GB2141094A

GB2141094A - Apparatus and method for forming capsules

Info

Publication number: GB2141094A
Application number: GB08416174A
Authority: GB
Inventors: Sydney Alexander Chasman
Original assignee: Individual
Current assignee: Individual
Priority date: 1980-11-24
Filing date: 1984-06-25
Publication date: 1984-12-12
Also published as: GB8416176D0; GB2140384A; GB2087829A; GB8416175D0; GB8416174D0; DE3146337A1; GB2141993A; GB2087829B; GB2140384B; GB2141094B; GB2141993B

Abstract

A pair of cylindrical sealing rolls (32) are arranged in nipping relationship for feeding webs (24) of capsule forming material having cavities (26) formed therein along predetermined paths. A wedge member (290) is provided for displacing air from the cavities (26) and substituting therefor an inert gas prior to the cavities (26) being sealed by the rolls (32) so that substantially deaerated capsules are formed. Passages (302, 304) are provided in the wedge member (29) for depositing a material into the cavities (26). <IMAGE>

Description

1 GB 2 141 094A 1

SPECIFICATION

Apparatus and method for forming capsules The present invention relates generally to a method and apparatus for forming capsules containing a measured amount of solid and/or liquid fill material, and more particularly to a method and apparatus for forming cap- sules from webs or sheets of capsule forming material, such as gelatin, as well as to various features of such method ard apparatus, and is divided from our application No. 8132501.

Many products are encapsulated for conve- nience in distribution and use. Among these are medicinal compounds, such as drugs or vitamins, which are commonly encased in gelatin capsules. Capsules are also used when small, accurately determined quantities of ma- terial are to be used in compounding other products, such as for example, small capsules of food coloring for combining with artificial food products to produce a desired color. Such capsules may be filled with either a powdered material or a liquid, or even possibly a combination of such materials.

While a number of prior art arrangements are known for the manufacture and production of gelatin capsules either for pow- dered material or a liquid, such prior art arrangements generally are not readily adaptable for filling of capsules with both powdered material and a liquid. Rather, such prior art arrangements are generally only directed to the utilization of a fill powder or a fill liquid.

For instance, U.S. Patent No. 3,092,942 entitled "Apparatus for Encapsulating" to Chasman is directed to a machine and method for making fluid filled capsules from continu- ous sheets of plastic film. However, the machine disclosed in this patent is not readily adapted to filling the capsules with a dry fill powder. On the other hand, U.S. Patent No. 2,775,084 is directed to an apparatus for filling capsules with a powder material. Again, however, such apparatus is not readily adaptable for filling the capsules with a fluid or liquid.

Generally, in many of the prior art capsule forming apparatus and methods, a pair of plastic webs, for example webs of gelatin material, are fed about a pair of sealing rolls having a series of depressions or recesses formed in the surface thereof. The recesses in each sealing roll may be connected to a suitable source of vacuum for applying a suction to the web when it is laid onto the surface to thereby form a series of cavities or pockets in the surface of the web. The depres- sions or recesses in the sealing rolls are arranged with respect to one another and the sealing rolls driven in unison and synchronized with one another so that as the sealing rolls are rotated in opposite directions, the depressions on one sealing roll register with the depressions on the other sealing roll in the nip of the two rolls. Thus, as the webs are directed toward the nip of the sealing rolls, the pockets or cavities formed in the web travelling on one roll are brought into juxtaposition with the pockets or cavities formed in the other web. That is, as the webs progress through the nip, the portions of the respective webs surrounding each depression are pinched together to essentially create a seal about the pair of juxtaposed pockets or cavities and thereby form a completed capsule. Generally, either a liquid or dry powder material is deposited into one or both of the cavities of the respective webs just prior to the two webs being brought into juxtaposition and sealingly closed.

While a number of such apparatus of this general nature are known, a number of prob- lems have existed with such prior art apparatus, both with respect to the dry fill type apparatus and the liquid fill type apparatus. For example, with conventional powder fill capsule forming apparatus, one problem has been the precise control of the amount of fill material deposited in the capsule, both from the standpoint of initial measurement of the amount as well as from the standpoint of spillage or loss of such material in depositing the fill materials into the capsule halves. For instance, in the apparatus shown in British Patent Specification No. 881,022, entitled "Improvements Relating to Methods and Machines for Forming and Filling Capsules in

Gelating or the Like", there is disclosed an apparatus of the general type described above in which capsule halves are formed from gelatin webs and then brought into juxtaposition and sealed after the placement of a dry fill powder in each cavity half. In this apparatus, there is provided a medicament supply hopper containing a supply of fill powder above each of the sealing rolls. A rotary feed roll is disposed between each supply hopper and its respective sealing roll for receiving a supply of powder from the hopper and depositing same in the capsule halves. The feed roll has at its periphery axial and circumferential rows of chambers which are spaced so as to coincide with the spacing of the cavities on its respective sealing roll. The chambers each include a spring loaded plunger or ejector therewithin which is normally in a retracted position. As the feed roll rotates, the cham- bers which are in alignment with the hopper are supplied with powder or granules of material to be encapsulated. The size of the chamber is designed so that it will receive a desired quantity of material. The filled cham- bers are then rotated within a stationary annular housing which serves to maintain the charge of powder material within the chamber. An opening is provided at the bottom of the annular housing through which the pow- der material in the chamber is deposited into 2 GB 2 141 094A 2 a cavity on the sealing roll when the chamber moves into alignment therewith. A cam mem ber is provided for forcing the plunger out wardly against the spring to ensure that the fill material is ejected from the chamber and into the cavity formed in the web on the sealing roll. As can be appreciated, with such an arrangement, it is most difficult to change or adjust the amount of fill material which is received within each chamber, and further there is a possibility that the chamber will not be completely filled, or that powder or fill material will be lost during the transfer from the feed roll into the cavity since the fill material is only loosely received in the cham bers.

Additionally, as is known in the art, some types of fill materials, especially certain types of liquids, such as vitamins, when exposed to air over a period of time, deteriorate and may 85 become rancid. As can be appreciated, since the cavity halves in each web are open and exposed to the surrounding atmosphere dur ing the filling operation, it has not been possible heretofore to produce capsules hav ing such fill materials with conventional cap sule forming apparatus of the type disclosed unless the entire capsule forming apparatus is operated in an inert atmosphere.

Still further, with some prior art capsule forming apparatus, the gelatin web is formed by depositing molten gelatin onto a rotating casting drum which is at a somewhat cooler temperature to solidify the gelatin and form a web which is then continuously pulled off of the drum. with such prior art arrangements, the gelatin supply box rests directly on the gel forming surface of the casting drum and mol ten gelatin flows onto the drum as it is rotated, the thickness of the layer of gelatin 105 being controlled by a---doctor-blade arranged at the forward end of the gelatin supply box.

Generally, the doctor blade is carried by the gelatin supply box, and its position above the surface of the casting drum, which defines the 110 thickness of the formed gelatin web, is adjust able. Since the gelatin supply box rides on the surface of the casting drum, should a film or very thin layer of gelatin remain on the cast ing drum during operation, the thickness of the formed gelatin web may not be precisely accurate. Furthermore, as the adjustment mechanism for adjusting the position of the doctor blade is on the gelatin supply box itself, there is a possibility of damage_break- 120 age, etc., when the gelatin supply box is cleaned between operations.

Accordingly, in view of the above and other disadvantages, a need exists for improved methods and apparatus for forming capsules, as well as for forming webs for making cap sules.

In accordance with the present invention, there is provided apparatus for making cap sules comprising: feeding means for feeding 130 capsule forming material having a series of cavities formed therein, said capsule forming material forming a portion of the casing of the capsules, and said feeding means including sealing means for sealing said cavities; depositing means for depositing a material in said cavities of said capsule forming material prior to said cavities being sealed by said sealing means; and air displacing means for displacing air from said cavities and substituting therefor an inert gas prior to said cavities being sealed by said sealing means so that substantially deaerated capsules are formed.

Further in accordance with the present in- vention, there is provided a method of making capsules comprising the steps of: feeding capsule forming material having a series of cavities formed therein along a predetermined path, said capsule forming material forming a portion of the casing of the capsules; depositing a material to be encapsulated into said cavities of said capsule forming material as said capsule forming material is moved along said path; displacing air from said cavities and substituting therefor an inert gas as said cap- sule forming material is moved along said predetermined path; and then sealing said cavities in said capsule forming material to form substantially dearated capsules. 95 In order that the invention may be fully understood, it will now be described with reference to the accompanying drawings in which: Figure 1 is a schematic end elevation view of the apparatus in accordance with the present invention; Figure 2 is a side sectional view of a portion of the apparatus shown in Fig. 1 in accordance with the present invention; Figure 3 is an enlarged side elevational view of the portion of the apparatus shown in Fig. 2, illustrating the means for adjusting the thickness of the web being formed; Figure 4 is a sectional view taken along lines 4-4 of Fig. 3; Figure 5 is an enlarged end sectional view of a portion of the apparatus shown in Fig. 1, illustrating the sealing rolls and related apparatus in accordance with the present inven- tion; Figure 6 is a still further enlarged end sectional view of a portion of the sealing rolls and wedge member positioned adjacent the nip of the sealing rolls.

Figure 7 is a plan view of a portion of the surface of one sealing roll.

Figure 8 is an enlarged end sectional view of a portion of the apparatus shown in Fig. 1, illustrating the punch, roll and weight adjust- ment and compaction cam mechanisms for forming compacted slugs in accordance with the- present invention.

Figures 9a and 9b are partial end sectional views illustrating different positions of the weight adjustment and compaction cam mem- W 3 GB 2 141 094A 3 bers.

Figure 10 is a punch roll.

Figure 11 is a partial perspective view of the punch roll.

Figure 12 is an end elevational view of a cam track ring utilized in the punch roll.

Figure 13 is a side elevational view of a pair of cam track rings.

Figure 14 is a schematic illustration of the movement of a punch member as the punch roll is rotated.

Figure 15 is a top plan view df the central portion of the apparatus shown in Fig. 1, with the wedge removed for clarity, illustrating the punch and transfer rolls.

Figure 16 is a schematic side elevational view of the sealing rolls and illustrating the pumping mechanism for depositing liquid fill material into cavities in gelatin webs.

Figure 17 is a schematic end sectional view of the pumping apparatus.

Figure 18 is a plan view of the pumping apparatus.

