Automated prescription and/or literature bagger system and method optionally integrated with automated dispensing system and/or automated labeling and packaging system Number:7,386,965 from the United States Patent and Trademark Office (PTO) owispatent A system and method places a printed label on a bag. A first plurality of rollers can feed one or more bags, and a second plurality of rollers can feed one or more labels. A tamp pad can place the label on the bag.<H prescription, dispensing, Automated, presc, 7386965.html, Patent, pto, 7386965

Title: Automated prescription and/or literature bagger system and method optionally integrated with automated dispensing system and/or automated labeling and packaging system

Abstract: A system and method places a printed label on a bag. A first plurality of rollers can feed one or more bags, and a second plurality of rollers can feed one or more labels. A tamp pad can place the label on the bag.

Patent Number: 7,386,965 Issued on 06/17/2008 to McErlean, et al.

Inventors: McErlean; James G. (Allendale, NJ), Leu; Chih-Jen (East Brunswick, NJ), Szesko; Michael J. (Freehold, NJ)
Assignee: Medco Health Solutions, Inc. (Franklin Lakes, NJ)

Appl. No.: 11/296,616

Filed: December 7, 2005

Related U.S. Patent Documents


Application Number	Filing Date	Patent Number	Issue Date
10634991	Mar., 2006	7010899
10215249	Aug., 2002	6892512
60401340	Aug., 2002

Current U.S. Class: 53/135.2 ; 53/411; 53/459

Current International Class: B65B 61/26 (20060101)

Field of Search: 53/411,415,457,459,467-469,477,479,131.2,131.4,135.1,135.2,135.3 156/540-542

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Other References

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Primary Examiner: Desai; Hemant M.
Attorney, Agent or Firm: Donner; Irah H Wilmer Cutler Pickering Hale and Dorr LLP

Parent Case Text

RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No. 10/634,991, filed Aug. 6, 2003, (now U.S. Pat. No. 7,010,899, Issued Mar. 14, 2006, which claims priority to, and is a continuation-in-part of U.S. application Ser. No. 10/215,249, filed Aug. 9, 2002 now U.S. Pat. No. 6,892,512, which claims priority from U.S. provisional application Ser. No. 60/401,340 filed Aug. 7, 2002, each incorporated herein by reference.

Claims

What is claimed is:

1. A method for filling a plurality of prescription orders, comprising the steps of: transporting in at least a first direction a plurality of containers by a first plurality of rollers; transporting in the first direction a plurality of labels by a second plurality of rollers, optionally disposed on a backing sheet; printing on a label for at least one of the plurality of containers, the name and address information of a recipient of a prescription order; securely placing a label on the at least one of the plurality of containers, one container at a time, when the at least one of the plurality of containers reach a predetermined position; opening the at least one of the plurality of containers; and placing in the opened at least one of the plurality of containers a pharmaceutical container with enclosed medication, corresponding to the prescription order associated with the label, and sending the at least one of the plurality of containers with the medication to the recipient of the prescription.

2. The method according to claim 1, further comprising the step of discarding a container that cannot be opened.

3. The method according to claim 1, further comprising the step of placing a literature pack in the opened container.

4. The method according to claim 3, further comprising the step of sealing the opened container.

5. The method according to claim 4, further comprising the step of transporting the at least one of the plurality of containers in at least a second direction subsequent to sealing the container.

6. The method according to claim 1, further comprising the step of sealing the opened container.

7. The method according to claim 1, further comprising the step of conveying the plurality of containers a predetermined amount in the at least first direction to a position where the container is opened.

8. The method according to claim 7, further comprising the step of sensing whether the at least one of the plurality of containers is in position for opening.

9. The method according to claim 1, further comprising the step sensing whether the at least one of the containers is in position for opening.

10. The method according to claim 1, further comprising the step of separating the label from the backing sheet prior to said placing step.

11. The method according to claim 10, further comprising the step of providing a vacuum to hold the label in place prior to placing the label on the at least one of the plurality of containers.

12. The method according to claim 1, further comprising the step of providing a vacuum to hold the label in place prior to placing the label on at least one of the plurality of containers.

13. The method according to claim 1, further comprising the step of placing the label on a first one of the plurality of containers substantially simultaneously while opening a second one of the plurality of containers having another label placed thereon.

14. The method according to claim 1, wherein at least one of the first plurality of rollers and second plurality of rollers rotate in concert in the first direction to convey at least one of the plurality of containers and plurality of labels.

15. The method according to claim 1, wherein the first plurality of rollers define an area through which the containers are conveyed.

16. The method according to claim 1, wherein the second plurality of rollers define an area through which the plurality of labels and the backing material are conveyed.

