Perforation Tensile Separation of Packages

Description

BACKGROUND

Certain types of manufactured packages, including those used to package ophthalmic devices like contact lenses, include a package strip comprising an array of individual packages. For ease of manufacturing, the array size may be set, for example, to comprise three, five, or six individual packages. The entire array may be hermetically sealed with a single piece of non-rigid material, such as a multi-layer foil or other suitable material. Perforations may be applied to the non-rigid material between individual packages to assist in separating the packages. Even with perforations, however, the package may be separated in a manner that tears or shears the non-rigid material not along the perforations. Such a tear can appear rough or jagged such that it adversely impacts the appearance of the consumer product. It may also physically break the sealed portion of the non-rigid material to the package strip, causing a packaging integrity and sterility issue.

Additionally, sometimes it is desirable to have a different package array size than what a manufacturing line is designed to produce. For example, a manufacturing line may produce arrays of six when arrays of two or three, or even single individual packages, are desired.

SUMMARY

A package separator is disclosed herein that includes a chassis and a sled that includes a plurality of package seats, where the plurality of package seats is configured to accept a package strip, and where the sled is configured to slide into the chassis.

A package separator is also disclosed herein that includes a chassis and a sled that includes a first package seat on a first arm, a second package seat on a second arm, and a third package seat disposed between the first package seat and the second package seat.

A method for separating a package strip into a plurality of packages is also disclosed, the method including inserting the package strip into a sled of a package separator and sliding the sled into a chassis of the package separator, where sliding the sled into the chassis causes the package strip to separate into the plurality of packages.

The description herein is exemplary and explanatory in nature and intended to provide an understanding of the present disclosure without limiting the scope of the present disclosure. In that regard, additional aspects, features, and advantages of the present disclosure will be apparent to one skilled in the art from the following detailed description.

BRIEF DESCRIPTION OF DRAWINGS

These drawings illustrate certain aspects of some examples of the present disclosure and should not be used to limit or define the disclosure.

FIG. 1A is a diagram of a package.

FIG. 1B is a diagram of a package strip.

FIG. 1C is a cutaway diagram of a package.

FIG. 1D is an exploded cutaway diagram of a package.

FIG. 1E is a diagram of an example package strip.

FIG. 1F is a diagram of an example package strip.

FIG. 1G is a diagram of a package strip under lateral tension.

FIG. 1H is a diagram of perforation lines under lateral tension.

FIG. 1I is a diagram of a package strip under tearing tension.

FIG. 1J is a diagram of perforation lines under tearing tension.

FIG. 2A is a diagram of an open package separator.

FIG. 2B is a diagram of an open package separator with a package strip.

FIG. 2C is a diagram of a closed package separator.

FIG. 3A is a diagram of an open package separator with a cover.

FIG. 3B is a diagram of a sled.

FIG. 3C is a diagram of a base.

FIG. 3D is a diagram of an arm.

FIG. 4A is a diagram of a simplified base.

FIG. 4B is a diagram showing arm pins navigating through pin slots.

FIG. 5A is a diagram of package strip with three attached packages.

FIG. 5B is a diagram of a package strip with two attached packages and one separated package.

FIG. 5C is a diagram of three separated packages.

FIG. 6 is a flowchart of a method for using the package separator to separate packages in a package strip.

FIG. 7A is a vertically exploded view of an example package separator.

FIG. 7B is a diagram of a package separator showing insertion of a package strip.

FIG. 7C is a diagram of a package separator with a package strip installed.

FIG. 8A is a diagram of a package separator separating a first package from a package strip.

FIG. 8B is a diagram of a package separator separating a second package from a package strip.

FIG. 8C is a diagram of a package separator separating a third package from a package strip.

FIG. 8D is a diagram of a package separator separating a package strip into two packages.

FIG. 9 is a diagram of a system for automating separation of packages.

DETAILED DESCRIPTION

This application discloses methods and systems for separating packages in a package strip. Specifically, disclosed herein is a package separator that can accept a package strip and, when actuated, separates the package strip into one or more smaller arrays.

Conventionally, when a contact lens package is formed, several packages (e.g., two or more) are formed into a single continuous package strip. Prior to shipping the package strip, perforation lines are added between each adjacent package within the strip. As designed, two packages are separated by “breaking” a single row of perforations simultaneously (e.g., bending the package strip using the perforation line as a “hinge” or snapping packages apart over the edge of a surface). Ideally, such perforation lines make it easier for a user to separate the individual packages of the package strip.

However, even with perforations, the packages may still be too cumbersome or otherwise difficult to separate. Worse yet, when separating packages, a user may “tear” packages apart by grabbing two adjacent packages and moving them in opposite directions, attempting to break each perforation consecutively along the perforations. However, such “tearing” motion often causes the separation to veer off the perforation line. In such instances, the tear may deviate into the bowl of the package base or bowl holding the contact lens, thereby prematurely opening the contact lens and contaminating the sterile enclosure.

A package separator is disclosed that allows an individual or machine to easily separate a package strip into individual packages. Specifically, the device allows a user to separate the packages without risking tearing into the sterile volume of the package.

FIG. 1A-1F

FIG. 1A is a diagram of a package. FIG. 1B is a diagram of a package strip. FIG. 1C is a cutaway diagram of a package. FIG. 1D is an exploded cutaway diagram of a package. FIG. 1E is a diagram of an example package strip. FIG. 1F is a diagram of an example package strip.