Referring now to the drawings wherein like reference characters represent like elements, there is shown in Fig. 1 a schematic end elevational view of the apparatus 20 for manufacturing capsules 22 from a a pair of sheets of plastic material 24, such as gelatin. The capsules 22 manufactured with the apparatus 20 of the present invention are completely closed and sealed, and are made from webs 24 having pockets 26 formed therein with fill material deposited.in the pockets 26, a pair of 100 such webs 24 being brought together so that the pockets 26 are juxtaposed to one another and sealed about their periphery. The capsules 22 manufactured in this manner are to be contrasted with capsules which are cornprised of a pair of open ended capsule halves which are assembled one within the other. The apparatus 20 may be used for the manufacture of the capsules 22 filled with either a dry fill powder, or a liquid fill material, or a combination of both powder and liquid if desired.

The basic apparatus 20 include a pair of web casting apparatus 30 for producing a pair of continuous webs or sheets 24 of plastic material, such as webs 24 of soft gelatin, a pair of sealing rolls 32 for forming capsule pockets 26 in the webs 24 and then sealing same after they have been filled with fill material, and filling apparatus 34, 36 for filling the capsule pockets 26 formed in the webs 24 with either a dry fill powder, a liquid fill material or a combination of dry and liquid fill materials. The web casting apparatus 30 includes a pair of web casting drums 38 and a series of rolls or drums 40, 42, 44, 46, 48 about which the cast webs 24 are passed to properly condition and treat the webs 24 before being trained about the sealing rolls 32. The pair of sealing rolls 32 are arranged side sectional view of the in nipping relationship to one another and are adapted to rotate in opposite directions so as to feed the pair of webs or continuous sheets 24 between the nip formed therebetween.

Each of the sealing rolls 32 is provided with a plurality of recesses or depressions 50 arranged on its entire outer surface, and the pair of sealing rolls 32 are driven in unison and synchronized such that the depressions 50 in one roll 32 register with those in the other roll 32 at the nip. As the sheets or webs 24 of gel material are trained about the sealing rolls 32, the sheet material 24 is forced into the depressions 50 in the sealing rolls 32 to form the pockets or cavities 26 in each of the webs 24. As the sheets or webs 24 progress toward the nip of the sealing rolls 32, material to be capsulated is deposited in each of the pockets or cavities 26 by means of appropriate filling apparatus 34, 36, to be described in more detail hereinbelow. The filled pockets 26 are then carried toward the nip between the sealing rolls 32. As the webs 24 pass through the nip, respective pockets 26 in each of the webs 24 are brought into juxtaposition with one another and sealed about the circumference thereof to form a completely enclosed capsule 22 having the fill material contained therewithin. That is, at the nip of the sealing rolls 32, the sealing rolls 32 serve to bring the two webs 24 into contact and to seal the webs 24 about the periphery of the formed pockets 26. Thereafter, as the formed capsules 22 are removed or separated from the pair of webs 24, they are collected, washed and directed to a suitable drying and quality control areas, as is known in the art.

The key aspects or areas with which the present invention is concerned include the formation of the webs 24, and the filling of the cavities 26 formed in the webs 24 with suitable fill material, including both dry fill powder and liquid fill material. Additionally, there are various other features of the appara- tus 20 and method which provide for a more rapid and efficient manufacture of capsules 22.

Turning now to a more detailed description of the apparatus 20, the web forming or casting apparatus 30 will be discussed first. As can be seen in Fig. 1, the pair of web casting apparatus 30 for forming the pair of webs 24 from capsule forming material are identical to one another. Accordingly, only one of such apparatus 30 will be described hereinbelow, it being understood that the apparatus 30 for and manner of producing the other web 24 is essentially the same.

As shown best in Figs. 1-4, each web casting drum 38 includes a central axially extending shaft 52 which has a plurality of radially extending arms 54 supported thereon which are connected at their outer extremities to the inner surface of a cylindrical casting member 56 for supporting the casting mem- 4 GB 2 141 094A 4 ber for rotation about the axis of the shaft 52.

The outer cylindrical surface of the casting member 56 defines the casting surface on which a layer of molten plastic material is to be cast to form a continuous web 24 of capsule forming material. At the opposite axial ends of the casting member 56 there is provided a pair of support rings 58. The support rings 58 are mounted on the shaft 52 and have an inner shoulder 60 thereon on which a lip 62 of the casting member 56 rests and an outer cylindrical surface 64 which is spaced radially inwardly of the outer surface of the casting member 56 (see Fig. 3).

The casting drum 38 is suitably supported from the main frame or base of the apparatus and is driven in suitable time relationship with the rest of the apparatus 20 by suitable mechanical drive mechanisms which may be of a conventional nature.

A molten material supply hopper or box 65 is arranged on top of the casting drum 38 for depositing a layer of capsule forming material onto the surface of the casting member 56 to thereby cast a continuous web 24 of capsule forming material. The capsule forming ma terial may for example comprise a gelatin material which is generally acceptable for cap sules to be taken internally. The specific gela tin material to be used may vary depending upon the types of materials to be encapsu lated, as well as its conditions of use. Gener ally, such gelatin materials are characterized by their strength, which corresponds to the weight the gelatin material will support at a given temperature, and the amount of water and other plasticizers or materials that may be used in forming the gelatin material. For example, one typical type of gel comprises a " 150" gel strength gelatin which for example may comprise a mixture of 40% of commer cial gelatin with the remaining constituents comprising glycerine (as plasticizer) and water, together with flavoring and coloring material as may be desired. Of course, for capsules for other uses, such as marketing chemicals for specific applications, other types of plastic materials may be utilized. These other ma terials being selected according to the material to be encapsulated and its conditions of use, as is well known in the art.

The molten gelatin, or other capsule form ing material, is initially prepared and then fed into the gelatin supply hopper 66 from a suitable source of supply which serves to 120 maintain a reasonably uniform level of molten gelatin therein. The molten gelatin may for example be supplied at a temperature of about 140F. The supply hopper 66 is de signed to maintain the gelatin in its molten state. For this purpose, it is preferred that the hopper 66 be equipped with a plurality of fluid passageways 68 in the walls thereof through which a heated fluid, such as water, may be circulated in order to maintain the proper temperature of the molten gelatin mass to ensure that it remains in a molten state in the supply hopper 66 (see Fig. 4).

The supply hopper 66 is suitably supported relative to the cylindrical surface of the casting drum 38 so that the molten gelatin therein continuously flows through a longitudinally extending opening 70 at the lower end thereof onto the web forming surface of the casting drum 38. More particularly, a deflecting blade 72 is provided along the bottom edge of the gelatin supply hopper 66 adjacent one side of the longitudinal opening 70 for deflecting molten gel onto the surface of the casting drum 38. A doctor blade 74 is fixedly positioned to the gelatin supply hopper 66 at its lower end adjacent the opposite side of the longitudinal opening 70 so as to extend downwardly beyond the lower edge of the gelatin supply hopper 66. As will be appreciated, the spacing between the lower edge of the doctor blade 74 and the surface of the casting drum 38 will define the thickness of the gelatin layer deposited onto the casting drum 38 as the drum 38 rotates. As is well known in the art, the molten gelatin substantially immediately solidifies or gels as it is deposited onto the relatively cool surface of the casting drum 38. In this regard, the room temperature for the apparatus 20 is typically approximately 60'F and the casting drum 38 is maintained at approximately 68F by the circulation of air through the substantially hollow interior thereof. For this purpose, the support rings 58 at the axial ends of the casting member 56 have suitable openings 76 therethrough.

In order to precisely control the thickness of the formed gelatin web 24 within desired ranges, in accordance with one aspect of the present invention, the gelatin supply hopper 66 is supported on a support bar 78 which extends across the width of the casting drum - 38 and which is supported at its ends by suitable ddjustment mechanisms 80. These adjustment mechanisms 80 control the height of the gelatin supply hopper 66 relative to the gelatin forming surface of the casting drum 38. More particularly, the gelatin supply hop- per 66 has a U-shaped bracket 82 secured on its rear surface by means of suitable bolts or fasteners 84. The support bar 78 which extends across the width of the casting drum 38 is adapted to be received within the U- shaped recess of the bracket 82. At each end, the lower surface 86 of the support bar 78 is inclined downwardly toward the center of the bar, as can best be seen in Fig. 2. The support bar 78 is supported at each end by an adjustable roller member 88 which is movable toward and away from the center of the bar 78 and on which the inclined surface 86 of the bar 78 rests. It will be appreciated that the elevation of each end of the support bar 78 is controlled by the position of the roller GB 2 141 094A 5 member 88 relative to the end of the support bar 78. That is, the farther inwardly the roller member 88 is positioned, the higher the ele vation of the end of the support bar 78; conversely, the farther the roller member 88 70 is positioned outwardly toward the end of the support bar 78, the lower the elevation of the end of the support bar 78.

The roller members 88 are supported at the opposite ends of the casting drum 38 by bracket members 90 which are pivotally mounted to pivot about a pivot pin 92 se cured to the main frame structure for the overall apparatus 20. As can best be seen in Fig. 4, the pivot pin 92 for the bracket members 90 is spaced away from the surface of the casting drum 38. Each of the bracket members 90 has a support roller.94 jour nailed therein which is adapted to ride along the outer shoulder or cylindrical surface 64 of the pair of support rings 58 as the casting drum 38 rotates. As noted hereinabove, the cylindrical surfaces 64 are each concentric with the gel forming surface of the casting member 56, but are spaced axially therefrom at the opposite ends of the casting member 56. Thus, it will be appreciated that the position of the bracket members 90 will re main in fixed relationship with respect to the gel forming surface of the casting drum 38 as the casting drum 38 rotates about its axis.

Each bracket member 90 includes a support ledge 96 on which a slidable block member 98 is supported for sliding movement toward and away from the center of the casting drum 38 (see Fig. 3). Each of the slidable support blocks 98 of the bracket members 90 carries one of the roller members 88 for supporting the ends of the support bar 78, as best seen in Figs. 2 and 3. In order to adjust the 105 position of the block member 98 on the support ledge 96 of the bracket 90, the block member 98 includes a recess 102 in the end thereof facing the side wall of the bracket 90 which has a threaded bushing 100 therein.

On the opposite of the side wall of the bracket there is provided a dial 104 having a threaded shaft 106 which extends through the side wall and is received in the threaded bushing 100 in the slidable block member 98. The threaded shaft 106 may preferably comprise a fine pitch micrometer thread or screw, which for example is capable of adjust ing the position of the block member 98 in increments of.0005 inch.