17. A method for filling a plurality of prescription orders, comprising the steps of: transporting in at least a first direction a plurality of containers by a first plurality of rollers; transporting in the first direction a plurality of labels by a second plurality of rollers, optionally disposed on a backing sheet; printing on a label for at least one of the plurality of containers, information corresponding to a recipient of a prescription order; securely placing a label on the at least one of the plurality of containers, one container at a time, when the at least one of the plurality of containers reach a predetermined position; opening the at least one of the plurality of containers; and placing in the opened at least one of the plurality of containers a pharmaceutical container with enclosed medication, corresponding to the prescription order associated with the label, and sending the at least one of the plurality of containers with the medication to the recipient of the prescription.

18. The method according to claim 17, further comprising the step of discarding a container that cannot be opened.

19. The method according to claim 17, further comprising the step of placing a literature pack in the opened container.

20. The method according to claim 17, further comprising the step of conveying the plurality of containers a predetermined amount in the at least first direction to a position where the container is opened.

21. The method according to claim 20, further comprising the step of sensing whether the at least one of the plurality of containers is in position for opening.

22. The method according to claim 17, further comprising the step sensing whether the at least one of the containers is in position for opening.

23. The method according to claim 17, further comprising the step of transporting the at least one of the plurality of containers in at least a second direction subsequent to sealing the container.

24. The method according to claim 17, further comprising the steps of separating the label from the backing sheet prior to said placing step, and providing a vacuum to hold the label in place prior to placing the label on the at least one of the plurality of containers.

25. The method according to claim 17, further comprising the step of placing the label on a first one of the plurality of containers substantially simultaneously while opening a second one of the plurality of containers having another label placed thereon.

26. The method according to claim 17, wherein at least one of the first plurality of rollers and second plurality of rollers rotate in concert in the first direction to convey at least one of the plurality of containers and plurality of labels.

27. The method according to claim 17, wherein the first plurality of rollers define an area through which the containers are conveyed.

28. The method according to claim 17, wherein the second plurality of rollers define an area through which the plurality of labels and the backing material are conveyed.

Description

FIELD OF THE INVENTION

The present invention generally relates to systems and methods for placing one or more literature packages and/or one or more pharmaceutical containers, that include medications, into a container to facilitate delivery of the literature package(s) and/or pharmaceutical container(s) to a recipient.

BACKGROUND OF THE INVENTION

In mail service pharmacies and large retail pharmacies, prescription drugs are dispensed in a high volume. For such services, automatic pill dispensing systems can be used to dispense prescription drugs and label pill containers, which can then be provided to a patient for whom the prescription was written.

A known automatic pill dispensing system 100 is described in U.S. Pat. No. 5,771,657, which is incorporated herein by reference. In the patent, as shown in FIG. 1A, orders (e.g., orders to fill prescriptions) are received by a host computer 9 which forwards the orders to a distributed computer system that can include a central computer called Pharmacy Automation Controller 10 (PAC). PAC 10 maintains an order file of the information about each prescription to be filled that can include information needed to fill each prescription. The order file can, for example, be used to prepare a prescription label for each bottle/container (hereinafter bottle). The order file can also be used to facilitate printing literature that can be placed in a shipping container with the bottle(s). PAC 10 can also update the order file to maintain a record of the current status of each prescription being filled as it progresses through the automated system.

PAC 10 can control a set of Print, Apply and Load (PAL) stations 14 which print prescription bottle labels, apply the labels to bottles, and load the labeled bottles onto bottle carriers that preferably receive the bottles in scheduled locations. PAC 10 can also control a carrier conveyer system 21 that carries the bottle carriers to different parts of system 100, and one or more automatic drug dispensing machines 23 that dispense tablets and/or capsules into the bottles in the bottle carriers as they are carried by conveyer system 21. In addition, PAC 10 controls bottle cappers 25 that apply caps to the bottles, and OCP stations 29 that unload bottles from the carriers and place them in shipping containers corresponding to a patient order. Further, PAC 10 can control literature printers 31 which print literature, for each prescription order, that can be enclosed in an envelope. Finally, PAC 10 can utilize bar code data that identifies the prescription order. The bar code can show through a window in the envelope. Envelopes can be placed on a literature conveyer 34 which carries the envelopes from the literature printers 31 to the OCP stations 29.

Conveyer system 21 carries the bottles in the carriers from PAL stations 14 through the automatic drug dispensing machines 23 to bottle cappers 25, and then from bottle cappers to OCP stations 29. Conveyer system 21 also carries empty carriers back to PAL stations 14. From bottle cappers 25, conveyers 56 feed the carriers onto an endless conveyer loop 71 which transports, for example, four carriers of a rank to one of, say, six OCP stations 29. Other numbers of OCP stations 29 can also be utilized. OCP stations 29 each also have a literature dispensing mechanism, which inserts the printed literature into each shipping container with the filled and capped prescription bottles.