In FIG. 1A, package 100 is a container for storing liquid 110 and optionally an object 108 (depicted herein as a contact lens). After object 108 is manufactured, object 108 may be placed in package 100 to provide a protective and sterile environment in which object 108 may be stored. To safely store object 108, package 100 may be constructed and assembled from several subcomponents, described below. Package 100 may be constructed in different shapes and/or sizes and consequently have varying convex contours. As a non-limiting example, package 100 depicted in FIG. 1A differs from packages 100 depicted in FIG. 1E, both of which differ from packages 100 depicted in FIG. 1F. The package 100 may have any suitable shape and size with additional contours, cutouts, and textures for a variety of reasons.

Base 102 is the primary structural hull of package 100. Base 102 may be a constructed from a semi-rigid plastic (e.g., polyethylene terephthalate (PET), polypropylene (PP), etc.) or any material more rigid than non-rigid material 106. Base 102 may be fabricated to be clear (e.g., transparent and/or translucent).

Bowl 104 is a hollow bulbous protrusion of base 102 that forms a concave volume in which object 108, liquid 110, and package gas 112 may be stored. Bowl 104 may be constructed from the same material as base 102. Bowl 104 may be clear (transparent and/or translucent) to allow a user to visually inspect the contents therein.

Non-rigid material 106 is a covering that may be applied to base 102 to seal the concave side of bowl 104. Thus, non-rigid material 106 may be used to isolate the contents of bowl 104 (e.g., object 108, liquid 110) and provide a protective barrier that prevents the contamination of the contents of bowl 104. Non-rigid material 106 may be any plastic, polymer, foil, laminate, and/or composite or multi-layer material adhered to base 102. Non-rigid material 106 may be adhesively applied to base 102 via a “sticky” substance (e.g., glue) and/or via heat or other suitable method. Non-rigid material 106 may be removed from base 102 via peeling, puncture, and/or tearing (e.g., by a user).

Liquid 110 may be a liquid fluid, gel, or paste stored in bowl 104. Liquid 110 may be used to preserve object 108 stored in package 100, or liquid 110 may be stored alone without any other object in package 100. In the case of contact lens manufacture, liquid 110 is sterile (e.g., sterilized saline).

Package gas 112 is a gaseous fluid that may be stored in bowl 104 with liquid 110 and object 108. When liquid 110 is added to bowl 104, liquid 110 may not entirely fill the volume of bowl 104, leaving some air (and/or other gases) to fill the remaining volume of bowl 104. When base 102 is adequately sealed with non-rigid material 106, package gas 112 is trapped inside bowl 104 until non-rigid material 106 is removed.

Package strip 114 may include a series of two or more connected packages 100. Two or more packages 100 may be manufactured in package strip 114 (e.g., molded as a single piece of plastic, covered with a single piece of non-rigid material 106, etc.).

Perforation line 116 may be the boundary between two adjoining packages 100 in package strip 114. Perforation line 116 may include one or more hole(s) and/or one or more indentation(s) in base 102 and non-rigid material 106, which demarcate a boundary between packages 100. The hole(s) and/or indentation(s) of perforation line 116 provide one or more point(s) of weakness in base 102 and non-rigid material 106, which allow for a greater likelihood of separating packages 100 along perforation line 116.

FIG. 1G-1J

FIG. 1G is a diagram of a package strip under lateral tension. FIG. 1H is a diagram of perforation lines under lateral tension. FIG. 1I is a diagram of a package strip under tearing tension. FIG. 1J is a diagram of perforation lines under tearing tension.

Separation angle Θ is the relative angle between two adjacent packages 100 joined by perforation line 116. Package strip 114 may be separated into individual packages 100 by applying tensile force across package strip 114 in a direction perpendicular to perforation line 116. The tensile force applied across packages 100 lies within the same axis causing a low separation angle Θ (e.g., less than 10 degrees (°), less than 1 degree) (as depicted in FIGS. 1G and 1H). However, the direction of force may not be exactly opposite and may further include rotation (i.e., applied torque). In such instances, separation angle Θ may be sufficiently large enough (e.g., greater than 1 degree, greater than 10 degrees) and packages 100 may “tear”down perforation line 116 (as depicted in FIGS. 1I and 1J).

Connections 117 are the physical bridges between holes of perforation line 116. In FIGS. 1G-1J, connections 117 across package A 110A and package B 100B are the same material as base 102 and non-rigid material 106 (through which perforation line 116 is made). Further, each connection 117 may withstand different thresholds of tension before breaking and separating (e.g., based on minor differences in thickness, width, material density, etc.).

As depicted in FIGS. 1G and 1H, if the separation angle is low (e.g., less than 10 degrees, less than 1 degree) and sufficient tension is applied, perforation line 116 may break evenly throughout. When increasing tension is applied evenly across perforation line 116, the weakest connection 117 is likely to break first. Once a first connection breaks (and is no longer a connection), the load from that broken connection is redistributed to the remaining connections 117. Consequently, the increased stress on the remaining connections 117 causes one or more of those connection(s) 117 to break—further increasing the load of the fewer remaining connections 117. Thus, once the first connection 117 breaks (which may be at any location within perforation line 116), the remaining connections 117 are likely to break in rapid succession across the entirety of perforation line 116. Such a method for separating packages 100 may be considered “one-dimensional”, “purely lateral”, and/or “without tearing”.