Thus, it will be appreciated that rotation of the dial 104 will cause the slidable block member 98 to slide towards or away from the bracket member 90, i.e., from right to left, or vice versa; as shown in Fig. 3, depending 125 upon the rotation of the threaded shaft 106, to thereby adjust the position of the roller member 88 carried thereby relative to the end of the support bar 78. Since the elevation of the support roller 94 remains in fixed relation- 130 ship to the surface of the casting drum 38, adjustment of the position of the roller member 88 is used to adjust and control the postion of the support bar 78 and th6s the position of the gelatin supply hopper 66 relative to the casting surface of the casting drum 38. More particularly, if each slidable block member 96 is moved inwardly away from its bracket member 90, the support bar 78 and gelatin supply hopper 66 will be raised, whereas if the block members 96 are moved outwardly toward their respective bracket members 90, the support bar 78 and gelatin supply hopper 66 will be lowered. This adjust- ment of the position of the gelatin supply hopper 66 in turn adjusts the position of the doctor blade 74 affixed to the gelatin supply hopper 66. It will thus be appreciated that a very precise and finely controlled adjustment of the position of the doctor blade 74 may be made with the disclosed apparatus 30. Additionally, it is possible to independently control the elevation of the ends of the support bar 78 to compensate for thin or thick areas of molten gelatin laid down on the casting drum 38 so that a substantially uniform thickness web 24 is produced.

It should be appreciated that the disclosed apparatus 30 for casting gelatin webs 24 is not subject to the disadvantages of the prior art since the gelatin supply hopper 66 and doctor blade 74 are supported so as to ride on support surfaces 64 which are spaced from the gel forming surface, and not on the gel forming surface itself. Specifically, the doctor blade 74 is fixedly positioned in the gelatin supply hopper 66 and the position of the gelatin supply hopper 66 is controlled with respect to the circumferential surfaces 64 on the ring members 58 which are axially spaced from the casting surface and concentric thereto. Thus, control of the position of the doctor blade 74 is completely independent of any films which may be formed on the casting surface. Additionally, the adjustment of the thickness of the gelatin webs 24 does not involve adjustment of the position of the doctor blade 74 relative to the gelatin supply hopper 66. Accordingly, adjustment mecha- nisms 80 will be not subjected to any damage during cleaning of the gelatin supply hopper 66 between different batch runs.

In the preferred embodiment, the casting drums 38 each have a diameter of approxi- mately thirty inches. The width (or axial length) for the casting surface may be any desired dimension, such as for example six inches up to approximately thirty-four inches if desired. It of course will be appreciated that the casting drum 38 can be used for the formation of webs 24 which are narrower than the width of the casting surface by simply controlling the amount of gelatin material deposited thereon. Also, the clearance between the edge of the doctor blade 74 and 6 GB 2 141 094A 6 the gel forming surface on the casting drum 38 may preferably range between.0 12 and.040 inch which will thereby produce a gelatin web 24, after full cooling and dehydration, having a thickness on the order of. 006 and.0 18 inch.

After the molten gelatin is cast onto the casting drum 38 and gels, it isdirected beneath a shroud 108 which overlies the surface of the drum 38 and which has dry cool air flowing in a direction opposite to the direction of movement of the web 24, In other words, with reference to Fig. 1, the casting drum 38 on the left hand side of the figure rotates in a counterclockwise direction to move the gelatin web 24 initially through the left end of the shroud 108 so that it exits from beneath the right hand end of the shroud 108, and the air flow is directed in a clockwise direction about the casting drum 38. This air serves to dehydrate some of the water from the gelatin material and to help cool the molten gelatin so that a desired consistency is achieved.

After passing through the exit end of the shroud 108, the gelatin web 24 is directed to a printing /coating station 110. The printing/coating staion 110 may be utilized for the printing of trade names, lot numbers or the like on the web 24 at the proper locations corresponding to the portions of the web 24 which will be used for the formation of capsules. Alternatively, or in addition to printing, the printing /coating station 110 may serve to coat a material on the inside of the gelatin web 24, such as for example an eatable shellac. This may be preferable in order to prevent breakdown of any powder fill material which is placed within the capsule. For instance, many types of powder fill material are subject to deterioration upon exposure to moisture. Since the gelatin webs 24, before dehydration, do hold a percentage of water, in order to prevent the moisture in the gelatin webs 24 from contacting the fill material, it is preferable to coat the inside surface of the web 24 with a suitable material to prevent such contact. This material may be applied at the printing/ coating station 110.

The printing /coating station 110 may comprise an idler roller 40 about which the gelatin 115 web 24 is trained and a printing /coating applicator 112, such as for example a trough having ink or coating liquid therein and a series of applicator rollers. After passing about the idler roller 40, the web is directed onto a secondary processing drum 42 which is similar to the casting drum 38. The secondary processing drum 42 includes an outer sleeve 114 having a solid outer cylindrical surface, the sleeve 114 being supported for rotation from a central shaft 116 by means of radially extending arms 118. Also, end ring members 120 are provided having openings 122 therethrough similar to ring members 58 for the casting drum 38. In the preferred embodi- ment, the secondary processing drum 42 is approximately thirty inches in diameter and has a main support surface which corresponds to the width for the casting drums 38. With such an arrangement, cool air may pass beneath the surface of the drum 42 to maintain the temperature of the drum 42 as desired so that the web 24 will remain at a proper consistency for subsequent formation. The secondary processing drum 42 also has a shroud 124 so that conditioned air may again be passed over the web 24 in a direction opposite to the direction of movement of the web to further dry and condition the gelatin web 24. In this regard, it is expected that further percentage of the water in the gelatin web 24 is driven off this location, for example an additional 12%.

Preferably, the secondary processing drum 42 is driven at a speed which is approximately 10% greater than the speed at which the casting drum 38 rotates in order to stretch the gelatin web 24 slightly in passing from the casting drum 38 to the secondary process- ing drum 42. Stretching of the web 24 slightly is desired at some time before the capsules 22 are formed in order to take up slack during the drying and also to allow the gelatin material to shrink about the fill ma- terial. If the web 24 is coated at the printing/coating station 110 with a coating which is not elastic, stretching of the web 24 after the coating dries might cause cracking or deterioration of the web 24. Therefore, it is preferable to stretch the web 24 slightly before any coating thereon dries.

After passing around the secondary processing drum 42, the gelatin web 24 is directed to a web oiling station 126 at which a lubri- cant or oil is applied to both surfaces of the web 24. In the preferred embodiment, the oiling station 126 includes a guide roller 44 which directs the web 24 downwardly to a first oiler roller 46. This oiler roller 46 may have a felt outer surface to which oil or other lubricant is applied through the main shaft thereof to thereby apply a coating of oil to one surface of the web 24 as the web 24 passes thereabout. A second oiler roller 48 for coating of the other side of the web 24, similar to the first oiler roller 46, is provided downstream of the first oiler roller 46. The lubricant may for example comprise a vegetable oil, and is particularly important for forma- tion of capsules 22 having liquid fill material therein. Oiling of the web 24 may also be desired in certain instances with respect to capsules having dry fill powder therein.

After passing from the last oiling roller 48, each web 24 is directed about a guide roller 128 onto the main sealing rolls 32. The pair of sealing rolls 32, which are each identical to one another, are arranged in a nipping relationship and adapted to rotate in opposite directions, so that the webs 24 will be di- 7 GB 2 141 094A 7 rected therethrough. As seen in Fig. 5, each sealing roll 32 comprises a stationary central core member 130 and an outer annular sleeve member 132 adapted to rotate with respect to the central core member 130, the outer annular sleeve member 132 being driven by appropriate drive mechanisms and synchronized so as to be driven at a speed such that the gelatin webs 24 are not stretched or slack- ened in passing from the secondary processing drums 42 in the sealing roll 32. In this regard, the sealing rolls 32 in the preferred embodiment are each approximately ten inches in diameter and thus are driven at approximately three times the speed of rotation of the secondary processing drums 42. Also, the sealing rolls 32 are of a width corresponding to the width of the casting and secondary processing drums 38, 42.

Each annular sleeve member 132 has an outer surface which includes a series of de pressions or recesses 50 therein for the forma tion of cavities or pockets 26 in the webs 24 to thereby define capsules halves. As can best be seen in Figs. 5, 6 and 7, in the preferred embodiment, each of the depressions 50 is generally of an oblong shape (see Fig. 7) and is substantially rectangular in cross section (see Fig. 6). The series of depressions 50 on the surface of each sealing roll 32 are ar- 95 ranged in rows 134 extending along the axial length of the roll 32, with the series of rows progressing about the circumference of the sealing roll 132 (see Fig. 7). The depressions or recesses 50 of adjacent rows are offset with respect to one another, i.e., the one row I 34A along the length of the sealing roll 32 has one arrangement of depressions 50A which correspond with and are in axial alignment with the depressions of the third row 1 34A, shown in Fig. 7, whereas the depressions 50B of the second row, shown in Fig. 7, are shifted along the axial length of the sealing roll 32 approximately one-half the distance between the centers of the adjacent depressions 50A so that the center of the depressions 50B in the second row 1 34B are intermediate the depressions 50A in the first and third rows 1 34A. For simplicity purposes, the depressions 50A of the first and third rows 1 34A will be referred to as the "A" series or pattern of depressions 50A, and the depressions 50B in the adjacent rows 1 34B as the "B" series or pattern of depressions 50B. It will be appreciated that the number of 120 recesses 50A in each row 1 34A of the A series will be one greater than the number of depressions 50B in each row 1 34B of the B series. In the preferred embodiment, for example, the number of capsule defining recesses 50A in each row 1 34A of the A series is 33 and the number in each row 1 34B of the B series is 32.

In this regard, each of the capsule forming depressions or recesses 50 in the surface of the sealing roll 32 is defined by a land or shoulder 51 which extends outwardly from the bottom of the recessed area 50. Additionally, between each of the main capsule form- ing recesses 50, the surface of the roll 32 includes additional relieved areas or sections 136 which are shaped so as to define a series of triangularly shaped lands 138 between the shoulders 51 defining the cavity forming re- cesses 50 (see Fig. 7). These lands 138 aid in holding the gel webs 24 to prevent sliding or slippage thereof relative to the sealing roll 32 as a result of the lubricating oil which is applied to both sides of the gelatin web 24.

As can best be seen in Fig. 7, these lands 138 are located between the rows 134 of recesses or cavities 50 with one triangular tip thereof extending slightly between adjacent recesses 50 in each row 134.

Each of the recesses 50 in the surface of the rotatable sleeve 132 includes a radially extending passageway 140 which extends from the bottom surface of the recess 50 to the inner cylindrical surface of the sleeve member 132. The core member 130 of the sealing roll 32 in turn has a pair of circumfer ential recessed areas 142, 144 which are spaced radially inwardly from the inner sur face of the rotating sleeve member 132 and which extend about respective portions of the circumference of the core member 130. These circumferential recess areas 142, 144 extend substantially the entire axial length of the core member 130 and are closed or sealed at their ends. One of the circumferential recesses 142 communicates through a port 146 with a source of vacuum or reduced pressure, which vacuum or reduced pressure is in turn applied through the radial passageways 140 to the bottom of each of the recesses 50 when such passageways 140 are in communication with the circumferential recess 142. The other circumferential recess 144 communicates through a port 148 with a source of air pressure which is communicated to the bottom of the recesses 50 when the radial passageways 140 thereof are in communication with this circumferential recess 144. The pair of circumferential recesses 142, 144 are maintained separate from one another by virtue of the circumferential raised sealing surfaces 150, 152 on the core member 130 which serves to seal against the inner cylindri cal surface of the rotating sleeve member 132. As will be appreciated, as the sleeve member 132 of the sealing roll 32 rotates about the core member 130, different radial passageways 140 come into communication, respectively, with the vacuum in the circumferential recess 142 and with the pressurized air in the circumferential recess 144, and remain in communication therewith until suc passageways 140 move past the raised surfaces 150, 152, respectively.