As shown in FIG. 1B, bottles to be automatically filled with the prescription drugs are introduced to the automated system by hoppers 37, which receive the bottles in bulk form and automatically feed the bottles to unscramblers 39. One of the hoppers 37 and one of the unscramblers 39 will be for large bottles (e.g., 160 cc), and the remaining hoppers and unscramblers will be for small bottles (e.g., 110 cc). The small bottle size can preferably accommodate a majority of the automatically filled prescriptions. In the unscramblers, the bottles are singulated and oriented so that the bottle opening first faces downward. The bottles are then righted and directed to PAL stations 14 on bottle conveyers 41 and 43, one for large bottles and one for small bottles.

Conveyers 45, under control by PAC 10, carry the bottle carriers from the four PAL stations 14 to carrier buffers at the entrances of the four automatic drug dispensing machines 23 in which the tablets or capsules of the prescriptions are automatically dispensed into the prescription bottles under the control of PAC 10. Because of the organization provided by the carriers, the bottles are arranged into four columns approaching each automatic dispensing machine 23. Since there are four automatic dispensing machines 23, 16 parallel prescription bottle columns can approach the dispensing machines. In this embodiment, the four automatic drug dispensing machines each have 384 drug dispensers arranged four columns wide and 96 rows deep to provide a total of 1,536 pill dispensers. The automatic drug dispensing machines are similar to those described in the U.S. Pat. No. 5,660,305, which is hereby incorporated by reference. Each dispensing lane is divided into 32 buffer assemblies, each containing twelve drug dispensers oriented six on each side of a conveyer within the dispensing machine.

The carrier will be released by PAL station 14 onto a conveyer 45 which carries the carrier loaded with the labeled empty prescription bottles to an automatic dispensing machine 23, of which there are four, one for each PAL station 14. When a carrier moves out of the last row position in a dispensing machine, all of the prescription bottles in that bottle carrier should be filled and a conveyer 56 transports the prescription bottles now filled with the prescriptions to a bottle capper 25.

Bottle quality assurance area 109 has several stations at which pharmacists can scan the bar code on the bottles and visually inspect the contents of the bottles. The scan of the bottle bar code will bring up a display on the pharmacist's terminal which preferably includes all the information regarding the particular prescription and order. Such information can include, for example, the drug name, and instructions which identify the reason for the verification. All of the bottles that pass this inspection can be inserted or reinserted by the pharmacist on a bottle stream conveyer 111 to send the inspected bottles to the BSP station 112. Conveyer 108 leads to a star wheel diverter mechanism 114 which, optionally under the control of a controller for BSP station 112, deposits the bottle in a bottle stream conveyer 116 leading to the bottle quality assurance area 109 or into a bottle stream conveyer 118 leading to BSP station 112.

If the literature pack is on conveyer 34, but because of failure of the bar code reader (not shown) or the literature sorting mechanism (not shown), does not get diverted at BSP station 112, conveyer 34 will carry the literature package to package quality assurance area 96 where the literature pack can be manually added to the package. If, because of a malfunction, a literature envelope is not deflected by a deflector 89 (FIG. 1C), because of, for example, an improper bar code on the envelope, the envelope will continue on conveyer 34 to the end of the conveyer and be dumped into a receptacle at the package quality assurance station 96. If the bag does not contain a literature pack, then the bag is diverted into a tote (not shown) which will then be transported by a conveyer 34 to the package quality assurance station 96, where the shipping container will be assembled with the literature pack manually 137.

As shown in the OCP station 29 of FIG. 1C, the four carriers of a rank are first received in a carrier buffer 75 from which they are loaded onto a turntable 77. An RFID tag reader (not shown) verifies that the correct carriers are in place on turntable 77, which selectively rotates the carriers into a position to have the bottles removed by robotic arm 79. OCP station 29 also contains equipment 91 for packing literature into shipping containers, which take the form of bags 83, along with the prescription bottles of a given order. OCP station 29 also includes a bagging machine 181 which presents the bags for successive orders to be loaded in sequence at a loading position. Bagging machine 181 can print a bar code identifying the order directly on each bag 83. The printed data may include the mailing address to which the shipping container is to be sent.

Bag 83 is shown at the loading position with its mouth open. The opening of the mouth of bag 83 can be accomplished by a blower (not shown) provided as part of bagging machine 181. Conveyer 34 brings envelopes 85 containing literature to be packed in shipping containers to OCP station 29 in the reverse sequence that the patient orders are to be packed at that OCP station 29 for a given rank of carriers. At OCP stations 29, literature conveyor 34 can be in the form of a literature sortation system of the type used in mail sortation by the U.S. Post Office. The literature sortation system can include a pair of belts 88 that pass the envelopes along from station to station. Deflector 89 can optionally be located between each pair of belts 88, and be controlled by the OCP station controller to deflect selected literature envelopes into a literature dispensing mechanism 91.

