing device is operated by one of electrical means, pneumatic means and hydraulic means.  
     
     
         12 . The apparatus of  claim 1 , wherein the indexing mechanism is operated by one of electrical means, pneumatic means and hydraulic means.  
     
     
         13 . A Ferris wheel type apparatus for filling and sealing vials, the apparatus comprising: 
 at least one vertical wheel assembly with one or more vial fixtures pivotally attached thereto for holding a one or more vials, wherein the vertical wheel assembly is rotatably mounted on a horizontal shaft for positioning the one or more vial fixtures to a plurality of stations placed at different elevations with respect to the shaft, the plurality of stations comprising; 
 a filler station mounted at first circular position with respect to the vertical wheel, the filler station comprising filler mechanism and manifold system for dispensing a substance into at least one of the vials;  
 a sealing station mounted at a second circular position with respect to the vertical wheel, the sealing station comprising a moveable sealing device for providing pressure against an opposing sealing device thereby creating the necessary force to seal at least one of the vials, wherein the sealing station includes a material flattener, attached to the moveable sealing device, so as to pre-flatten one or more vials below a sealing area to facilitate sealing the at least one vials in order to create a reliable seal without damaging the vial;  
 an unloading station mounted at a third circular position with respect to the vertical wheel for removing filled and sealed vials from vial fixture; and  
   a control system electrically coupled to one or more of the stations and to a motor for rotating the vertical wheel in order to control the movement of the vial fixtures between the plurality of stations.    
     
     
         14 . The apparatus of  claim 13 , wherein the vial fixtures pivotally attached to the vertical wheel assembly includes a roller wheel which is adapted to engage a stationary race-way attached to the horizontal shaft, so as the vial fixture is positioned from one station to another station and the vial fixture passes by the stationary race, the vial fixture is rotated in a direction opposite to a direction of the vertical wheel and to an angle sufficient to cause at least one of the vials loaded into the fixture to fall out of the fixture due to gravity.  
     
     
         15 . The apparatus of  claim 13 , wherein the vial fixtures pivotally attached to the vertical wheel assembly includes elongate troughs attached to a second vertical wheel assemble rotatably mounted on a second shaft which is coaxially positioned to the shaft of the vertical wheel, so that when both the vertical wheel assembly and the second vertical wheel assembly rotate, the vial fixtures are moved to the plurality of stations positioned along a circular path around the shaft.  
     
     
         16 . The apparatus of  claim 13 , wherein the moveable sealing device comprises at least one of a stack, anvil and flattener.  
     
     
         17 . The apparatus of  claim 13 , wherein the opposing respective device comprises at least one of a stack, anvil and flattener.  
     
     
         18 . A stadium type apparatus for filling and sealing vials, the apparatus comprising: 
 a horizontal conveyor system with one or more vial fixtures attached thereto for holding one or more vials, the conveyor system adapted to position the one or more vial fixtures to a plurality of stations placed at different locations along the conveyor system, the plurality of stations comprising; 
 a filler station mounted at first position with respect to conveyor system, the filler station comprising filler mechanism and manifold system for dispensing a substance into at least one of the vials;  
 a sealing station mounted at a second position with respect to conveyor system, the sealing station comprising a moveable sealing device for providing pressure against an opposing sealing device thereby creating the necessary force to seal at least one of the vials, wherein the sealing station includes a material flattener, attached to the moveable sealing device, so as to pre-flatten one or more vials below a sealing area to facilitate sealing the at least one of the vials in order to create a reliable seal without damaging the vial;  
 an unloading station mounted at a third position with respect to the conveyor system for removing filled and sealed vials from vial fixture; and  
   a control system electrically coupled to one or more of the stations and to a motor for positioning the conveyor system in order to control the movement of the vial fixtures between the plurality of stations.    
     
     
         19 . The apparatus of  claim 18 , wherein the unloading station is positioned at an elevation lower than a top surface of the conveyor system so that at least one of the vials fall out of the fixture due to gravity.  
     
     
         20 . The apparatus of  claim 18 , wherein the moveable sealing device comprises at least one of a stack, anvil and flattener  
     
     
         21 . The apparatus of  claim 18 , wherein the opposing respective device comprises at least one of a stack, anvil and flattener  
     
     
         22 . The apparatus of  claim 18 , wherein at least one of the stations is operated manually.  
     
     
         23 . The apparatus of  claim 18 , wherein the vials are interconnected by strips to form a collection of vials.  
     
     
         24 . The apparatus of  claim 7 , wherein a single generator is electrically connected to a plurality of stacks for sealing the vials, whereby the generator is electrically switched so as to sequentially energize each of the plurality of stacks for a predetermined period of time.  
     
     
         25 . The apparatus of  claim 8 , wherein a single generator is electrically connected to a plurality of stacks for sealing the vials, whereby the generator is electrically switched so as to sequentially energize each of the plurality of stacks for a predetermined period of time.  
     
     
         26 . The apparatus of  claim 1 , further comprising an exit slide for receiving the vials, which have been filled and sealed.