One side of the circumferential recess 142 8 communicating with the source of vacuum is located adjacent to circumferential location that the gelatin web 24 comes into contact with the sleeve member 132. As the gelatin web 24 contacts and covers the raised shoulders or lands 51 about the recesses 50, the source of vacuum communicating with thebottoms of the recesses 50 serves to stretch or pull portions of the web 24 downwardly within the recesses 50 and form a series of pockets 26 thereon, one pocket 26 in each recess 50. As best seen in Fig. 6, each pocket 26 formed in the surface of the web 24 is substantially semi-circular in cross-section. These pockets 26 formed in the web 24 serve 80 as cavities for receipt of fill material which is deposited therein as the web 24 is moved about the sealing roll 32, and as will be described more fully hereinbelow.

The vacuum in the recess 142 is continuously applied to the recesses 50 to hold the pockets 26 in place as the sealing roll 32 rotates until the radial passageway 140 for particular recesses 50 rotate past the raised surface or section 150 which is adjacent the nip of a pair of sealing rolls 32. Specifically, as each row 134 of recesses 50 approaches the nip, their radial passageways 140 are closed off by the surface 150 on the core member 130. Subsequently, as the sealing rolls 32 continue to rotate, the respective passageways 140 are brought into communication with the circumferential recess 144 communicating with the source of pressurized air. This occurs just after the corresponding row 134 of recesses 50 has passed through the nip. The pressurized air serves to force the portions of the web 24 in the recesses 50 thereoutof. The passageways 140 remain in communication with the recess 144 and subjected to air pressure until they pass the raised surface 152 on the core member 130, and thereafter the passageways 140 again communicate with the source of vacuum in recess 142 to pull or stretch a new portion of the web 24 downwardly into the recesses 50.

The series of recesses 50 or depressions on each of the sealing rolls 32 are arranged on the surfaces thereof, and the sealing rolls 32 rotated in unison and synchronized so that the recesses 50 on one of the sealing rolls 32 are brought into juxtaposition and aligned with respective recesses 50 on the other sealing roll at the nip of the sealing rolls 32. That is, for example, an A series of recesses 50A on the sealing roll 32 are precisely aligned with a corresponding A series of recesses 50A on the other sealing roll 32 at the nip, and thereafter, as the sealing rolls 32 are continued to be rotated, respective B series of recesses 50B on the sealing rolls 32 are brought into juxtaposition and aligned at the nip, and so on. Accordingly, as pockets 26 are formed in the pair of gelatin webs 24 at the locations of the recesses 50 on the surface of the sealing GB 2 141 094A 8 rolls 32, the pockets 26 in the respective webs 24 are also brought into juxtaposition and alignment at the nip between the rolls 32. At the nip between the sealing rolls 32, the shoulders or lands 51 surrounding each recess 50 of the respective sealing rolls 32 press against one another to thereby seal the gelatin webs 24 together about the circumference of each of the pockets 26. In other words, at the nip, the pair of gelatin webs 24 are fused together about each of the respective pockets 26.

As more fully described hereinbelow, after creation of the pockets 26 but before the pockets 26 are advanced to the nip, a suitable fill material is deposited in each pocket 26. Thus, when the pockets 26 are advanced through the nip and sealed, they are sealed with the fill material therein to thus form completed capsules 22. Also, as will be more fully described hereinbelow, the temperature of the portions of the pair of webs 24 is preferably elevated slightly just prior to the portions being rhoved into the nip so that the webs 24 will effectively be sealed about the pockets 26 in each web 24 by the action of the lands or shoulders 51 on the sealing rolls 32 pressing against one another. Still further, as noted above, the sealing rolls 32 are preferably each ten inches in diameter. This size is advantageous in allowing for a longer dwell time at the point of sealing, thereby ensuring that effective seals are created. The formed capsules 22 after passing through the nip fall out into troughs located therebelow as the sealing rolls 32 continue to rotate and the web sections 24 move downwardly. Any formed capsules 22 that may be loosely held in the web section 24 are removed therefrom by means of rotating paddles 156.

The apparatus 20 is operative to deposit either a solid or dry powder fill material into the pockets 26 in the webs 24 as they move along on the sealing rolls 32, or a liquid fill material, 'or both a solid and liquid fill material, depending upon the end use of the capsules 22. If dry fill powder is to be deposited, the apparatus 20 includes means 34 for forming compacted slugs of a precisely pre- determined quantity and depositing them in each of the pockets 26 as the webs 24 pass about the sealing rolls 32. If a liquid fill material is to be deposited, the apparatus includes means 36 for depositing a precise quantity of liquid fill material in each of the pockets 26 just prior to the pockets 26 being brought into juxtaposition at the nip of the sealing rolls 32. Both of these means 34, 36 for depositing a dry fill powder and liquid fill material are operative independently of one another so that both dry fill powder and liquid fill material may be deposited in each of the pockets 26 if desired.

The dry powder fill apparatus 34 is shown more particularly with reference to Figs. 5, 8, 9 GB 2 141 094A 9 9a, 9b, 10 and 11 and comprises generally a dry powder supply hopper 160 containing a supply of dry fill powder, a punch roll 162 for precisely measuring out a predetermined quantity or charge of dry powder and for 70 compacting the dry fill powder into com pacted slugs 164, and a transfer roll 166 for transferring the compacted slugs 164 from the punch roll 162 and depositing them into the cavities or pockets 26 formed in the 75 gelatin web 24 passing about the sealing rolls 32. Such a dry fill powder apparatus 34 is provided for each of the sealing rolls 32 in accordance with the present invention, and thus only one such apparatus 34 will be described.

Also, as noted above, a number of cavities or pockets 26 are provided in each row in the web 24 along the axial length of the sealing rolls 32. The punch and transfer rolls 162, 166 in accordance with the present invention serves to deposit a compacted slug 164 of dry fill material into each pocket 26 in each row along the axial length, as well as to deposit slugs 164 of compacted fill material into pockets 26 in each row arranged about the circumference of the sealing rolls 32. However, for simplicity of description, the basic apparatus 34 will generally be described with reference to simply depositing a single or series of compacted slugs 164 into one or a series of cavities located at.one axial position on the gelatin web 24, it being realized that a plurality of similar components are provided along the axial length of the punch and transfer rolls 162, 166 so that a plurality of compacted slugs 164 are substantially simultaneously deposited in each of the pockets 26 provided in each row. Also, although only four stations will be shown about the circumference of each of the punch rolls 162 and two stations about the circumference of each transfer roll 166, it will be appreciated that the number of stations could be greater or less, depending on the speed of rotation of the various rolls 162 166, in order to ensure that as each pocket 6 is moved past the transfer roll 166, a compacted slug 164 of dry fill material will be deposited thereinto.

As best seen in Figs. 1 and 5, the transfer roll 166 is mounted for rotation directly above its respective sealing roll 32 so that the axes of rotation are vertically aligned, and the punch roll 162 is mounted for rotation laterally to one side of its respective transfer roll 166 so that the axes of rotation thereof are horizontally aligned. The supply hopper 160 is supported vertically above its respective punch roll 162. In essence, the powder supply hopper 160 sits on the surface of the punch roll 162 and has suitable side walls 168 and end walls (not shown) for maintaining a supply of dry fill powder therein. Flexible sealing members 170, 172 are provided at the lower ends of the side walls 168 for engaging the surface of the punch roll 162 to maintain the supply of dry fill powder within the hopper 160. As best seen in Fig. 8, the fill powder covers that portion of the surface of the punch roll 162 which is located between the side walls 168 within the hopper 160. The hopper 160 also includes a rotatable paddle 174 for agitating the powder to provide fine granules or a powder to facilitate filling chambers 180 in the punch roll 162.

The punch roll 162 includes a stationary cylindrical core member 182 and a rotatable annular outer housing 184 comprised of an outer ring member 1 84a and an inner annular ring member 184b. The outer ring member 1 84a includes a plurality of radially extending apertures 186 therein about the circumference and along the axial length thereof. Each of these openings 186 has a die member 188 mounted therein. The die members 188 each have radially extending openings therethrough which define charging chambers 180 for receiving a charge of fill powder. The die members 188 may be removed and replaced with different die members to change the configuration of the chamber opening, if desired. The inner annular ring member 184b, which is secured to the outer annular member 1 84a so as to rotate therewith, also has a plurality of radially extending openings 187 therein aligned with the openings 186 in the outer ring member 184a. A plurality of punch members 190 housed in bushings 192 are mounted within each of the radially extending openings 187. Each of the punch members 190 is slidable radially within its respective bushings 192, and includes a punch head 194 which is slidably received within the chamber opening 180 of its respective die member 188. The punch head 194 includes an end which is shaped to correspond in shape to the die cavity or pocket 26 formed in the gelatin web 24, i.e., semi-circular in cross section and of an oblong nature in the pre- ferred embodiment.

The number of punch members 190 and corresponding die members 188 provided about the circumference of the punch roll 162 may vary depending on the anticipated speed of rotation of the punch roll 162 with respect to the rotational speed of the sealing roll 32, as explained more fully hereinbelow. In the preferred embodiment, four such punch members 190 are shown at each axial location of the punch roll 162. In this regard, it will be recalled that the pockets 26 are formed in the webs 24 in rows which extend across the width of the web 24 (i.e., along the axial length of the sealing roll 32, see Fig. 7), and also that the arrangement of the pockets 26 (as a result of the recesses 50 in each roll 32) is offset for alternating rows. As the punch rolls 162 are operative to produce a compacted slug 164 of dry fill material for each pocket 26, punch members 190 and die GB 2 141 094A 10 members 188 are provided along the axial length of the punch roll 162 corresponding to the number and location of the pockets 26 formed in the rows of pockets 26 in the web 24, as also will be explained more fully hereinbelow with reference to Fig. 11. For the time being, it simply should be noted that a plurality of punch and die members 190, 188 are provided about the circumference and along the axial length of the punch roll 162.