When a rank of carriers is directed to a given OCP station 29 by PAC 10 from bottle cappers 25, PAC 10 can send an unload message to the controller for the OCP station 29. The unload message can contain an indication of the sequence that the orders are to be unloaded from the rank of carriers at the station, as well as containing the information as to the scheduled position of the bottles of each order in the four carriers of the rank of carriers to be unloaded. At the same time that PAC 10 sends an unload message to the controller of the OCP station 29, it can send a corresponding autopublish message to printers 31. The message can contain the information to be printed for the complete orders contained in the rank of carriers being sent to an OCP station 29. The autopublish message will also contain the sequence in which the corresponding orders are to be unloaded at the OCP station 29. In response to the autopublish message, one of the printers 31 will print literature for the orders and deposit the literature packs for the orders on literature conveyer 34 in reverse order from that in which the orders are to be unloaded at the OCP station 29.

Each literature pack is preferably enclosed in an envelope having a die cut window through which a bar code is readable by a bar code reader 87. The bar code can be printed by an appropriate printer 31 to identify the order for which the literature pack is printed. As the envelopes containing literature packs are carried past the OCP station 29 in the literature sortation system, the bar code readable through the window in each envelope will be read by a bar code reader 87, that can verify that the bar code coincides with an order in the unload message received by the controller for OCP station 29. The controller for OCP station 29 will then cause deflector 89 to deflect the envelope into literature dispensing mechanism 91. Since the conveyor brings the literature envelopes to an OCP station 29 in the reverse sequence that the corresponding patient order is to be packed at the packing station, the envelopes will be packed into the dispensing mechanism in that sequence. When bag 83 is ready to be packed at an OCP station 29, literature dispensing mechanism 91 first inserts a literature envelope into the bag 83 where it will be positioned at one side of the bag (by, e.g., gravity). This effect is achieved by orienting the bag 83 at a slight tilted position at bagging machine 181. After the literature has been inserted, robotic arm 79 unloads the bottles of the order from the scheduled positions in the four carriers on the turntable in accordance with the unload message. Robotic arm 79 preferably includes a bar code reader so that each time a bottle is lifted out of a carrier by robotic arm 79, the label on the bottle is read and verified.

The prescription bottles are then loaded into the bag 83 by a bottle loading mechanism 93. When the shipping containers 83 have been verified and filled with a literature pack and with a patient's order, the bag is sealed and dropped onto a conveyer 95 which carries the sealed shipping container to a mailing area where the bag is read and logged and then mailed to the customer. If the bag 83 does not contain a literature pack, then the bag is diverted into a tote 99 which will then be transported by a conveyer 101 to the package quality assurance station 96 where the shipping container will be assembled with the literature pack manually.

SUMMARY OF THE INVENTION

The present invention provides additional information and features with regard to the bagging machine disclosed, for example, in FIG. 1C. The bagging machine disclosed herein can also be advantageously used in connection with other pharmaceutical dispensing systems, as will be described herein.

The present invention includes a system that places a label on a bag. The system includes a first plurality of rollers contacting a bag film that includes a plurality of bags, each bag being delimited by a perforation. The first plurality of rollers define an area through which the bag film is conveyed, and rotate in concert in a first direction to convey the bag film. At least one of the plurality of rollers is driven to convey the bag film. The system also includes a printer for printing a plurality of labels disposed on a backing material.

The system also includes a second plurality of rollers that contact the plurality of labels and the backing material. The second plurality of rollers can define an area through which the plurality of labels and the backing material are conveyed. The second plurality of rollers rotate in concert to convey the plurality of labels and the backing material for indicia to be printed thereon. The system also includes a tamp that receives at least one printed label and places the printed label on the bag.

At least one of the second plurality of rollers can be under a biasing force, and move dynamically as labels are received by said printer. A spring can be used to provide the biasing force. In addition, a cam can be used that moves in concert with the at least one of the second plurality of rollers under the biasing force. The cam can engage a switch, such that when one of the second plurality of rollers includes a label roll, labels are dispensed from the label roll when the switch is engaged by the cam.

The system can also include a first sensor for determining a first position of the bag. The tamp can place the printed label on the bag responsive to the first position determined by the first sensor.

In addition, the system can also include at least one bag opening mechanism movably mounted to open the bag subsequent to labeling. A seal bar assembly can also be provided that includes a heater element and a seal bar to seal the bag. The seal bar can move toward the bag to seal the bag.

The at least one bag opening mechanism can include a second sensor to determine whether the bag is in position for opening. The first plurality of rollers can also rotate in a second direction subsequent to sealing the bag to break a perforation between the bag and a second bag.

A third sensor can be provided that detects a position of a perforation between the bag and a second bag. The perforation position can be used to convey the bag a predetermined amount in the first direction to the seal bar assembly.