As depicted in FIGS. 1I and 1J, if the separation angle is high (e.g., above 10 degrees) and sufficient tension is applied, perforation line 116 may break by “tearing”. In such a separation, connections 117 break in sequence along perforation line 116 starting from one edge where greater separating force is applied. When tearing, the packages 100 become slightly further separated when any connection 117 breaks, allowing greater force to be applied to the next adjacent connection 117. Consequently, as the tension continues to increase, that next adjacent connection 117 breaks, continuing the separation down perforation line 116. The process may repeat until all connections 117 of perforation line 116 are broken and package A 100A separates from package B 100B. Such a method for separating packages 100 may be considered “two-dimensional”, “twisting”, and/or “tearing”.

FIGS. 2a-2c

FIG. 2A is a diagram of an open package separator. FIG. 2B is a diagram of an open package separator with a package strip. FIG. 2C is a diagram of a closed package separator.

Package separator 220 may be a mechanical device used to separate packages 100 in package strip 114. Package separator 220 may be made from one or more subcomponents. As shown in FIGS. 2A-C, package separator 220 may include a chassis 224 and sled 222. Package separator 220 may function by accepting package strip 114 to be inserted into sled 222, where sled 222 is then moved into chassis 224. Package separator 220 may be made from any suitable material or combination of materials (e.g., metal, plastic, wood, etc.).

Sled 222 may be a mechanical device adapted to accept package strip 114 and slide into chassis 224. When sled 222 is fully inserted into chassis 224, sled 222 (and package separator 220, generally) may be considered in a “closed” or “inserted” position. When sled 222 is fully extended from chassis 224, sled 222 (and package separator 220, generally) may be considered in an “open” or “fully extended” position. Additional details regarding sled 222 may be found in the description of FIG. 3A and FIG. 3B.

Chassis 224 may include base 226 and cover 228. Chassis 224 may be largely hollowing (allowing sled 222 to translate therein) with additional components to guide sled 222 and separate packages 100. To keep package separator 220 stationary during the translation of the sled 222, chassis 224 may (i) have a mass greater than the mass of the sled 222, (ii) be fixed to a surface, and/or (iii) have a bottom surface and/or be placed on a surface with a high coefficient of friction (e.g., a rubber pad, textured “anti-slip” tape, etc.).

Base 226 may be a mechanical device forming a general support structure and include one or more components of package separator 220. Additional details regarding base 226 may be found in the description of FIG. 3A and FIG. 3C.

Cover 228 may be a structure that forms the top, sides, or both (top and sides) of package separator 220. Cover 228 constrains the vertical movement of package strip 114 and/or individual package(s) 100 when sled is inserted into chassis 224 (e.g., cover 228 prevents packages 100 from displacing upwards, out of package seats 338).

Leading edge 229 may be a structure installed at an opening of cover 228. Leading edge 229 may be chamfered to allow for package strip 114 to slide into chassis 224 more easily, reducing the likelihood of one or more package(s) 100 impacting or catching on cover 228 during insertion.

Central longitudinal axis 250 is an imaginary axis disposed along the length of package separator 220. Central longitudinal axis 250 is parallel to the direction of translation of sled 222 into and out of chassis 224. Additionally, central longitudinal axis 250 divides package separator 220 into two lateral halves. That is, central longitudinal axis 250 may extend along to the longitudinal center of package separator 220.

A “front” of package separator 220 may be the side that includes sled 222. A “back” of package separator 220 may be the side opposite the “front”. A “bottom” of package separator 220 may be the side with base 226, and the “top” the side with cover 228.

FIGS. 3a-3d

FIG. 3A is a diagram of an open package separator with a cover. FIG. 3B is a diagram of a sled. FIG. 3C is a diagram of a base. FIG. 3D is a diagram of an arm.

Sled 222 may be a mechanical device configured to accept package strip 114, slide into chassis 224, and allow for the separation of package strip 114 into packages 100. Sled 222 may include one or more rail slot(s) 331, one or more handle(s) 334, and one or more arm(s) 336.

Rail slot 331 may constrain the motion of sled 222 with respect to chassis 224 of package separator 220. Rail slot 331 may have a shape that complements sled guide rail 342 (e.g., rail slot 331 interlocks with sled guide rail 342) to limit respective motion to a single dimension (i.e., linear motion, translation in a direction parallel to central longitudinal axis 250). Rail slot 331 may be inserted onto sled guide rail 342 (or sled guide rail 342 may be inserted onto rail slot 331) at a distal end of package separator 220.

Handle 334 may allow interaction with and/or control of package separator 220. Handle 334 may be an elongated member constructed from a rigid material and sized such that a human user of package separator 220 may grasp the structure with their hand to apply force and cause the motion of sled 222. Suitable alternatives may be substituted for handle 334 without changing the function of package separator 220, such as a knob or a machine controlled linear actuator.

Arm 336 may be a mechanical device used to support package 100 (e.g., via package seat 338). Arm 336 includes package seat 338, package seat pin 339, arm pin 330, and pivot pin 332 rotatably affixed to sled 222. Arm 336 is affixed to sled 222 causing arm 336 to move with sled 222, as sled 222 translates along the length of package separator 220 (e.g., in the direction of central longitudinal axis 250).

Package seat 338 may provide support to package 100. Package seat 338 may have concave contours that complement the convex contours of package 100 (e.g., bowl 104). Further, package seat 338 may include a package seat pin 339. When a user utilizes package separator 220, the user places package strip 114 into two or more corresponding package seats 338. Package seat 338 may include a concave portion that allows package 100 to fit (at least partially) therein. The contour portion of package seat 338 may be adapted to allow for multiple types of packages 100 to fit at least partially therein. That is, packages 100 may be different shapes and sizes and consequently have varying convex contours. Accordingly, package seat 338 may be constructed to allow for packages 100 of different shapes and/or sizes to “fit” into package seat 338 (e.g., having three or more points of contact that allow for a stabilized positioning of package 100).