The radially innermost end of the punch member 190 includes a cam head 196 thereon which is adapted to ride within a cam track 198 stationarily fixed with respect to the core member 182 as the inner and outer ring members 1 84a, 1 84b are rotated thereabout. The cam track 198 for the punch members 190 serves to guide the punch members 190 for movement in a radial direction as the punch roll 162 rotates about the central core member 182, according to a desired pattern of movement to be described more fully hereinbelow. Along a portion of the circumference, the cam track 188 is open and does not serve to control the precise positioning of the punch members 190 as the punch members 190 move therepast. Rather, at this location, the positioning of the punch member 190 is controlled by a weight adjusting cam member 200 and a compaction adjustment cam member 202. These two cam members 200, 202 extend along the axial length of the core member 182 and their position may be changed or adjusted to provide for a different amount of material to be recieved within each chamber 180 and to provide for different compaction force to be applied to produce a compacted slug 164.

More particularly, the stationary core mem- ber 182 is generally of a cylindrical shape and has a U-shaped recess 204 cut through one side thereof for receipt of the weight adjustment cam member 200 and compaction cam member 202. Each of these cam members 200, 202 comprise a longitudinally ezxtending member which is supported for sliding movement into and out of the recessed 204 of the central core 182. Each cam member 200, 202 also includes a hollowed out cylin- drical recess 206, 208 area which is adapted to receive a rotatable shaft 210, 212 which has a plurality of eccentrically mounted discs 214, 216 thereon (see Figs. 8 and 10). A series of pockets 220 are provided beneath each of the cam members 200, 202 at the locations of the eccentric discs 214, 216 for receipt of spring devices 218, such as bevel springs. In this manner, the springs 218 force the cam members 200, 202 in a direction out of the U-shaped recess 204 so that the lower surfaces of the circular recesses 206, 208 will be in engagement with the eccentrically mounted discs 214, 216 on the shafts 210, 212. Thus, depending upon the rotational position of the eccentrically mounted discs 214, 216, the cam members 200, 202 may be moved between a fully retracted position (such as shown in Fig. 9a) in which the axis of rotation of the shafts 210, 212 are located at a maximum from the portion of the sur- faces of the cylindrical recesses 206, 208 which are adjacent the springs 218, or a fully extended position (as shown in Fig. 9b) in which the distance from the axis of rotation to the portion of the surfaces of the circular recesses 206, 208 which are adjacent the springs 218 is a minimum. Of course, each cam member 200, 202 may be adjusted independently of the other.

As best seen in Fig. 10, the shafts 210, 212 to which the eccentric discs 214, 216 are mounted extend axially outwardly beyond the forward end of the punch roll 162. In this regard, it will thus be appreciated that it is possible to adjust the weight of the compacted slugs 164 of fill material as well as the compaction force while the machine is in operation by simply rotating the shafts 210, 212 to rotate the eccentric discs 214, 216 to in turn adjust the position of the weight adjust cam member 200 and the compaction cam member 202. This feature of adjustability during the machine operation is most important since measurements of the desired weight of the material during operation can be utilized to correct for any deviations which are detected.

While the cam head 196 of each punch member 190 is confined within the cam track 198, the movements of the punch member 190 along the predetermined path is basically the same irrespective of the amount of material received in the chamber 180 and/or the compaction force applied. However, as the camming head 196 leaves the cam track 198 at the open section 222 (see Fig. 8), the position of the punch member 190 is controlled by the camming surface of the weight adjusting cam member 200 as the inner and outer ring members 184a, 184b continue to rotate. After the camming head 196 moves past the weight adjustment cam member 200, its positioned is then controlled by the camming surface of the compaction cam member 202 whose position is also variable to provide for a different compaction force to be applied. Upon leaving the compaction cam member 202, the camming head 196 is again directed into the camming track 198 which controls movement of the punch members 190 upon continued rotation of the inner and outer ring members 184a, 184b.

The cam tracks 198 for the various punch members 190 comprise a pair of cam track halves 232 which are adapted to be slid over the central core member 182 and locked against rotational movement by means of a key block 234 extending axially along the core member 182 (see Fig. 8). Each cam half member 232 has grooved surfaces 236 on GB 2 141 094A 11 one of the side faces thereof so that a respective pair of cam track halves 232 define the desired cam track 198 for the cam heads 196 of the punch members 190 (see Fig. 13). A portion of the grooved surface 236 of each cam track half 232 is removed at the circumferential position corresponding to the weight adjustment and compaction cam members 200, 202 to define an open section 222 for the punch members 190 to drop into engagement with the weight adjust and compaction cam members 200, 202.This open section 222 is also advantageous for changing punch members 190, bushings 192, die members 188, etc., to provide for different slug shapes and sizes.

The cam track halves 232 are so dimensioned that they may be stacked in side by side relationship on the central core member 182 with the mating surfaces for each cam track half 232 of a respective pair being aligned with the axis of the corresponding punch members 190 whose cam heads 196 are received in the cam track 198 defined thereby. In this regard, the punch members 190 are axially spaced along the punch roll 162 so as to correspond to one-half the spacing between the centers of the adjacent recesses 50 in a row 134 of recesses 50 on the sealing roll 32. That is, the centerline of axially adjacent punch members 190 corresponds to the axial spacing between the center of an A series recess 50A and the center of an adjacent B series recess 50B, i.e., the spacing between the centerline 240, 242 on Fig. 7. Here, it should be noted that the axially adjacent rows of punch members 190 and die members 188 on the punch roll 162 serve different rows 134 of recesses 50 in the sealing roll 32. It is also to be noted that the punch members 190 and die members 188A serving the A series of recesses 50A are circumferentially offset from the punch members 190 and die members 1 88B serving the B series of recesses 50. For four punch members 190 arranged circumferentially about the punch roll 162 at each axial location on the punch roll 162, the circumferential or angular offset for axially adjacent punch members 190 is 45', i.e., the punch members 190 and die members 1 88B for the B series recess are each positioned 45 about the circumference of the punch roll 162 from the punch members 190 and die members 188A for the A series recesses 50A. (This is shown best in the perspective view of Fig. 11.) Here, it will be noted that the spacing between the centerlines 246 and 248 on Fig. 11 correspond to the spacing between the centerline 240, 242 on Fig. 7, and also the spacing between the centerlines 246 and 250 on Fig. 11 correspond to the spacing between the centerlines 240 and 244 in Fig. 7.

The stationary core member 182, as best opposite axial ends between a rear wall 224 and a forward support bar 226. The stationary core member 182 has suitable bearings 225 disposed on its opposite ends for sup- porting the inner and outer cylindrical ring members 184a, 184b for rotational movement relative thereto. The inner and outer ring members 1 84a, 1 84b are centrally supported about the central core member 182 and spaced by means of axial end rings or sleeves 228 provided at the opposite ends. In this position, the various die members 188, punch members 190, and openings in each of the rings 184a, 184b are aligned with one another.

The cam track halves 232 are maintained in axial position relative to the rotatable cylindrical rings 184a, 184b by means of spacer blocks or rings 252 provided at the opposite ends, and the axial end sleeves 228 which are pin connected to the rotatable inner and outer ring members 184a, 184b. Mounted to these end block sleeves 228 are respective sleeve members 230 which are connected to an appropriate drive mechanism for rotating the inner and outer ring members 1 84a, 1 84b about the stationary central core 182, as best seen in Fig. 10. The bearings 227 are provided for permitting the end sleeve mem- bers 230 to rotate between the rear wall 224 and front support bar 226.

The specific pattern of movement of the punch member 190 is shown in Fig. 14. When a punch member 190 is at the zero degree reference position, the punch member 190 and thus the die member 188 have just entered the supply hopper 160. The punch member 190 is in a fully retracted position, and thus a supply or charge of dry fill powder is received in the die chamber 180. The amount of material received is greater than the desired predetermined charge to be deposited in a pocket 26 in the web 24. At this lowest or most retracted position, the end of the punch head 194 is still within the die opening 180, i.e., the edge of the punch head 194 never clears the lower radially innermost edge of the die member 188.

The inner and outer ring members 184a, 1 84b continue to rotate and as the punch member 190 moves past the 30' position, the camming head 196 leaves the camming track 198 and engages the cam surface of the weight adjust cam member 200. At this posi- tion, the punch member 190 is still in a retracted position such that the quantity of fill powder within the die chamber 180 is greater than the amount of fill powder for the desired predetermined charge. As the punch roll 162 continues to rotate, the camming head 196 is forced upwardly by the cam surface of the weight adjustment cam member 200 until it reaches an approximate maximum extension which corresponds to a charge within the 6 5 seen in Fig. 10, is stationarily supported at its 130 chamber 180 which is equivalent to the de- 12 GB 2 141 094A 12 sired predetermined quantity of fill powder to be encapsulated. This occurs at approximately the 80-84 position (see Figs. 8 and 14). At about this position, as the inner and outer ring members 1 84a, 1 84b continue to rotate the flexible sealing member 172 on the hopper 160 serves to scrape the excess powder out of the chamber 180.

As the inner and outer ring members 1 84a, 1 84b continue to rotate, at about the 90 position, the open end of the die chamber 180 is closed by a belt member 260 which is trained about vertically spaced drive rollers 262. The belt memler 260 has a width corresponding to the width of the punch roll 162. The belt member 260 follows the contour of the outer surface of the punch roll 162 for approximately 80 of rotation of the punch roll 162, i.e., to about the 170 position. The belt 260 serves to close completely the open ends of the die members 188 to ensure that the powder remains within the chambers 180. As the punch roll 162 rotates from the 90' position, the camming head 196 of the punch member 190 engages the compaction adjust cam member 202 and is forced radially outward to compact the dry fill powder within the chamber 180 against the surface of the belt 260. The maximum amount of compaction occurs at approximately the 135 position where a belt pressure roll 264 is provided. Depending on the position of the compaction adjust camming member 202 relative to the central core member 182, the degree of com- paction can be precisely controlled.

At approximately the 135 position, the camming head again engages the camming track 198 and the punch member 190 retracts slightly as the die member leaves the belt 260 during continued rotation of the punch roll 162. The punch member 190 remains in the same radial position as the punch roll 162 continues to rotate until the punch member 190 approaches the transfer roll 165 which is located at approximately the 315 rotational position. During this rotation of the punch roll 162, the compacted slug 164 of dry fill powder remains at the entrance or edge of the die chamber 180 as a result of it having been tightly compacted thereat. In other words, after the dry powder has been compacted into a slug 164, the punch member 190 may be retracted slightly but the slug 164 remains in position at the die chamber 180 by virtue of its having been tightly compacted thereat.