In addition, a third roller can be provided that separates at least one of the plurality of labels from the backing material when the backing material rotates about the third roller. A surface of the tamp can include a plurality of vacuum holes that facilitate maintaining the label on the surface prior to placing the printed label on the bag.

While a first bag can be tamped, a second bag can substantially simultaneously be opened by the at least one bag opening mechanism. A motor and a belt can also be utilized to drive the at least one of the first plurality of rollers.

The system can also include a controller that associates at least one of a pharmaceutical container and a literature package corresponding to a prescription order with the bag label. A robotic mechanism can be used to place the pharmaceutical container in the bag.

A system in accordance with an embodiment of the present invention can also include a first dancer assembly that receives and conveys a bag film the includes a plurality of bags, each bag being separated by a perforation. The first dancer assembly can define an area through which the bags are conveyed, and can include a plurality of rollers. A motor and belt can drive at least one of the plurality of rollers. The system can also include a printer for printing a plurality of labels disposed on a backing material.

A second dancer assembly can convey the plurality of labels and the backing material, and define an area through which the plurality of labels and the backing material are conveyed. A tamp can receive at least one printed label.

A control system can associate at least one of a pharmaceutical container and a literature package corresponding to a prescription order with the label. A sensor system can be provided that senses a first position of the bag with respect to the tamp to facilitate the tamp placing the printed label on the bag, responsive to the first position determined by the sensor system.

The system can also include at least one bag opening mechanism movably mounted to open the bag subsequent to labeling, and a seal bar assembly that includes a heater element and a seal bar to seal the bag. The at least one bag opening mechanism can include a first sensor to determine whether a bag is in position for opening.

A second sensor can also be utilized that detects a position of a perforation between the bag and a second bag. The perforation position can be used to convey the bag a predetermined amount in a first direction to the seal bar assembly. The seal bar can move toward the bag to seal the bag. At least a portion of said first dancer assembly can rotate in a second direction subsequent to sealing the bag to break a perforation between the bag and a second bag.

A roller can be used that separates at least one of the labels from the backing material when the backing material rotates about the roller. A surface of the tamp can include a plurality of vacuum holes that facilitate maintaining the label on the surface prior to placing the printed label on the bag.

The second dancer assembly can include a roller under a biasing force that moves dynamically as labels are received by the printer. A spring can provide the biasing force. In addition, a cam can be provided that moves in concert with the roller under the biasing force.

The system can also include a switch that is engaged by the cam, and a label roll so that when the switch is engaged by the cam, labels are dispensed from the label roll. The label roll can be a part of the second dancer assembly.

A method for filling a plurality of prescription orders in accordance with an embodiment of the present invention can include the steps of transporting in a first direction a bag film that includes a plurality of bags, and transporting in the first direction a plurality of labels disposed on a backing sheet. The name and address information of a recipient of a prescription order can be printed on a label for each of the plurality of bags. The label can be placed on one of the plurality of bags from the bag film, when the corresponding bag reaches a predetermined position. The labeled bags can be opened, a pharmaceutical container with enclosed pharmaceuticals, corresponding to a prescription order associated with the bag label, can be placed in the opened bag. A literature pack corresponding to a prescription order can also be placed in the opened bag. A method in accordance with the present invention can also include the step of discarding a bag that cannot be opened.

The opened bag can also be sealed. The bag can be conveyed a predetermined amount in the first direction to a position where the bag is opened, responsive to detecting a perforation between two bags. A sensor can optionally be used to verify that a bag is in position for opening. Optionally after sealing, the bag can be transported in a second direction subsequent to break a perforation between the bag and a second bag.

Labels can be separated from the backing sheet prior to placing a label on a bag. A vacuum can be used to hold the label in place prior to placing the label on the bag. A label can be placed on a first bag substantially simultaneously while opening a second bag that already has a label placed thereon.

There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto.

In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.

As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.

Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.

The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be made to the accompanying drawings and descriptive matter in which there is illustrated preferred embodiments of the invention.

NOTATIONS AND NOMENCLATURE

The detailed descriptions which follow may be presented in terms of program procedures executed on computing or processing systems such as, for example, a stand-alone computing machine, a computer or network of computers. These procedural descriptions and representations are the means used by those skilled in the art to most effectively convey the substance of their work to others skilled in the art.

A procedure is here, and generally, conceived to be a sequence of steps leading to a desired result. These steps are those that may require physical manipulations of physical quantities (e.g., combining various pharmaceutical products into packages). Usually, though not necessarily, these quantities take the form of electrical, optical or magnetic signals capable of being stored, transferred, combined, compared and otherwise manipulated. It proves convenient at times, principally for reasons of common usage, to refer to these signals as bits, values, elements, symbols, characters, terms, numbers, or the like. It should be noted, however, that all of these and similar terms are to be associated with the appropriate physical quantities and are merely convenient labels applied to these quantities.

