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MXPA06011269A - Inspection system for blister packages - Google Patents

Inspection system for blister packages

Info

Publication number
MXPA06011269A
MXPA06011269A MXPA/A/2006/011269A MXPA06011269A MXPA06011269A MX PA06011269 A MXPA06011269 A MX PA06011269A MX PA06011269 A MXPA06011269 A MX PA06011269A MX PA06011269 A MXPA06011269 A MX PA06011269A
Authority
MX
Mexico
Prior art keywords
blister pack
level
images
inspection
predetermined
Prior art date
Application number
MXPA/A/2006/011269A
Other languages
Spanish (es)
Inventor
Paud Barry
W Murphy Michael
Roche Eoin
Original Assignee
Paud Barry
Bausch & Lomb Incorporated
W Murphy Michael
Roche Eoin
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Paud Barry, Bausch & Lomb Incorporated, W Murphy Michael, Roche Eoin filed Critical Paud Barry
Publication of MXPA06011269A publication Critical patent/MXPA06011269A/en

Links

Abstract

An inspection system for inspecting the seal area and/or volume fill level of a blister package comprising an image pick-up device and providing an image pick-up device;presenting the blister package with cover adhered thereto to the field of view of said image pick-up device;imaging and determining the grey level of said seal area and comparing the imaged grey level to a predetermined grey level value;and passing the blister package inspection if the imaged grey level is substantially the same as the predetermined grey level value or rejecting the blister package inspection is the imaged grey level is not substantially the same as the predetermined grey level value.