Package seat pin 339 may be affixed to an underside of package seat 338. Package seat pin 339 may slide into a hole in arm 336, while still allowing package seat pin 339 (and package seat 338, generally) to pivot or swivel within arm 336.

Arm pin 330 may be affixed to a leading distal end of arm 336. Arm pin 330 may be at least partially disposed within the walls of pin slot 340. Accordingly, as arm 336 (and sled 222, generally) slides into chassis 224 of package separator 220, the position and movement of arm pin 330 is guided by the contours of pin slot 340.

Pivot pin 332 may rotationally affix arm 336 to sled 222. Pivot pin 332 traverses at least partially through arm 336 and sled 222 thereby acting as a hinge around which arm 336 may pivot or swivel with respect to sled 222. Pivot pin 332 may allow for the rotation of arm 336 due to the lateral displaced of arm pin 330 caused by the contours of pin slot 340. Further, pivot pin 332 may be between package seat 338 and arm pin 330. Accordingly, any rotation of arm 336 around pivot pin 332, clockwise or counterclockwise, causes package seat 338 and arm pin 330 to move in opposite lateral directions (e.g., tangential to the rotation, but in the same direction rotationally).

Base 226 provides support for package separator 220 and components for guiding the movement of sled 222. Base 226 may include one or more pin slot(s) 340 and one or more sled guide rail(s) 342. Base 226 may have a mass that is multiple times greater than sled 222 to allow base 226 to maintain its position while sled 222 slides thereupon.

Pin slot 340 may be adapted to constrain the motion of arm pin 330. Pin slot 340 may be a concave channel adapted to fit arm pin 330 at least partially within its contours. Pin slot 340 may have a path that extends along a direction largely parallel to central longitudinal axis 250. The walls of pin slot 340 may include one or more curved section(s) or contours used to control the direction of arm pin 330 as arm pin 330 slides through pin slot 340. In FIGS. 3A and 3C, each pin slot 340 includes an initial curved section that alters the direction of pin slot 340 inward (i.e., towards central longitudinal axis 250 when translating sled 222 into chassis 224) before a second curved section that alters the direction of pin slot 340 to again run parallel to central longitudinal axis 250. Accordingly, as arm pin 330 is constrained by the walls of pin slot 340, arm 336 pivots (i.e., around pivot pin 332) as arm pin 330 navigates the curved sections of pin slot 340.

Sled guide rail 342 may constrain the motion of sled 222. Sled guide rail 342 has a shape that complements rail slot 331 (e.g., rail slot 331 interlocks with sled guide rail 342). Accordingly, due to the physical constraints of the connection between rail slot 331 and sled guide rail 342, the motion of sled 222 may be limited to a single dimension of linear motion (i.e., translation in a direction parallel to central longitudinal axis 250).

FIGS. 4a-4b

FIG. 4A is a diagram of a simplified base. FIG. 4B is a diagram of an example showing arm pins navigating through pin slots.

As depicted in FIG. 4A, base 226 may include multiple pin slots 340, including, as an example, pin slot A 340A, pin slot B 340B, pin slot D 340D, and pin slot E 340E. Each of these pin slots 340 may correspond to a respective arm pin 330 (e.g., arm pin A 330A, arm pin B 330B, arm pin D 330D, and arm pin E 330E, respectively).

At T0, sled 222 (not shown) is in the fully extended position and each arm pin 330 is at or near the rear-most contours of each respective pin slot 340.

After T0, but before T1, sled 222 moves along base 226 parallel to central longitudinal axis 250 (downward as shown in FIG. 4B). As sled 222 moves, each arm pin 330 rides in their respective pin slot 340.

At T1, arm pin A 330A moves laterally inward towards central longitudinal axis 250 while continuing to translate forward (downward as depicted in FIG. 4B). The lateral inward motion of arm pin A 330A causes arm A 336A (not shown) to pivot around pivot pin A 332A (not shown) in a counterclockwise direction. Due to the rotation of arm A 336A around pivot pin A 332A, package seat A 338A (not shown, holding package A 100A, not shown) shifts laterally outward away from central longitudinal axis 250. Due to this lateral movement outward, package A 100A separates from package B 100B (not shown).

After T1 and until T2, arm pin A 330A may shift laterally inward twice (or more) as required to cause the separation of package A 100A from package B 100B. By laterally shifting arm pin A 330A more than required to cause separation, sufficient space is provided for arm pin B 330B to laterally shift away from package C 100C (without contacting package A 100A).

At T2, arm pin B 330B moves laterally inward (i.e., towards central longitudinal axis 250) while continuing to translate forward (downward as depicted in FIG. 4B). The lateral inward motion of arm pin B 330B causes arm B 336B (not shown) to pivot around pivot pin B 332B (not shown) in a counterclockwise direction. Due to the rotation of arm B 336B around pivot pin B 332B, package seat B 338B (not shown, holding package B 100B) shifts laterally outward (i.e., away from central longitudinal axis 250). Due to this lateral movement outward, package B 100B separates from package C 100C (not shown). Further, as arm A 336A pivoted (at least) twice the distance required, arm B 336B has sufficient space to move without interfering with package A 100A.