Further, the manipulations performed are often referred to in terms, such as adding or comparing, which are commonly associated with mental operations performed by a human operator. No such capability of a human operator is necessary, or desirable in most cases, in any of the operations described herein which form part of the present invention; the operations are machine operations. Useful machines for performing the operation of the present invention include general purpose digital computers or similar devices, including, but not limited to, microprocessors.

BRIEF DESCRIPTION OF THE DRAWINGS

The detailed description of the present application showing various distinctive features may be best understood when the detailed description is read in reference to the appended drawing in which:

FIGS. 1A, 1B and 1C are exemplary diagrams illustrating a conventional automated pill dispenser that can utilize the bagger system disclosed herein;

FIGS. 2A-2E are exemplary diagrams illustrating aspects of an automated pill dispensing system that can utilize the bagger system disclosed herein;

FIG. 3A is an exemplary diagram illustrating an embodiment of an automated pill dispensing system in accordance with the present invention;

FIG. 3B is an exemplary diagram illustrating an aspect of an automated pill dispenser that can be used with the present invention;

FIG. 4A is an elevation view of an exemplary bagger;

FIG. 4B is an exemplary bag feed dancer assembly of the bagger;

FIG. 4C is a cross section view of an exemplary bagger;

FIG. 5 is an exemplary embodiment of a tamp pad assembly of the bagger;

FIG. 6 is an exemplary embodiment of a seal bar assembly of the bagger;

FIG. 7 is an exemplary embodiment of a bag open finger;

FIG. 8A is a top view of an exemplary aspect of the seal bar assembly;

FIG. 8B is an elevation view of an exemplary aspect of the seal bar assembly; and

FIGS. 9A, 9B and 9C, taken together, is an exemplary embodiment of a flow chart of a method of operation of the bagger.

DETAILED DESCRIPTION OF THE INVENTION

Reference now will be made in detail to the presently preferred embodiments of the invention. Such embodiments are provided by way of explanation of the invention, which is not intended to be limited thereto. In fact, those of ordinary skill in the art may appreciate upon reading the present specification and viewing the present drawings that various modifications and variations can be made.

For example, features illustrated or described as part of one embodiment can be used on other embodiments to yield a still further embodiment. Additionally, certain features may be interchanged with similar devices or features not mentioned yet which perform the same or similar functions. It is therefore intended that such modifications and variations are included within the totality of the present invention.

Embodiments of the present invention are directed to dispensing orders that include various pharmaceutical products (e.g., bottles that contain counted pills, packages that include liquid or pre-packaged pharmaceutical products and/or patient specific literatures). In embodiments of the present invention, the term "pills" also refer to tablets, capsules and other similar terms known in the art. As used herein, the term pill can thus be used interchangeably with, for example, the terms tablet and/or capsule.

FIGS. 2A-2E show the automated prescription filling system with automated labeling and packaging 250 as described in U.S. patent application Ser. No. 10/215,249, which is incorporated herein by reference. System 250 can be referred to as a automated labeling and packaging system (ALPS). In particular, FIG. 2A shows a system 250 that can include a storage device for packages 203, a dispenser for the packages 205, a storage device for bottles filled with counted pills 209, a dispenser for the bottles with counted pills 207, a storage device for patient specific literatures 211, a dispenser for the patient specific literatures 213, a consolidation station 215, and a host computer 201.

The system shown in FIGS. 2A-2E can also include one or more local computers (not shown). For instance, each of the components (e.g., 203, 205, 209, 207, 211 and 213) can be connected to one or more local computers. The local computers in turn are optionally connected to central or host computer 201. In this way, the optional central or host computer 201 and local computers can be configured to control the various components of the present invention.

A local computer can also function with a standard Programmable Logic Controller (PLC). A PLC typically includes an I/O card to turn on/off a device. Accordingly, when a component is to be controlled by turning it on/off, a PLC can be used. When a large quantity of data is to be exchanged, a local computer can be used.

Central computer 201 can receive a request to fill an order, optionally in combination with the local computer(s) and/or the various components. Alternatively, local computers can receive the request to fill an order directly. In response, host computer 201 creates an order number and determines whether the order contains an order that requires bottles to be filled by counting individual tablets, and whether the order contains an order that requires packages from the storage device for bottles 209.

The storage device for packages 203 stores packages that contain pharmaceutical products. For example, one set of packages may contain a predetermined number of tablets (e.g., 500 tablets) of a certain drug (e.g., Allegra). Another set of example packages may include liquid pharmaceutical products. The packages can be made by original producers of drugs (e.g., Hoechst Marion Roussel). The packages can also be bulk bottles that are filled by any one of many automated (e.g., the ADDS) or manual methods known in the art. These packages can then be shelved so that their locations can be automatically identified. In turn, the dispenser for the packages 205 is configured to automatically identify the location of any package with a certain type of drug, dosage and/or quantity and configured to pick one or more packages from the identified location. In other words, a package contains a pharmaceutical product without having been pre-designated for any specific order when the package was created.