Description

INSPECTION SYSTEMS FOR BLISTER CONTAINERS BACKGROUND OF THE INVENTION The present invention relates to inspection systems in a production line. More particularly, the present invention relates to an inspection system for inspecting the sealing area and / or the solution volume of a blister pack containing an ophthalmic lens in solution. Ophthalmic lenses such as contact lenses are usually packaged in small containers called blister packs comprising a disposable plastic container having a well containing a single lens in an amount of storage solution (eg, saline). A foil lid is applied to the blister pack and sealed thereto, usually around the perimeter of the well containing the lens and solution. The foil lid of metallized paper may comprise a laminate, for example, a first layer of polypropylene which is placed against the blister followed by a layer of metallized paper in which a layer of paint can be applied for the graphic application followed by a top layer of lacquer. The sealing of the laminar lid to the blister pack can be done by the application of heat that seals the polypropylene layer to the plastic blister. The sealing process is carried out in an automated way so that many blister packs can be sealed very quickly. Although automation increases the productivity of the production line, errors can occur during the sealing process that may remain undetected. Sealing errors may include, for example, bubbles, voids, particulate matter and over-sealing. Any of these errors can cause imperfect sealing leading to contamination of the lens or filtering of the storage solution from the blister after which the blister and the lens should be discarded. In the past, manual inspection has been carried out, however, manual inspection is prone to human error and takes a lot of time and work. Therefore, it is desirable to have a robust sealing process that includes the detection of sealing errors so that the blister having the imperfect seal can be discarded before it is transported to the consumer. It is also desirable to automatically inspect the volume loading level of the storage solution in the blister pack to ensure that the appropriate amount of storage solution has been delivered in the blister pack. SUMMARY OF THE INVENTION In a first aspect, the present invention provides an inspection system that is operative to detect errors in the sealing area of a laminar lid applied to a blister pack. The inspection system includes an image-taking device, (for example, a camera) directed towards the sealing area of a blister pack. The sealing area is typically the area surrounding the deep well that houses the lens and storage solution although it may also include a larger flanking area surrounding the well. The seal around the perimeter of the well, typically called a "hint" in the art, should be a complete seal if the lens can not be contaminated and the solution can be leaked from the blister pack and then discarded. The inspection system applies a pattern to the track, for example, small square or rectangular squares placed successively around the entire track. A software installation connected to the image taking device checks the pattern for a predetermined amount or grayscale interval in the boxes. A gray level difference threshold is treated as an error. This is because a good seal will have a measurable level or grayscale value, caused by the correct application of heat, pressure and time to the two materials that are joining together (ie, the laminar cover and the blister track). If the detected gray level is different from the threshold value or interval, the software installation then calculates the size of the detected error. If the size is outside the acceptable range or value, that blister is marked to be discarded. In a second aspect of the invention, an inspection system is provided for inspecting in volume (loading level) of the storage solution in a sealed blister pack. The vision system includes an image-taking device (e.g., a camera) that is operative to detect the level of solution in a blister pack. In one embodiment, the blister pack may be presented vertically to the imaging device. If the detected solution level matches outside a predetermined accepted amount or range, the blister pack is marked for disposal. In a particularly advantageous embodiment of the invention, the sealing inspection system is integrated with the volume inspection system. Brief Description of the Drawings Figure 1 is a perspective view of a representative blister pack showing the partially removed cover; Figure 2 is a cross-sectional view of the blister pack generally taken along line 2-2 of Figure 1 except that the cover is sealed to the blister pack; Figure 3 is a bottom plan view of the blister pack; Figure 4 is an enlarged cross-sectional view of the cover showing the individual layers thereof; Figure 5 is a schematic view of the equipment of the inspection system of the present invention; Figure 6 is a plan view from below of a blister pack showing a consecutive series of white ROIs in part of the sealing area of a blister pack undergoing inspection; Figure 7 is a view of Figure 6 showing a type of sealing error detected by the inspection system; Figure 8 is the view of Figure 7 showing another type of possible possible sealing error; Figure 9 is a bottom plan view of a blister pack showing inspection of the volume loading level of the package; and Figure 10 is the view of Figure 9 showing a different load level.
Detailed Description With reference to the drawings, a representative blister pack 10 used for packaging a hydrophilic contact lens 12 is seen in the Figures. The blister 10 is made of a disposable plastic (e.g., polypropylene) and includes a deep well 14 in the lens 12 is placed with an amount of storage solution 13 (eg, saline). A cover 16 is sealed around the well 14. The cover 16 is typically a foil laminate having a first base layer that will be attached to the blister pack after the application of heat and pressure. As seen in Figure 4, the first base layer 16 can be polypropylene, for example, followed by a layer of foil 16b and an upper layer of the protective lacquer 16c. The cover 16 is sealed at least around the perimeter or "track" 18 of the well 14. The track 18 can be flushed or rinsed away relative to the flanking area 19 surrounding the track 18. The cover 16 can additionally include a fastening part without sealing 16d to enable the user to easily grip and remove the cover 16 of the blister 10 to access the lens 12 therein. As seen in Figure 5, the station of the inspection system 20 of the invention is shown schematically and includes an image-taking device (e.g., a DSL5000 camera) 22 having a lens 24 (e.g. 35 mm) directed to a blister pack 10 to be inspected. A lower angle light ring 26 is placed between the blister pack 10 and the image taking device 22. A lens 12 and storage solution 13 had previously been deposited in the blister pack 10 in the well 14 thereof and had been placed in the blister pack 10. sealing a cover 20 thereto around the track 18. The sealing station (not shown) may comprise a heat sealing station that applies heat and pressure to the cover at the position of the track 18, thus sealing the well 14 and its contents. Prior to transport to the consumer, the blister packs will undergo sterilization to ensure that the lens is sterilized for safe application in the user's eye. Therefore, it is clear that the sealing process can ensure a seal that will not compromise the sterility of the lens in the blister pack. Therefore, in a first aspect of the invention, an inspection station 20 is provided for inspecting the sealing area (track) 18 of the blister pack. If inspection indicates problems with sealing, the blister will be marked for disposal. The image taking device 22 of the inspection station includes a means for projecting ROI (regions of interest) into the track area 18 of the sealed blister 10. The ROIs marked 28 in Figure 6 comprise small square or rectangular boxes that, although only several are shown in the figure, they extend in a sequential series around the full length of the track 18. The image taking device 22 forms images of the blister 10 and the track 18 and is connected to a computer 30 having an inspection software that analyzes the image taken by the image taking device 22. An inspection software and hardware suitable for use with the present invention include Inspection Builder 3.1 by PPT Vision System. To give an initial reading, a seal which is known to be good by the image taking device 22 is directly entered or measured and stored in the computer 30. The pixels of the image are analyzed for their gray level (contrast ) and this will be the initial number accepted. After receiving a blister pack for inspection, the image taking device 22 forms images of the blister track 18 and the software installation examines the ROIs to determine their level of grays. This reading is compared to the initial number on the computer and if it is within a range of acceptable deviation, the blister pack passes the sealing inspection. If a gray level is detected instead of the acceptable deviation range, the software installation examines the size of the area outside the acceptable deviation range. If the area is of a size that is not acceptable, the blister pack is marked for disposal. If the size is considered in acceptable parameters instead, the blister pack passes the sealing inspection. Note that the second analysis stage in which the area size is calculated and compared with an acceptable value previously entered in the computer can be integrated in a similar way in the stage of gray level analysis by the computer. The second analysis can also be eliminated if desired, if the gray level analysis is determined sufficient to determine the failed blister packs. Note that the blister pack can be oriented vertically as shown in Figure 5 during the inspection. The lower part of the well 14 is directed towards the image taking device. As the blister pack is translucent, the image taking device can see through the package to the track 18. The heat sealing process causes a certain level of grays to appear on the track 18 on which the cover has been adhered 20 to the track of the blister 18. This gray level contrasts with the level of grays appearing in the unsealed area of the deck 20 (ie, areas both inside and outside of track 18). A good seal will have a certain level of grays around the track 18. Measuring this level of grays makes it possible for the system to compare each blister that is undergoing inspection at the known acceptable gray level. Gray levels outside of an acceptable deviation range will be rejected. For example, Figure 7 shows a representative blister pack 10 undergoing inspection in which a sealing error in the form of a sealing hole is indicated in reference number 30. This gap in the sealing area would probably cause leakage of the storage solution from the well 14 and would contaminate the lens 12 therein. The inspection system 20 will read this area as a difference in acceptable gray level and mark this blister pack for disposal. The system can sound a bell to amaze the worker to remove the failed package or the system can send a signal that instructs the automated machinery to remove the blister from the production line. Figure 8 shows another type of sealing error in the form of air bubbles 32 captured between the cover 20 and the track 18. Again, this type of error would probably compromise the integrity of the seal and contaminate the lens 12 therein and the inspection system would mark the blister to discard it. As discussed above, a second analysis step can be performed in which a gray area area size detected outside acceptable parameters is calculated and compared to an acceptable area value previously entered into the computer. In another aspect of the invention, the charge level (volume) of the storage solution 13 can also be inspected by the inspection system 20. The image taking device 22 reads the contrast difference in the load line FL which is indicative of the solution loading level. If the charge level is detected below the threshold level, the blister is marked for disposal. In an advantageous embodiment, the inspection of the volume is done together with the inspection of the sealing. Note that the blister packs can be presented to the inspection station 20 in an automated sequence and can be operated by a conveyor belt and / or a fastening device presenting the blister pack in the correct orientation to the image taking device 22. Although the invention has been described herein in relation to a particular blister pack designIt is understood that the invention can be used with other blister package designs.