Package C 100C (not shown) is not attached to an arm 336. Accordingly, while package C 100C may translate along with sled 222, package C 100C does not shift laterally during this motion. Accordingly, the motion of package C 100C is not matched with a respective pin slot 340 in the examples of FIGS. 4A and 4B.

At T3, arm pin E 330E moves laterally inward (i.e., towards central longitudinal axis 250) while continuing to translate forward (downward as depicted in FIG. 4B). The lateral inward motion of arm pin E 330E causes arm E 336E (not shown) to pivot around pivot pin E 332E (not shown) in a clockwise direction. Due to the rotation of arm E 336E around pivot pin E 332E, package seat E 338E (not shown, holding package E 100E, not shown) shifts laterally outward (i.e., away from central longitudinal axis 250). Due to this lateral movement outward, package E 100E separates from package D 100D (not shown).

After T3 and until T4, arm pin E 330E may shift laterally inward twice or more as required to cause the separation of package E 100E from package D 100D. By laterally shifting arm pin E 330E more than required to cause separation, sufficient space is provided for arm pin D 330D to laterally shift away from package C 100C without contacting package E 100E.

At T4, arm pin D 330D moves laterally inward (i.e., towards central longitudinal axis 250) while continuing to translate forward (downward as depicted in FIG. 4B). The lateral inward motion of arm pin D 330D causes arm D 336D (not shown) to pivot around pivot pin D 332D (not shown) in a clockwise direction. Due to the rotation of arm D 336D around pivot pin D 332D, package seat D 338D (not shown, holding package D 100D) shifts laterally outward (i.e., away from central longitudinal axis 250). Due to this lateral movement outward, package D 100D separates from package C 100C. Further, as arm E 336E pivoted at least twice the distance required, arm D 336D has sufficient space to move without interfering with package E 100E.

After T4, each package 100 may be separated from each other package 100, thereby deconstructing package strip 114 into individual packages 100.

At T5, the motion of sled 222 is limited by each arm pin 330 contacting the forward-most contours of each respective pin slot 340. Accordingly, at T5, sled 222 may be considered “fully inserted” into package separator 220 (or the chassis 224 thereof).

Throughout the example of FIG. 4B, as sled 222 moves along base 226, each package 100 separates at a different time and distance throughout the motion. Accordingly, a user of package separator 220, may feel (e.g., as increased counterforce) four relatively equal “spikes” during the motion. Package separator 220 may be designed such that two or more packages 100 separate nearer in distance/time (e.g., simultaneously, concurrently, overlapping, etc.). Staggered separation may be easier for a human user, while concurrent separation may be more practical for machine interaction as it would take less time.

FIGS. 5a-5c

FIG. 5A is a diagram of package strip with three attached packages. FIG. 5B is a diagram of a package strip with two attached packages and one separated package. FIG. 5C is a diagram of three separated packages.

FIG. 5A shows a point in time when package strip 114 (joining package A 100A, package B 100B, and package C 100C) is initially placed into package separator 220. Each package is joined to at least one neighboring package by perforation line 116 (e.g., package A 100A is joined to package B 100B at perforation line AB 116AB, and package B 100B is joined to package C 100C at perforation line BC 116BC).

FIG. 5B shows a point in time when arm pin A 330A and arm pin C 330C slide along the contours of pin slot A 340A (not shown) and pin slot C 340C (not shown). In turn, the contours of pin slot A 340A shift arm pin A 330A laterally inward causing counterclockwise rotation of arm A 336A around pivot pin A 332A. As package A 100A is on the opposite distal end of arm A 336A from arm pin A 330A (with pivot pin A 332A therebetween), package A 100A shifts laterally outward consistent with the counterclockwise motion of arm A 336A. Accordingly, package A 100A is forced away from package B 100B in a direction substantially orthogonal to central longitudinal axis 250 (not shown), thereby causing package A 100A and package B 100B to separate along perforation line AB 116AB. As used herein, “substantially orthogonal” means the deviation from a perfectly orthogonal angle is less than 15 degrees, 10 degrees, 5 degrees, or even less than 1 degree.

Further, package seat A 338A (not shown, under package A 100A) may be rotationally affixed to arm A 336A (e.g., via package seat pin A 339A, not shown). Accordingly, as arm A 336A rotates counterclockwise, package seat A 338A rotates clockwise (with respect to arm A 336A) to remain parallel to package seat B 338B (not shown). The clockwise rotation of package seat A 338A is caused by the stresses distributed across perforation line AB 116AB, and package seat A 338A pivoting due to any net moment caused by those forces. Consequently, the rotation of package seat A 338A allows perforation line AB 116AB to break simultaneously or in short succession across the length (e.g., as shown in FIGS. 1G and 1H). Whereas, if package seat A 338A was unable to pivot, a “tearing” separation would occur starting at the rear-most edge (top edge, as shown in FIG. 5B) (e.g., as shown in FIGS. 1I and 1J).

FIG. 5C shows a point in time when arm pin A 330A and arm pin C 330C continue sliding along the contours of pin slot A 340A and pin slot C 340C. In turn, the contours of pin slot C 340C shift arm pin C 330C laterally inward, causing clockwise rotation of arm C 336C around pivot pin C 332C. As package C 100C is on the opposite distal end of arm C 336C from arm pin C 330C (with pivot pin C 332C disposed therebetween), package C 100C shifts laterally outward (consistent with the clockwise motion of arm C 336C). Accordingly, package C 100C is forced away from package B 100B in direction a substantially orthogonal to central longitudinal axis 250 (not shown), thereby causing package C 100C and package B 100B to separate along perforation line BC 116BC.