In operation, the command to locate and pick one or more packages is received from host computer 201. The dispenser for packages can also be connected to its own local computer to perform the necessary functions to locate and pick one or more packages in accordance with the command from host computer 201. Packages stored in the storage device for packages 203 are not designated for any specific patient. In other words, any package can be picked to fill an order of a patient as long as the type of drug, dosage and/or quantity are matched with the order.

FIG. 2A can also include a standard sensor or a standard counter to indicate when a specific type of package is out of stock in the storage device for packages 203. These sensors or counters can be present at each location (or a substantial number of them). The signals from the sensors or counters can be communicated to, for example, the central or host computer 201 via the local computer. In turn, central or host computer 201 can notify an operator or system to replenish the specific packages and/or stop the process of filling orders that require the specific type of package that are out of stock in the storage device for packages 203. In addition, or optionally, central or host computer 201 can send a query to the storage device for packages 203 regarding whether a certain number of certain packages are available to be dispensed. In response, the storage device for packages 203, or in combination with its local computer, can send a response based on information from the sensors and/or counters. Alternatively, sensors may be placed on a picking device (e.g., a robot arm) to provide the similar functionality. In yet another alternative, sensors are not utilized and the system keeps logical control by knowing how many packages have been placed in a channel and how many packages have been removed from the channel.

The dispenser for bottles 207 is configured to receive bottles that contain specific number (e.g., 1-500 or more) of pills for a specific order. For example, one bottle may include 350 tablets of one type of drug for patient A, while another bottle may include 600 tablets of another type of drug for patient B. The bottles can be filled by any automatic dispensing mechanisms known in the art (e.g., the system shown in U.S. Pat. No. 5,771,657, which is incorporated herein by reference). Bottles can also be manually filled (by, e.g., a pharmacist).

If an automatic dispensing system is used, central or host computer 201 sends commands to fill bottles with certain number of pills for a certain type of drug. Once they are filled, the bottles are stored in the storage device for bottles 209. In a similar fashion, in a manual system, the dispensing person would receive an instruction to count certain number of tablets for a certain type of drug. The person fills bottles according to the instructions and forwards the bottles to the storage device for bottles 209.

Once the storage device for bottles 209 receives all the bottles necessary to fill an order, the storage device for bottles 209 or in connection with its local computer sends a message to, for example, the central or host computer 201 indicating that the bottle portion of the order has been filled. For example, an order to be filled may require 1450 pills of a certain type of drug. In this example, the storage device for packages 203 may already have two packages each with 500 pills of the drug. If so, one bottle with 450 pills of the drug is necessary to fill the bottle portion of the order. (If one bottle cannot receive all 450 pills then more than one bottle would become necessary to provide the 450 pills).

The storage device for literature packs 211 contains literature to be packaged with specific orders. For example, a set of literature packs for one order may include information relating to each of the prescribed drugs, how often each drug must be taken, billing information, special instructions from the prescribing doctor, insurance information, refilling information and/or general information, for example health or notification of other services. The set of literature packs is then packaged per order and collected in the storage device for literature packs 211. Once the necessary literature packs are created, the storage device for literature packs 211, or in combination with its local computer, can notify the host computer 201 that the literature pack has been printed.

Upon receiving various information from the storage device for packages 203, storage device for bottles 209 and storage device for literature packs 211, computer 201 then sends instructions to the dispenser for the packages 205, dispenser for bottles 207 and dispenser for literature packs 213, or to their local computers, to dispense necessary bottle(s), package(s) and literature pack(s) to fill one or more orders. The dispensed bottle(s), package(s) and literature pack(s) are then consolidated by the consolidation station 215 and then sent, distributed or mailed out directly or indirectly to patients associated with the orders.

FIG. 2B shows an exemplary block diagram of aspects of system 250. Picking robot 225 can pick pharmaceutical containers from pick racks 203. Induct belt 1403 is configured to receive packages picked and unloaded by the picking robot 225. Received packages are then transported to a separation and accumulation belt 1405 configured to put gaps between the packages. The separation and accumulation belt 1405 then moves the packages into a set of barcode scanners in barcode tunnel 1407. Tunnel 1407 scanners are configured to detect and read barcodes from, for example, any of five exposed sides of the packages. (Since the packages are boxes, when the packages are placed on the belt 1405, five sides are exposed other than the side that touches the belt.) In such embodiments, when the packages are replenished into the shelves, their barcodes should preferably not be on the bottom. In some other embodiments, only a top side can be scanned as long as the packages are placed into the shelves so that their barcodes are on the top. Accordingly, any combination of barcode readers can be used as long as barcodes on the packages can be detected and read. It should be noted that in some embodiments of the present invention, belt 1405 can be transparent so that barcodes from the bottom side of the packages can also be detected and read by a barcode reader located below the belt 1405.