At the transfer location, the camming yack 198 guides the punch member 190 radially outward to cause the head 194 of the punch member 190 to engage the slug 164 and push the slug 164 from the die chamber 180 at precisely the 315' rotational position. At this position, the transfer roll 166, which has a series of recesses 266 on the surface thereof (see Fig. 5), has been rotated into position so that one of the recesses 266 is in alignment with the die chamber 180 to receive the compacted slug 164 ejected from the punch roll 162. As the punch roll 162 continues to rotate, the cam track 198 guides the punch member 190 toward a retracted position until the 360'/0' position is reached, and the cycle repeated to produce and transfer compacted slugs 164 of a precise predetermined quantity of dry fill powder.

The transfer roll 166 includes a stationary central core member 268 and a rotating annular sleeve member 270 which has the series of cavities or recesses 266 on the surface thereof. Radially extending passageways 272 are provided in communication with each cavity or recess 266 which provide communication with the inner cylindrical surface of the sleeve 270. Portions of the surface of the stationary core 268 have been cut away or recessed to provide a pair of circumferential recesses 274, 276 between the rotating sleeve 270 and the stationary core 268. One of the circumferential recesses 274 extends approximately 270 about the circumference of the stationary core 268 and is connected via a port 278 with a source of vacuum or reduced air pressure. The other recess 276 extends only approximately 15% and is con- nected via a port 280 with a source of pressurized air. The smaller recessed area 276 is directly vertically aligned with the axis of the sealing roll 32.

The transfer roll 166, which in the preferred embodiment is of a smaller dimension than the punch roll 162, is rotated at an appropriate speed so that the series of cavities or recesses 266 provided in the surface thereof are timed to be in juxtaposition with the die chambers 180 on the punch roll 162 so as to receive compacted slugs 164 at the transfer point when the punch member 190 force the slugs 164 radially outward from the punch roll 162. At the approximate transfer position for the trbnsfer of compacted slugs 164 from the punch roll 162 to the transfer roll 162, it will be seen from Fig. 5 that the passageway 272 for the recess 266 in the transfer roll 166 in juxtaposition with the die chamber 180 in the punch roll 162 is in communication with the large circumferential recess 274 which is connected to a source of vacuum or reduced pressure so that the compacted slug 164 is pulled or sucked from the punch roll 162 into the recess 266 in the transfer roll 166. By virtue of the passageway 272 being connected to the source of vacuum, the slugs are "popped" out of the punch roll and into position in the recesses 266 of the transfer roll 166. It will be noted that the recesses 266 in the transfer roll 166 are of a size greater than the size of the slugs 164.

As the sleeve member 270 of the transfer roll 166 continues to rotate about the core -W 13 GB 2 141 094A 13 member 268, the passageway 272 having the slug 164 therein remains in communi cation with the source of vacuum until the passageway 274 moves past the raised sur face 282 and then into communication with 70 the smaller circumferential passageway 276 which is connected to the source of pressur ized air. The pressurized air serves to in es sence---spit-the slug 164 out of the recess 266 in the transfer roll 166 into a cavity or 75 pocket 26 formed in the gelatin web 24 as the web 24 moves on the sealing roll 32. It will be noticed from Fig. 5 that the direction of rotation of the sealing roll 32 corresponds to and is the same direction of rotation as the 80 transfer roll 166 (i.e. , the surfaces of the sealing and transfer rolls 32, 166 move in opposite directions at the nip thereof), and thus a small or slight clearance is provided between the two rolls 32, 166 to prevent rubbing therebetween. The timing of rotation is such that the recesses 266 in the transfer roll 166 are moved into position and a slug 164 ejected from the transfer roll 166 as each new circumferential cavity or pocket 26 90 is moved into position in alignment with the transfer roll 166. In other words, the com pacted slugs 164 are deliverd by the transfer roll 166 at a rate equivalent to the rate that the cavities or pockets 26 in the web 24 move past the transfer roll 166. By appropri ately choosing the speeds of rotation for the transfer roll 166, the punch roll 162 and the sealing roll 32, as well as the dimensions, and in addition, the number of locations provided 100 on the circumference of the transfer roll 166, punch roll 162 and sealing roll 32, it is possible to coordinate the various rolls such that a compacted slug 164 is delivered to each cavity or pocket 26 as the cavity or pocket 26 is moved past the transfer roll 166.

In this regard, in the prefereed embodi ment, the diameters of the sealing rolls 32 and punch rolls 162 are each ten inches, whereas the diameter of the transfer rolls 166 110 is five inches. On the surface of the sealing roll 32, there are provided 96 rows 134 of equally spaced recesses 50-48 rows 1 34A of A series and 48 rows 1 34B of B series.

There are four stations evenly spaced about the circumference on the punch roll 162 at each axial location for the A series of pockets 26 and four stations evenly spaced about the circumference at each axial location for the B series of pockets 26. As the B series of pockets 26 are provided intermediate each row of A series of pockets 26 on the web 24, the stations for the B series are circumferentially spaced between the stations for the A series, i.e., 45' from each A station (see Fig.

11). The punch roll 162 must thus be rotated at twelve times the speed of the sealing roll 32. The transfer roll 166 has two stations at each axial location for the A series of pockets 26 and two stations at each axial location for130 the B series of pockets 26. The reason for this is that the transfer roll is five inches in diameter and thus is one half the size of the punch roll 162. Accordingly, by providing two stations, the circumferential distance between stations on the transfer roll 166 will be equal to the circumferential distance between stations on the punch roll 162. In order to maintain alignment of the recesses 266 in the transfer roll 166 with the die chambers 180 in the punch roll 162, the transfer roll is rotated twice as fast as the punch roll, and thus twenty-four times the speed that the sealing roll rotates.

Between the pair of rotatable sleeve members 1 84a, 1 84b, it will be noted that an annular space 254 is provided. This annular space 254 also communicates with each of the chambers 180 around the punch heads 94. The annular space 254 is connected with a suitable source of air pressure provided through an air passageway 256 in one end of the central core member 182 which thus provides a cooling effect on each of the chambers 180, as well as for keeping excess powder or dust which might be created from contaminating the entire apparatus 20.

In this regard, it is very important to prevent any excess powder from dropping onto the gelatin webs 24 as such powder would prevent the making of good seals as the webs 24 pass through the nip of the sealing rolls 32. This concern is the reason why a transfer roll 166 is utilized together with an air vacuum so that completely clean powder free slugs are delivered onto the gelatin web 24. Further in this regard, the compaction of the fill powder is very important in order to ensure that the entire desired amount of material is delivered in the proper position onto the gelatin web 24. Compaction minimizes the possibility of excess dust or powder which might adversely affect the sealing by failing onto the web 24.

The rear ends of the sealing rolls 32 and transfer rolls 166, as well as the punch rolls 162, are all supported in the relatively substantial rear wall member 224. Also extending from the rear wall 224, as best seen in Fig.

15, are a plurality of locking bars 286 arranged on the opposite lateral sides of the rolls 32, 162, 166 which serves to mount the forward support bar 226 which supports the forward ends of the punch and transfer rolls 162, 166. A second forward support bar (not shown), located at a lower elevation is provided for supporting the forward ends of the sealing rolls 32. At each of the forward ends of the locking bars 286 as well as at the forward ends of the punch rolls 162, transfer rolls 166 and sealing rolls 32, there is provided with hand wheels 288 for tightening of the locking bars 286 and various rolls to thereby maintain a fixed desired axial positioning of the various rolls with respect to one 14 GB 2 141 094A 14 another.

The apparatus 36 for filling the pockets 26 in the webs 24 with liquid fill material utilizes a wedge-shaped head 290 which is supported between the pair of sealing rolls 32 adjacent 70 the nip thereof, as can best be seen in Figs. 5 and 6. More particularly, the wedge member 290 extends longitudinally across the width of the sealing rolls 32 and has a generally trian gular Gross-sectional shape which includes a pair of generally concavely shaped surfaces 292 which are complimentary to the circum ferential surfaces of each of the sealing rolls 32. The concavely shaped surfaces 292 of the wedge member 290 convege toward a tip 80 294 which is adapted to be arranged adjacent to the nip between the pair of sealing rolls 32. The wedge member 290 is suitably supported above the pair of sealing rolls 32 by 20 means of pairs of support bars 296, 298. More particularly, one end of each of the vertically extending bars 296 is arranged above the longitudinal center of the wedge member 290 and is received within recessed openings in the upper surface of the wedge member and retained thereinplace. As best seen in Fig. 16, the opposite ends of the bars 296 are supported by rearwardly extending bars 298 which in turn are supported from the main support frame for the liquid pump (to be described in more detail hereinbelow). The wedge member 290 is thus designed to "float" on each of the gelatin webs 24 as they are moved towards the nip between the pair of sealing rolls 32.

The shaped member 290 includes a plurality of water passageways 300 therethrough through which heated water may be passed to heat the gelatin webs 24 just prior to the webs 24 being moved into the nip between the sealing rolls 32. For example, it is generally preferred to maintain the wedge member 290 at approximately 92' to 105' F which will serve to sufficiently heat the gelatin webs 24 to an appropriate temperature at which a good and efficient sea[ will be made as the webs 24 pass through the nip of the sealing rolls 32 and the shoulders or lands 51 surrounding the recesses 50 on the surface of the sealing rolls 32 press the webs 24 together around each pocket 26.

For filling the cavities or pockets 26 in the webs 24 with a liquid fill material, the wedge member 290 includes a series of passageways 302 provided along the longitudinal length thereof which extend downwardly toward the tip 294. The lower end of each passageway 302 is connected to a "T" passageway 304 which has open ends 306 which communi- cate with each of the concave surfaces 292 at positions just above the nip of the sealing rolls 32 for injecting a liquid fill material into the cavities or pockets 26 as they pass the open ends 306 of the "T" passageway 304. In this regard, it will be noted from Fig. 6 that the concave surfaces 292 of the wedge member 290 at the location of the open ends 306 of the -Tpassageway 304, and toward the tip 294 of the wedge member 290 precisely conform to the cylindrical surfaces of the sealing rolls 32 so as to effectively seal against the outer surface of the gelatin webs 24 as the webs 24 move therepast. This is important in order to retain the liquid fill material in the pockets 26 as the progress toward the nip and thus prevent the loss or spillage of liquid. That is, in essence, the only open area for the liquid is in the cavities or pockets 26 formed in the surface of the webs 24. The tip 294 of the wedge member 290 terminates just above the nip so that as the respective webs 24 each leave contact with the wedge member 290, they are immediately brought into contact with one another and sealed.