Claims (7)

1. A method comprising the steps of: a) placing a contact lens and a container solution in a well of a blister pack, and adhering a laminar lid to the blister pack around the well; b) provide an image taking device; c) presenting the blister pack with the laminar cap adhered thereto to the field of view of said imaging device; d) forming images and determining the gray level of a sealing area between the blister pack and the laminar cover, and comparing the gray level of the images with a predetermined gray level value; and e) pass the inspection of the blister pack if the gray level of the image is substantially equal to the predetermined gray level value or reject inspection of the blister pack if the gray level of the image is not substantially equal to the gray level value predetraminated
2. The method of claim 1 and further comprising the step of projecting a series of ROI into the sealing area from which images have been taken and in which the gray level imaging of the sealing area occurs in each ROI .
3. The method of claim 2 and further comprising the step of calculating the size of a gray level from which images have been taken which is not equal to the predetermined gray level value and passing inspection of the blister pack if the size is substantially equal or smaller than a predetermined acceptable size or reject inspection of the blister pack if the size is larger than the predetermined acceptable size.
. The method of claim 1 and further comprising the step of forming images of the charge level of the solution maintained in the blister pack and comparing the load level from which images have been taken with a predetermined acceptable charge level and passing the package blister if the load level from which images have been formed is substantially equal to the predetermined accepted load level or reject the blister pack if the load level from which images have been formed is less than the predetermined acceptable load level.
5. The method of claim 4, wherein said blister pack is oriented vertically during said inspection.
6. A method for inspecting the level of charge of a solution in a sealed blister pack containing a contact lens, said method comprising the steps of: providing an imaging device; presenting the blister pack to the field of view of said image taking device; forming images and determining the level of loading of the solution in the blister pack and comparing the load level from which images have been taken with a predetermined charge level value; and pass the inspection of the blister pack if the level of load from which images have been taken is substantially equal to the value of the predetermined charge level or reject inspection of the blister pack if the load level from which images have been taken is not substantially equal to the value of the default charge level.
7. The method of claim 6, wherein said blister pack is oriented vertically with respect to said image taking device.
MXPA/A/2006/011269A 2004-03-31 2006-09-29 Inspection system for blister packages MXPA06011269A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US10813860 2004-03-31

Publications (1)

Publication Number Publication Date
MXPA06011269A true MXPA06011269A (en) 2007-04-20

Family

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