When barcodes are read, they can be verified by a local computer, which ensures that the scanned package actually belongs to the order that is about to be filled by the consolidation station 215. After the barcode scanners are used, the images of the packages are captured by a camera (not shown). The images are then sent to the local computer to determine the shape and orientation of the packages as they lay on belt 1405. Based on the determined shape, height and orientation, the local computer commands robot 1505 arm to pick up the package from belt 1405. An example of conventional computer vision software includes Adept AIM System, Motionware, Robot & Vision, Version 3.3B-Jun. 9, 1999, U.S. Pat. No. 4,835,730, incorporated herein by reference.

The local computer causes a patient label to be printed by the patient labeler 1501 for each package. While a package is picked up by the robot 1505 and being transported, its label is affixed to the package. Then robot 1505 can move the package next to the barcode reader 1503. The presence of a correct label is determined by the label barcode reader 1503. In addition, robot 1501, label barcode reader 1503, and their local computer can also be configured to cooperate with each other to detect labels and reject any packages without a label or with an incorrect label. Once, the package is determined to have a correct label affixed thereto, robot 1505 can drop the package into the bag opened in (and by) bagger 181.

With respect to bottles, metal detect conveyor 1509 can have a metal detector 1511 which can determine the presence of metallic substances in the bottles. Bottles with metallic substances can be rejected. The bottles belonging to one order are then placed into a standard bottle magazine 1513 by a standard pick-and-place device 1507 (e.g., a robot). An example of pick-and-place devices includes Stelron, Model: SVIP-A-M-P-6.00, X-2.00 Y-spec, U.S. Pat. No. 3,703,834, Mahwah, N.J. In this example embodiment, bottle barcode reader 1525 is provided to ensure that correct bottles have been delivered to the bottle magazine. Once all the bottles have been loaded to the bottle magazine, they can be released into a corresponding bag 83 held (and opened) by bagger 181.

With respect to the literature packs, they are transported to bagger 181 via literature conveyor 221. As the packs arrive at bagger 181, their barcodes are detected and checked by literature barcode reader 1517 to verify that correct literature packs are to be included in the bag 83. As the literature packs arrive, they are discharged into bag 83 as will be discussed herein.

In an embodiment, conveyor belt 221 can have three positions. Position 1 designates the position on the belt 221 in which its literature pack is ready to be disposed into the bag 83 at bagger 813. Position 2 designates the position on the belt 221 in which its literature pack can be discarded if some error is detected. Position 3 designates the position on the belt 221 in which a barcode reader 1517 can detect and read the barcode of the literature pack.

Literature handling logic can report on the status of the literature packs in the three positions. Consolidation logic can instruct literature handling logic to perform one or more tasks (e.g., accept or reject certain literature packs and/or advance the conveyor belt 221).

With regard to bagger 181, bags 83 are fed from the bag supply 265 (FIG. 2E), for example, one at a time. As bags 83 move up through bagger 181, a label or information about the order that is about to be filled is placed on the bag 83. For example, standard tamp 255 (FIGS. 4A and 5) can be used to place the label on a bag 83. The label or information is then detected and read by a scanner or barcode reader 251, which can verify that the correct label is printed and/or the label is properly affixed to the bag 83. As will be discussed herein, bagger 181 can then open bag 83 to place one or more literature packages and/or pharmaceuticals therein.

If bagger 181 seals a bag 83, the sealed bag 83 can be placed on a conveyor belt 1519 for subsequent distribution to a patient. If bagger 181 leaves a bag unsealed, the unsealed bags can be placed in a tote, which is placed on tote conveyor 1521. The tote is then transferred to an operator who can then completely fill the order by manually adding any (additional) required package(s).

FIG. 2C is a top view of a schematic illustrating an exemplary consolidation station, as is shown in block diagram for in FIG. 2B. In particular, FIG. 2B illustrates the bottle storage table 223 for the bottles, picking robot 225 and conveyor belt 221 for the literature packs. The bottles, packages and literature packs are combined in the order consolidation station 227, and put into one or more bags 83 at the bagger 181.

In operation, bottles filled with counted pills are stored at bottle storage table 223. When a complete set of bottles is received by the bottle storage table 223, its local computer notifies computer 201 that all the bottles for a particular order have been received. In response, computer 201 causes literature packs for the order to be printed and sent to the dispatch unit (either in a batch or individually). When the literature packs are received, they are organized such that literature packs for one order are next to each other. A dispatch unit (not shown) can determine the sequence of orders that the literature packs are received by reading identification codes affixed (or printed) on the literature packs. The dispatch unit then sends the lit