The number and the location of the liquid passageways 302 and corresponding -Tpassageways 304 provided in the wedge member 29 are the same as the number and locations of the pockets 26 in each pair of adjacent rows of pockets 26 in the webs 24. That is, as with the punch roll 162, the passageways 302, 304 are aligned with the centerline of each of the pockets 26 in a row of A series pockets and in a row of B series pockets. Thus, it will be appreciated that every other passageway 302 along the length of the wedge member 290 will serve to provide liquid fill material through its corre- sponding -T- passageway 304 into the pockets 26 of an A series row, and the alternate pockets of passageways 302, 304 will serve to provide liquid into the B series row. In order to alternately pump liquid fill material through the alternate passageways 303, 304, since at any given time only one row of pockets 26 will be in position to be filled, a Scotch yoke type pumping apparatus 308 is utilized. More particularly, the Scotch yoke type punip apparatus 308 is a reciprocating pump which during one stroke serves to charge half of the passageways 302, 304, for example passageways 302, 304 serving the B series of pockets 26 in the webs 24, and during the reciprocating stroke, serves to charge the remaining passageways 302, 304, for example the passageways 302, 304 for the A series of pockets 26.

As best seen in Fig. 17, the pump 308 includes a central hopper 316 filled with an appropriate liquid fill material which is to be encapsulated. The hopper 316 is supported on a distribution manifold 312 which is located above the main pump body 314. The hopper 316 is open at its bottom end and communicates with a central opening 322 in the distribution manifold 312. A slide valve 318 is slidably supported in a recess provided between the distribution manifold 312 and the main pump body 314 and is adapted to 1 U GB 2 141 094A 15 reciprocate therein. The slide valve 318 has a series of passageways 320 therethrough which communicate with a central opening 322 in the distribution manifold 312 so as to receive liquid fill material from the hopper 316. The main pump body 314 likewise has a plurality of passageways 324 therein which lead from beneath the slide valve 318 to corresponding pump chambers 326 located on opposite sides of the pump body 314 along the length of the pump body. A plurality of pistons 328 are provided in the chambers 326 for reciprocating movement therewithin. The number of pump chambers 326A and pistons 328A along one side of the pump body 314 correspond to the number of recesses 50A in each A series row 134A of recesses 50 of the sealing roll 32, whereas the number of pump chambers 326B and pistons 328B along the other side of the pump body 314 correspond to the number of recesses 50B in each B series row 1 34B of recesses 50. For space economy, the chambers 326 and pistons 328 on each side of the pump body 314 are arranged in two rows, one above the other.

As the slide valve 318 reciprocates, the passageways 320 in the slide valve 318 are adapted to alternately communicate with the passageways 324 in the main pump body 314 to alternately fill the chambers 326 first on one side of the pump body 314 and then on the other side of the pump body 314. That is, when the slide valve 318 is at one end of its stroke, the passageways 320A are aligned with the passageways 342A which serve the chambers 326A on one side of the pump body 314 and the passageways 324B are blocked. When the slide valve 318 is at the other end of its stroke, the passageways 320B 105 thereof are aligned with the passageways 324B which serve the pump chambers 326B on the other side of the pump body 314, and the passageways 324A are closed.

A second series of passageways 330 are provided in the pump body 314 in communi cation with the pump chambers 326, and a second series of passageways 332 are pro vided in the slide valve 318 for alternate communication with the passageways 330 as the slide valve 318 reciprocates. In the distribution manifold 312, there is also provided a series of passageways 334 which are open on the opposite sides of the manifold 312. Flex- ible conduits 310 are connected to one end to these passageways 334 in the manifold 312 and at their other ends to the passageways 302 in the wedge member 290. More parti cularly, the passageways 334A on one side of the manifold 312 serve the passageways 302 12 which are aligned with the pockets 26 in an A series row, and the passageways 334B on the other side of the manifold 314 serve the passageways 302 which are aligned with the pockets 26 in a B series row.

The passageways 332 in the slide valve 318 are arranged so that they provide communication between the pump chambers 326 and passageways 334 on one side of the pump body 314 when the chambers 326 on the other side of the pump body 314 are in communication with the hopper 316 through the opening 322 and passageways 320. That is, when the passageways 320B of the slide valve 318 are aligned with the passageways 342B, the passageways 332A are aligned with the passageways 320A and 334B, and similarly, when the passageways 320A are aligned with the passageways 342A, the passageways 332B are in communication with the passageways 330B and 334B.

The series of pistons 328 provided in each of the chambers 326 on opposite sides of the pump body 314 are interconnected to one another by appropriate means on each side of the pump body 314 so that as the pistons 328A on one side of the pump body 314 move towards the center of the pump body 314, the pistons 328B on the other side will move away from the center of the piston body 314, and vice versa. Movement of the piston rods 328 and the slide valve 318 are timed and synchronized so that as the piston rods 328 retract in their respective chambers 326, the chambers 326 are in communication with the hopper 316 and liquid is thus drawn from the liquid hopper 316 into the respective chambers 326. Similarly, as the pistons 328 move toward the center of the piston body 314, the chambers 326 are in communication with the flexible conduits 310 so that the liquid in the respective chambers 326 is pumped into the passageways 302 in the wedge member 290. Thus, it will be appreciated that during the reciprocating movement of the pistons 328, liquid from the liquid hopper 316 is being supplied into the chambers 326A corresponding to one row of pockets 26 in the sealing roll 32, for example the A series, while in the chambers 326B for the adjacent row of pockets 26, i.e., the B series, the liquid is being pumped into the corresponding passageways 302 in the wedge member 290, thereby resulting in the B series of pockets 26 being filled with liquid. Upon the reciprocating stroke the reverse takes place, i.e., a row of A series pockets 26 is charged with liquid fill matereial and the chambers 326B for a row of B series pockets are filled with liquid.

It should be noted in this regard that during the chamber fill stroke, the liquid in the corresponding passageways 302, 304 in the wedge member 290 and in the flexible lines 310 remains in the flexible lines, 310 and passageway 302, 304, and is not discharged therefrom. In other words, because liquid is always in the various lines 310 and passageways 302, 304, when one set of pistons 328 is retracted to draw more liquid from the 16 GB 2 141 094A 16 hopper 316 into the respective chambers 326, the liquid already in the corresponding flow lines 310 and passageways 302, 304 will not flow out thereof and spill onto the gelatin webs. Conversely, during the chamber discharge stroke, the liquid in the chamber 326 is forced or pumped into the corresponding flexible lines 310 in communication with the corresponding passageways 302, 304 in the wedge member 290, thereby causing a portion of the liquid fill material therein to be forced or discharged through the passageway 304 into the pockets 26 in the pair of webs 24 on the sealing rolls 32. Also, it will be appreciated that each of the various pockets 26 in respective rows extending across the width of the sealing rolls 32 will be filled simultaneously by the supply of liquid to each of the passageways 302, 304 in the wedge member 290 in alignment therewith.

In the preferred embodiment, the main pump body 314 remains stationary during operation, and only the piston rods 328 are moved. More particularly, the ends of the pistons 328 on each side of the pump body314 are supported in respective piston bars 336, and the piston bars 336 on each side of the pump body 314 are connected together at the ends by tie rods 338 (see Fig. 18).

Beneath the pump body 314 and centrally located, an additional tie bar or plate 340 is connected to the pair of piston plates 336.

The central tie plate 340 has secured to its lower surface a pair of vertically extending brackets or plates 342 which are spaced from 100 one another and parallel to the bars 336.

Between the pair of plates 342, there is provided a rotatable cam disc 344 which has an eccentrically arranged shaft 346 extend'ing downwardly therefrom.

Because the shaft 346 is eccentric to the axis of the cam disc 344, rotation of the shaft 346 causes the plate members 342 to move back and forth to in turn cause the piston bars 336 to move toward and away from the 110 pump body 314.

A barrel cam apparatus 348 is provided for moving the slide valve 318 in timed relation ship to the movement of the pistons 328. The barrel cam arrangement includes a rotatable cam disc 350 having a circumferential groove 354 on which a camming pin 352 affixed to an extension of the slide valve 318 rides. The groove 354 is shaped so that as the disc 350 rotates, the pin 352 and thus the slide valve 318 reciprocates back and forth.

The disc 350 and the shaft 346 are both suitably connected to the main drive for the apparatus 20 so that they are timed and synchronized in the manner described above and operate in unison with the sealing rolls 32 so that as each new row of pockets 26 in the webs 24 are brought into alignment with the open ends 306 of the respective "T" passageways in the wedge member 290, the 130 direction of piston movement is changed in order to inject liquid fill material into the pockets 26 of the new row. In this regard, the movement of the pistons 328 is timed so that the discharge of liquid in the passageways 302, 304 is started when the leading edge of a pocket 26 first reaches the open end 306 in the wedge member 290 and the discharge stopped when the trailing edge of the pocket 26 leaves the open end 306 in the wedge member 290.

In some instances, the number of pockets 26 in a row to be filled will be less than the maximum number corresponding to that which the Scotch yoke pump 308 may handle. For example, if the pump 308 is designed to handle thirty-three pockets 26 per each row of A series and thirty-two pockets 26 for each row of the B series, but the webs 24 are only sized to provide twenty cavities and nineteen cavities, respectively, per row for the A and B series, then a selector plate 260 may be utilized which serves to block the passageways 302 which are not to be used (i.e., those passageways 302 for which pockets 26 are not provided in the webs 24). The selector plate 360 is located in the wedge member 290 serves to direct the liquid from the pump chambers 326 and flexible lines 310 into a common return line (not shown) which serves to return liquid therein back to the liquid hopper 316. The selector plate 360 is desired as it ensures that the liquid in the various lines and chambers is being continuously pumped at all times-i.e., either introduced into a pocket 26 on the web 24 or simply returned back to the hopper 316. This is most important especially if solid particles are suspended in the liquid to be encapsu- lated as otherwise jamming or clogging of the passageways might result.

As can best be seen in Fig. 6, the concave surfaces 292 of the wedge member 290 each include a recessed area 370 along a portion thereof iritermediate the tip 294 and the outer side edge 372 thereof. The nonrecessed portion adjacent the tip 294 and outer side edge 372 comprise edge sealing surfaces which are adapted to sea[ against the webs 24 as the webs 24 are moved past the wedge member 290. Suitable sealing surfaces are also provided at the longitudinal ends of the wedge member 290 so that the volume defined between each recessed surface 370 and the surface of the-web 24 is sealed from the surrounding atmosphere. The recessed surfaces 370 in each concave surfaces 292 extend longitudinally to the opposite edges of the web 24, and laterally from a point gener- ally near the edge that the web 24 first engages the wedge member 290 downwards toward the nip approximately 30. A series of first and second passageways 374, 376 are provided in communication with this recessed area 370 along the length of each concave 4 0 17 GB2141094A 17 surface 292. The first series of passageways 374 are connected to a suitable source of vacuum or reduced air pressure, and the seeond series of passageways 376 are connected to a suitable source of inert gas, such as for example nitrogen or carbon dioxide. As the numerous pockets 26 formed in the surface of the webs 24 move beneath the recessed areas 370, the air entrapped therein is evacuated through the first passageways 374 and an inert gas substituted therefor through the second passageways 376 so as to provide substantially deaerated pockets or cavities 26 in the webs 24. This deaeration is most impor- tant with many types of fill material to be encapsulated which may be subject to oxidation or other deterioration in the presence of air. For example, fill materials comprising flour, eggs, butter, and certain types of oils; as well as other materials may become rancid or deteriorate if encased in the presence of air or other oxidizing chemicals. With the arrangement of the wedge member 290 and the first and second passageways 374, 376, the air may be evacuated from the pockets 26 in the webs 24 and an inert gas, e.g., with a gas which is devoid of oxygen which might otherwise affect the stability of the product, substituted therefor. This thus allows for a greater variety of materials to be encapsulated.