Further, package seat C 338C (not shown, under package C 100C) may be rotationally affixed to arm C 336C (e.g., via package seat pin C 339C, not shown). Accordingly, as arm C 336C rotates clockwise, package seat C 338C rotates counterclockwise (with respect to arm C 336C) to remain parallel to package seat B 338B (not shown). The counterclockwise rotation of package seat C 338C is caused by the stresses across perforation line BC 116BC, and package seat C 338C pivoting due to any net motion caused by those forces. Consequently, the rotation of package seat C 338C allows perforation line BC 116BC to break simultaneously or in short succession across the length (e.g., as shown in FIGS. 1G and 1H). Whereas, if package seat C 338C was unable to pivot, a tearing separation would occur starting at the rear-most edge (top edge, as shown in FIG. 5C) (e.g., as shown in FIGS. 1I and 1J).

FIG. 6

FIG. 6 is a flowchart of a method for using the package separator to separate packages in a package strip. All or part of the method shown may be performed by one or more user(s) of a package separator. While the various steps in this flowchart are described sequentially, some or all steps may be executed in different orders, combined, or omitted, and some or all steps may be executed in parallel.

In step 600, a user obtains a package separator and a package strip. Obtaining the package strip may include a user physically acquiring a package strip by via one or more of their hand(s). Obtaining a package separator may include a user navigating to within a sufficient proximity of a package separator to allow for use of the package separator.

In step 602, a user determines whether the sled of the package separator is in a fully extended position. A user may visually assess the package separator to determine the current position of the sled with respect to the chassis of the package separator. If the sled is not in a fully extended position (step 602—NO), the method proceeds to step 604. However, if the sled is in a fully extended position (step 602—YES), the method proceeds to step 606.

In step 604, a user slides the sled out of the chassis of the package separator. A user may engage with a handle of the sled (e.g., using their hand to grasp a handle) and pull the sled in a direction away from the chassis of the package separator. The user may continue to slide the sled away from the chassis of the package separator until the sled is in a fully extended position (e.g., is mechanically prevented from moving further).

In step 606, a user inserts the package strip into the sled of the package separator. The package strip may be installed in the package separator by orienting the bowl-side of the packages downward and placing each of the bowls in a respective package seat. There may be an equal or greater quantity of package seats than packages in the package strip.

In step 608, a user slides the sled into the chassis of the package separator. A user may engage with a handle of the sled (e.g., using their hand to grasp a handle) and push the sled in a direction toward the chassis of the package separator along a central longitudinal axis. The user may continue to slide the sled into the chassis until the sled is in a fully inserted position (e.g., is mechanically prevented from moving further). During the insertion of the sled, the package strip may separate into individual packages via the mechanical stresses placed on the package strip during the translation of the package strip.

In step 610, a user slides the sled out of the chassis of the package separator. Step 610 may be substantially similar to step 604.

In step 612, a user removes the individual packages from the sled of the package separator. Each package may sit in a respective package seat after separation (in step 608). Accordingly, after a user pulls the sled out of the package separator, the user may collect the individual packages from each of the occupied package seats.

FIGS. 7A-7C

FIG. 7A is a vertically exploded view of an example package separator. FIG. 7B is a diagram of a package separator showing insertion of a package strip. FIG. 7C is a diagram of a package separator with a package strip installed.

As shown in FIGS. 7A-7C (and FIGS. 8A-8D), package separator 720 may include one or more package nest(s) 740 slidably mounted on nest guide rail 748. Further, piston 750 may actuate to slide one or more package nest(s) 740 along nest guide rail 748. Clamp plate 754 may be affixed to package separator 720 for keeping package(s) 100 (and/or package strip 114) in position. Each of these components is described below.

Package nest 740 is a structural component of package separator 720 which may slide along nest guide rail 748 to cause package strip 114 to separate into one or more individual package(s) 100. Package separator 720 depicted in FIGS. 7A-7C may be implemented in a manufacturing process, packaging process, or other assembly line and used to automate the process of separating package strip(s) 114 into individual package(s) 100 or smaller package strips 114.

Package nest 740 may include a concave portion constructed to allow package 100 to fit at least partially therein. The contour portion of package nest 740 may be adapted to allow for different types of packages 100 to fit at least partially therein. That is, packages 100 may be constructed in different shapes and sizes and consequently have varying convex contours. Accordingly, package nest 740 may be constructed to allow for packages 100 of different shapes and/or sizes to “fit” into package nest 740 (e.g., having three or more points of contact that allow for a stabilized positioning of package 100).

Package nest 740 may include (or otherwise be affixed with) nest link 742, link pin 746, a groove (not shown) to mount onto nest guide rail 748, and one or more fastener(s) for affixing any of the aforesaid components together.

Nest link 742 is a mechanical component that may limit the motion of adjacent package nests 740. Nest link 742 may be fixed to package nest 740 at one distal end and slidably fixed to an adjacent package nest 740 at the opposing distal end. Nest link 742 may include link slot 744 as a through hole for interaction with link pin 746. Nest link 742 may be constructed from any suitable material including, but not limited to, any metal, any plastic, wood, composite, and/or any combination thereof. Nest links 742 may be disposed on one of both sides of package nest 740.