It should be noted that the wedge member 290 may be utilized for the evacuation of air and the introduction of inert gas and may be utilized with respect to either solid fill materials or liquid fill materials, or both. For solid fill materials which are to be encapsulated, the compacted slugs 164 are deposited in the pockets 26 of the webs 24 prior to the pockets 26 being evacuated and an inert gas introduced. For liquid fill materials, the evacuation of air and substitution of an inert gas therefor is accomplished prior to the introduction of liquid fill material into the pockets 26.

Also, although in Fig. 6 the first passageways 374 are shown to be furthest from the nip and the second passageways 376 closest to the nip, the passageways 374, 376 could be reversed, i..e, the air evacuated through the passageways 376 closest to the nip and the inert gas introduced via the passageways 374 furthest from the nip.

Thus, with the wedge member 290 and the pumping apparatus 308, it is possible to deposit liquid fill material to be encapsulated into each of the pockets 26 in the webs 24 as the webs pass about the sealing rolls 32. Additionally, with the wedge member 290, the formed capsules 22 may be deaerated of oxidizing agents, i.e., air may be replaced with an inert gas which will not result in deterioration of the fill materials. Further in this regard, the wedge member 290 may be used either alone (i.e., if only liquid fill material is to be encapsulated) or in combination 130 with the fill powder apparatus (i.e., if fill powder is to be encapsulated, either with or without a liquid fill material).

After the webs 24 have passed between the nip of the sealing rolls 32 and the two capsule halves have been sealed to form a completed capsule 22, the capsules drop into and are collected in troughs 154 positioned below the sealing rolls 32. The troughs 154 contain a cold solvent which serves to wash the oil from the capsules and to sweep the capsules away to a suitable drying station. A pair of flippers members or strippers in the nature of rotatable paddles 156 are also provided which rotate and serve to extract the capsules which might hang from the remaining net of web material. Each of the paddles 156 comprises a rotatable shaft having rubber flippers therein which serve to gently knock the netting of web material. In this regard, it is to be noted that the capsules 22 as they exit from the sealing rolls 32 are still quite warm and are subject to deformation if struck too harshly. When the capsules 22 fall in the cold solvent, the solvent also serves to cool the capsules 22 to further solidify same. In this regard, it will be noted that the troughs 154 include upwardly extending guide plates 155 are provided on opposite sides of the troughs 154 to ensure that the capsules 22 extracted from the webs 24 are directed into the troughs 154.

Also, beneath the sealing rolls 32, there are provided rotatable nylon brushes 380 which serve to strip or remove any capsules which might have been struck or retained in the recesses 50 of the sealing rolls 32. Further, the netting or remaining portion of the gelatin webs 24 pass between the inner pair of guide plates 155 extending on either side of the solvent troughs 154 through a pair or rollers 382 which serve to hold the netting tightly and pull it downwardly to prevent it from jamming between the solvent troughs 154.

The gelatin netting may then be guided to an appropriate apparatus for chopping the netting up into small pieces which may then be soaked with cold solvent to remove the oil and then collected for recycling.

Certain features described herein form the subject-matter of the claims of Application No.

81.32501 and also the subject-matter of the claims of Application Nos. and which were also divided from Application No.

8132501.

Claims

1. Apparatus for making capsules comprising:

feeding means for feeding capsule forming material having a series of cavities forming therein, said capsule forming material a portion of the casing of the capsules, and said feeding means including sealing means for sealing said cavities; 18 GB 2 141 094A 18 depositing means for depositing a material in said cavities of said capsule forming ma terial prior to said cavities being sealed by said sealing means; and air displacing means for displacing air from said cavities and substituting therefor an inert gas prior to said cavities being sealed by said sealing means so that substantially deaerated capsules are formed.

2. An apparatus as claimed in claim 1, wherein said capsule forming material corn prises a pair of webs of capsule forming material having a series of cavities therein; wherein said feeding means comprises web feed means for feeding said webs along converging paths so that said cavities in one of said webs are brought into juxtaposition with said cavities in the other of said webs; and wherein said sealing means seals said webs together around said cavities to form closed capsules, the surfaces of said cavities forming the inner surfaces of said formed closed capsules.

3. An apparatus as claimed in claim 2, wherein said web feed means comprises first and second substantially cylindrical sealing rolls arranged in nipping relationship and mounted to rotate in opposite directions, each of said sealing rolls directing one of said webs towards the nip of said sealing rolls; and wherein said sealing means comprises the nip of said sealing rolls.

4. An apparatus as claimed in claim 3, including cavity forming means associated with said first and second sealing rolls for forming said series of cavities in predetermined positions in said webs prior to said webs being passed through the nip of said first and second sealing rolls.

5. An apparatus as claimed in claim 2 or 3, wherein said air displacing means cornprises a wedge member disposed between said first and second sealing rolls and having a first concave surface of complementary shape to the surface of said first sealing roll and a second concave surface of complementaty shape to the surface of said second sealing roll, said first and second concave surfaces converging towards one another adja- cent the nip between said first and second sealing rolls, said first and second concave surfaces of said wedge member being adapted to seal against said webs as said webs are moved toward said nip by said first and second sealing rolls, and said wedge member 120 including first and and second flow communication means communicating with each of said first and second concave surfaces, said first flow communication means communicat- ing with a source of vacuum for withdrawing air entrapped between the surfaces of said webs facing away from said first and second sealing rolls and said first and second concave surfaces, and said second flow communication gas for introducing an inert gas between said surfaces of said webs facing away from said first and second sealing rolls and first and second convcave surfaces so that air is evacu- ated from said cavities in said web and inert gas is injected into said cavities.

6. An apparatus as claimed in claim 5, wherein said first and second concave surfaces each include a recessed area and edge sealing means therearound for sealing against the outer surface of said webs as said webs are moved by said first and second sealing rolls, and wherein said first and second flow communication means communicate with said recessed areas in said first. and second concave surfaces.

7. An apparatus as claimed in claim 6, wherein said depositing means comprises a fluid communication passage in said wedge member for injecting a fluid into said cavities prior to said sealing rolls sealing said webs together, said fluid communication means communicating with said cavities in said webs adjacent the nip between said first and second sealing rolls.

8. An apparatus as claimed in claim 7, further including solid deposition means for depositing a solid material into said cavities prior to said cavities being brought into juxtoposition and sealed by the nip of said sealing rolls.

9. An apparatus as claimed in claim 6, wherein said depositing means comprises means for depositing a solid material into said cavities prior to said cavities being brought into juxtoposition and sealed by the nip of said sealing rolls.

10. A method of making capsules cornprising the steps of:- feeding capsule forming material having a series of cavities formed therein along a predetermined path, said capsule forming material forming a portion of the casing of the capsules; depositing a material to be encapsulated into said cavities of said capsule forming material as said capsule forming material is moved along said path; displacing air from said cavities and substituting therefor an insert gas as said capsule forming material is moved along said predetermined path; and then sealing said cavities in said capsule forming material to form substantially deaerated capsules.

11. A method as claimed in claim 10, ih which said capsule forming material cornprises a pair of webs having a series of cavities therein; wherein said step of feeding comprises feeding said webs along converging paths so that said cavities in one of said webs are brought into juxtaposition with said cavities in the other of said webs; and wherein said step of sealing comprises sealing said means communicating with a source of insert 130 webs around said juxtaposed cavities to form P, 1 19 GB 2 141 094A 19 said capsules.

12. A method as claimed in claim 11 wherein said step of feeding said webs cornprises feeding said webs about first and second sealing rolls arranged in nipping relationship and mounted to rotate in opposite directions, each of said sealing rolls directing one of said webs toward the nip of said sealing webs; and wherein said step of sealing corn- prises passing said webs through the nip of said first and second sealing rolls.

13. A method as claimed in claim 12 wherein said step of feeding said webs about sid first and second sealing rolls comprise feeding undeformed sheets of capsule forming material onto said first and second sealing rolls and the forming said cavities in said sheets as said selaing rolls move.said sheets toward the nip of said sealing rolls.

14. A method as claimed in claim 12 or 13, wherein said step of displacing air and substituting therefor an inert gas comprises disposing a wedge member between said first and second sealing rolls, said wedge member having first and second concave sides of complementary shape to the surfaces of ' said first and second sealing rolls respectively, said first and second concave surfaces of said wedge member converging towards one another adja- cent the nip between said first and second sealing rolls, and said first and second concave surfaces being adapted to seal against said webs as said webs move toward said nip of said first and second scaling rolls; and connecting a source of vacuum with a first portion of each of said first and second concave surfaces to withdraw air entrapped between the surfaces of said webs facing away from said first and second sealing rolls and said first and second concave surfaces, and connecting a source of inert gas with a second portion of each of said first and second concave surfaces to introduce an inert gas between said surfaces of said webs facing away from said first and second sealing rolls and said first and second concave surfaces so that air is evacuated from said cavities in said web and an inert gas is introduced into said cavities.

15. A method as claimed in claim 14, wherein said wedge member includes re cessed areas and sealing means therearound in each of said first and second concave surfaces for sealing against the outer surfaces of said webs as said webs are moved by said first and second sealing rolls, wherein said steps of connecting a source of vacuum and a source of inert gas comprise connecting said sources with said recessed areas in said first and second concave surfaces.

16. A method as claimed in any of claims 12 to 15, wherein the step of depositing a material comprises injecting a fluid into said cavities prior to said webs being brought into the nip of said sealing rolls.

17. A method as claimed in any of claims 12 to 15, wherein said step of depositing comprises depositing a solid material into said cavities prior to said cavities in said webs being brought into juxtaposition and sealed in the nip of said sealing rolls.

18. A method as claimed in any of claims 12 to 15, wherein said step of depositing comprises depositing a solid material into said cavities and injecting a liquid material into said cavities prior to said webs being brought into the nip of said sealing rolls.

Printed in the United Kingdom for Her Majesty's Stationery Office, Dd 8818935, 1984, 4235. Published at The Patent Office, 25 Southampton Buildings, London, WC2A lAY, from which copies may be obtained.