Link slot 744 is an elongated opening in nest link 742. Link slot 744 may be constructed to fit link pin 746 therethrough (i.e., the height of link slot 744 is greater than the height of link pin 746). The width of link slot 744 may be disposed along the length of nest guide rail 748—parallel to the motion of package nest(s) 740 along nest guide rail 748. The width of link slot 744 may be constructed to allow for adjacent package nests 740 to touch (i.e., not limiting the motion of link pin 746 in the leftward direction, as depicted in FIGS. 7A-7C). Further, link slot 744 may be constructed to allow adjacent package nests 740 to separate sufficiently far apart to cause separation of adjacent packages 100 in package strip 114 (i.e., allowing link pin 746 to translate sufficiently rightward, as depicted in FIGS. 7A-7C, before contacting the inner contours of link slot 744).

Link pin 746 is a mechanical component, fixed to package nest 740, which may traverse at least partially through link slot 744 of an adjacent package nest 740. When one or both of adjacent package nests 740 are translated apart (e.g., along nest guide rail 748), link pin 746 may be configured to engage the inner contours of the adjacent link slot 744. After contacting the adjacent nest link 742 (via link slot 744), link pin 746 may transfer the tension to the adjacent package nest 740 via the mechanical coupling between link pin 746 and nest link 742. Accordingly, as one package nest 740 is caused to translate, additional package nest(s) 740 may be caused to translate via the contact between link pin(s) 746 and link slot(s) 744 (of nest link(s) 742).

Nest guide rail 748 is a structure of package separator 720 which may constrain the motion of package nest 740. Nest guide rail 748 has a shape that complements a slot disposed on a side of package nest 740 (not shown) (e.g., package nest 740 interlocks with nest guide rail 748). Accordingly, due to the physical constraints of the connection between package nest 740 and nest guide rail 748, package nest 740 may be limited to a single dimension of linear motion (i.e., translation in a direction along the length of nest guide rail 748). Nest guide rail 748 may be fixed to a piston body of piston 750 directly or via a base and a package nest 740 (e.g., the leftmost package nest 740, as depicted in FIGS. 7A-7C).

Piston 750 is a mechanical device which may extend piston rod 752 therefrom. Piston 750 may include a piston body in which piston rod 752 may extend from and retract into. Piston rod 752 may extend from piston 750 via hydraulics (e.g., liquids), pneumatics (e.g., gases), mechanical components (e.g., gears, linkages, levers), and/or electronics (e.g., motors, piezoelectronics). The piston body of piston 750 may be fixed to a first component (e.g., a base or other structure) while piston rod 752 may be fixed to a second component that is intended to move with respect to the first component (e.g., a sliding component). Thus, as piston 750 actuates (extending piston rod 752) force may be applied to separate the two affixed components (i.e., fixed to piston body of piston 750 and piston rod 752). Piston body (of piston 750) may be affixed to the package nest 740 disposed at one end of the array of package nests 740 (e.g., a “first package nest”, the leftmost package nest 740, as depicted).

Piston rod 752 is a structural component of piston 750 which may be configured to extend from a piston body of piston 750. Piston rod 752 may be constructed from any suitable rigid material and used to exert force on another object (e.g., package nest 740). Piston rod 752 may have any suitable cross-sectional shape (e.g. rounded, square, rectangular, and/or combination thereof). Further, the exposed distal end of piston rod 752 may include one or more means for interlocking (e.g., a through hole, notch, pin, keyhole, threads, nuts, etc.) to another component (e.g., to package nest 740 using fasteners). Piston rod 752 may be affixed to the package nest 740 disposed at one end of the array of package nests 740 (e.g., a “last package nest”, the rightmost package nest 740, as depicted).

Clamp plate 754 is a structural component of package separator 720 which may be used to constrain movement of package(s) 100 and/or package strip 114. Clamp plate 754 may rest firmly upon package(s) 100 and/or package strip 114 on a side opposite the concave contours of package nest 740 to prevent package(s) 100 and/or package strip 114 from unseating from package nest 740. Thus, when piston rod 752 extends to cause stress across package strip 114, packages 100 (of package strip 114) may not simply lift out of their respective package nests 740 to reduce the stresses exerted thereon. Instead, packages 100 remain seated in their respective package nests 740 as clamp plate 754 constrains any such undesired movement.

Using package separator 720 depicted in FIGS. 7A-7C and FIGS. 8A-8D, the tension applied to packages 100 of package strip 114 may be considered “one-dimensional” (e.g., as shown in FIGS. 1G and 1H). That is, using package separator 720, packages 100 are pulled apart in the direction of motion of package nest 740—without any tearing, pivoting, rotating, twisting, or other two-dimensional deviation.

FIGS. 8a-8d

FIG. 8A is a diagram of a package separator separating a first package from a package strip. FIG. 8B is a diagram of a package separator separating a second package from a package strip. FIG. 8C is a diagram of a package separator separating a third package from a package strip. FIG. 8D is a diagram of a package separator separating a package strip into two packages.

In FIG. 8A, after piston rod 752 begins to extend, the right-most (as depicted) package nest 740 is forced rightward via the rigid attachment between piston rod 752 and the right-most package nest 740. Consequently, the right-most package 100 (resting within the contours of the right-most package nest 740) is similarly caused to move rightward and separate from package strip 114 (e.g., along perforation line 116). Additionally, while undergoing rightward motion, the right-most package nest 740 translates along nest guide rail 748, and link pin 746 translates within link slot 744 of the left-neighboring nest link 742.

In FIG. 8B, piston 750 continues to be actuated causing piston rod 752 to extend further rightward. Link pin 746 of the right-most package nest 740 is moved to engage nest link 742 of the second-to-the-right package nest 740. Consequently, the second-to-the-right package nest 740 begins to move rightward via the force applied by piston rod 752 and transmitted via link pin 746 and nest link 742. Similar to the right-most package nest 740, the second-to-the-right package nest 740 slides along nest guide rail 748 and causes package 100 sitting thereon to separate from package strip 114.

In FIG. 8C, similar to FIG. 8B, piston rod 752 continues to move rightward and separate another package 100 from package strip 114. Subsequently, piston rod 752 continues to extend rightward increasing the tension applied to the remaining perforation line 116 via the three right-most nest links 742.

In FIG. 8D, the two remaining packages 100 separate, eliminating package strip 114. Further, after each package 100 is separated, piston rod 752 may reach its maximum extension length and cause no additional stresses across nest links 742.

Although package(s) 100 are shown to separate sequentially from right to left, packages 100 may separate in any order using the package separator 720 depicted in FIGS. 7A-7C and FIGS. 8A-8D. Each perforation line 116 is likely to require some (albeit minor) different force to break. Thus, as piston rod 752 begins to extend, tension is distributed equally across package strip 114 and each perforation line 116 thereof. As piston rod 752 continues to extend, the weakest perforation line 116 is prone to break first (which may not necessarily be the rightmost perforation line 116). Subsequently, after the first perforation line 116 breaks, piston rod 752 continues to extend until link pin 746 and nest link 742 engage across the broken perforation line 116. As piston rod 752 extends further, tension is again built equally across each of the remaining perforation lines 116. Tension would continue to build until the applied stress exceeds the now-weakest perforation line 116 causing that perforation line 116 to break. Such separation may occur in any order in package strip 114.

FIG. 9

FIG. 9 is a diagram of a package separator using a conveyor.

Conveyor 956 is an electromechanical system which may move along a track, belt, or other circulating path. The movement of the conveyor 956 (e.g., by a motor mechanically coupled to the conveyor 956) may be controlled by a computing device (e.g., toggling the movement, controlling the speed of the motor). Non-limiting examples of a conveyor 956 include a belt conveyor and a roller conveyor. One or more pin slot(s) 340 may be disposed on the surface of conveyor 956 to control the movement of arm pin(s) 330.

As depicted for package separator 920 of FIG. 9, two or more arms 336 (see FIG. 3D) may be arranged into a lateral row to hold package strip 114 (e.g., a row of five package seats 338 as depicted in FIG. 9). Multiple rows of arms 336 may be disposed longitudinally to support an equal (or fewer) number of package strips 114 (not shown). Although only two rows of arms 336 are depicted, more arms 336 may be disposed in a line (e.g., 10, 30, 100 or more).

Arms 336 may be disposed on top of and into conveyor 956 such that each arm pin 330 inserts into a respective pin slot 340. Similar to pin slots(s) 340 depicted in FIGS. 3A, 3C, 4A, and 4B—pin slot(s) 340 of FIG. 9 are contoured and shaped in such a way as to cause arms 336 to separate package strip 114 (disposed in package seat(s) 338) into individual packages 100. However, unlike FIGS. 3A, 3C, 4A, and 4B—pin slot(s) 340 of FIG. 9 may cause multiple packages 100 to separate simultaneously (two packages 100 are separated simultaneously, as depicted in FIG. 9) as the process is controlled by machinery and not by human hand. Clamp plate 754 may be disposed on top of package strips 114 resting in package seats 338 to keep packages 100 seated therein.

Conveyor 956 may move under arms 336 while arms are stationary to cause the movements of arm pins 330. Similarly, arms 336 may translate across the surface of conveyor 956 (forcing arm pins 330 through the paths of pin slots 340) while conveyor is stationary (e.g., arms would be controlled by a separate conveyor not shown). Both arms 336 and conveyor 956 may move simultaneously, albeit in different directions or at different speeds, to allow arm pins 330 to travel the contoured paths of pin slots 340.

As used herein, adjective ordinal numbers (e.g., first, second, third, etc.) are used to distinguish between elements and do not create any ordering of the elements. As an example, a “first element” is distinct from a “second element”, but the “first element” may come after (or before) the “second element” in an ordering of elements. Accordingly, an order of elements exists only if ordered terminology is expressly provided (e.g., “before”, “between”, “after”, etc.) or a type of “order” is expressly provided (e.g., “chronological”, “alphabetical”, “by size”, etc.). Further, use of ordinal numbers does not preclude the existence of other elements. As an example, a “table with a first leg and a second leg” is any table with two or more legs (e.g., two legs, five legs, thirteen legs, etc.). A maximum quantity of elements exists only if express language is used to limit the upper bound (e.g., “two or fewer”, “exactly five”, “nine to twenty”, etc.). Similarly, singular use of an ordinal number does not imply the existence of another element. As an example, a “first threshold” may be the only threshold and therefore does not necessitate the existence of a “second threshold”.

As used herein, indefinite articles “a” and “an” mean “one or more”. That is, the explicit recitation of “an” element does not preclude the existence of a second element, a third element, etc. Further, definite articles (e.g., “the”, “said”) mean “any one of” the “one or more” elements when referring to previously introduced element(s). As an example, there may exist “a processor”, where such a recitation does not preclude the existence of any number of other processors. Further, “the processor receives data, and the processor processes data” means “any one of the one or more processors receives data” and “any one of the one or more processors processes data”. It is not required that the same processor both (i) receive data and (ii) process data. Rather, each of the steps (“receive” and “process”) may be performed by different processors.