Systems and methods of automated tablet dispensing, prescription filling, and packaging

• US 20060025884A1
• Filed: 05/20/2005
• Published: 02/02/2006
• Est. Priority Date: 05/20/2004
• Status: Active Grant

• Current Assignee: Knapp Logistics & Automation Incorporated
• Original Assignee: Knapp Logistics & Automation Incorporated
• Inventors: Henkel, Claus
• Granted Patent: US 8,141,330 B2
• Time in Patent Office: Days
• US Class Current: 700/216
• CPC Class Codes: B65B 37/04 by vibratory feeders
• CPC Class Codes: B65B 5/103 for packaging pills or tablets
• CPC Class Codes: B65B 57/20 Applications of counting devices for controlling the feed of articles other applications B65B65/08
• CPC Class Codes: G07F 11/46 from movable storage containers or supports
• CPC Class Codes: G07F 17/0092 for assembling and dispensing of pharmaceutical articles medical dispensers for private use, A61J7/00
• CPC Class Codes: G16H 20/13 delivered from dispensers

Abstract

Systems and methods of automatically dispensing tablets are disclosed. The systems and methods of the invention provide a highly secure, highly accurate and rapid means of dispensing tablets. The system includes an automatic dispensing tablet dispensing system as shown in the Figures and provides a means of lowering errors while preventing unauthorized tampering by non-authorized personnel. Moreover, the invention relates to systems and methods for packaging vials, packaging items from totes, and packaging items from totes with vials.

Claims

1. A system for automated tablet dispensing comprising:

a canister that holds tablets and is removably engaged with a counter;

the counter including;

a hopper assembly that receives tablets from the canister and transfers the tablets to a sensor, the hopper assembly including a dispenser reserve, singulation channels, and a vibrator;

the sensor, which counts the tablets; and

a buffer with two compartments that hold counted tablets before releasing the counted tablets into vials; and

a nozzle assembly through which counted tablets from the buffer are emptied into individual vials or trays.

2. The system according to claim 1, wherein the dispenser reserve and vibrator are balanced so that the tablets flow at a constant rate.

3. The system according to claim 1, wherein the canister further comprises an access door.

4. The system according to claim 3, wherein the canister has openings on either side that allow the insertion of a tamper proof security tag.

5. The system according to claim 1, wherein the canister contains a unique serial number that dedicates said canister to the sensor.

6. The system according to claim 1, wherein the sensor contains a scanner.

7. The system according to claim 6, wherein the scanner is selected from the group consisting of an electrostatic field scanner, an IR sensor, and a light barrier type sensor.

8. A system for automated packaging of prepackaged items stored in an automated warehouse system and/or vials filled to customer order, the system comprising:

a volume sensor that detects volume of items in a tote bin that is conveyed along a tote conveyor line;

a tote flipper that empties items from the tote bin and into at least one section of a bucket conveyor;

a vial loader that loads vials conveyed along a vial conveyor line into at least one section of the bucket conveyor;

the bucket conveyor that includes a plurality of sections each of which may receive prepackaged items, vials, or both based on a customer order;

a printer station that prints custom literature and internal labels and places the literature and labels into each section of the bucket conveyor that contains prepackaged items or vials;

a bucket unloader that empties each section of the bucket conveyor into a dynamic bagging/cartoning unit;

the dynamic bagging/cartoning unit that sizes a package for each section that is emptied, seals each package, and places an external shipping label on each package;

a bag/carton sorter that sorts each package for shipment; and

an error correction station to which any mismatched prepackaged items or vials are sent prior to package sizing carried out by the dynamic bagging/cartoning unit.

9. The system according to claim 8, wherein the automated packaging packs prepackaged items and vials.

10. The system according to claim 8, wherein the custom literature is selected from the group consisting of instructions, packing lists, and advertisements.

11. The system according to claim 8, further comprising an additional printer station.

12. The system according to claim 8, further comprising an additional volume sensor.

13. The system according to claim 12, wherein said additional volume sensor adds the volume of vials to the volume of the items in the tote bin of the other volume sensor.

14. The system according to claim 8, wherein the automated packaging system contains an additional one or more members selected from the group consisting of bucket unloaders, dynamic bagging/cartoning units, bag/carton conveyer lines, and bag/carton sorters.

15. The automated packaging system according to claim 8, wherein the automated packaging system packs at least one vial and the vial is filled by a system for automated tablet dispensing comprising:

a canister that holds tablets and is removably engaged with a counter;

the counter including;

a hopper assembly that receives tablets from the canister and transfers the tablets to a sensor, the hopper assembly including a dispenser reserve, singulation channels, and a vibrator;

the sensor, which counts the tablets; and

a buffer with multiple compartments that hold counted tablets before releasing the counted tablets into vials; and

a nozzle assembly through which counted tablets from the buffer are emptied into individual vials.

16. A method of automated tablet dispensing comprising:

holding tablets in a canister that is removably engaged with a counter;

transferring tablets from the canister into a hopper assembly of the counter and moving the tablets past or through a sensor;

counting the tablets with the sensor;

receiving the counted tablets in a first compartment of a buffer with multiple compartments before releasing the counted tablets into a vial; and

emptying the tablets from the first compartment of the buffer into a vial.

17. The method according to claim 16, further comprising balancing a dispenser reserve and a vibratory drive of the hopper assembly so that tablets flow evenly down a singulation channel.

18. The method according to claim 16, further comprising emptying other counted tablets from the second compartment of the buffer and into a vial before emptying the tablets from the first compartment of the buffer.

19. The method according to claim 18, wherein at least one compartment of the buffer contains tablets that have been counted and are ready to be emptied into a vial while the other compartment is being filled with tablets.

20. The method according to claim 16, further comprising counting the tablets with a sensor by an optical means or by an IR means.

21. A system for automatic packaging of goods/items, wherein said system is capable of performing one or more of the following tasks:

a) an ability to size a bag or a carton according to the volume of goods/items,

b) an ability to consolidate the goods/items into either of bags or cartons or a mix of bags and cartons,

c) an ability to add bags or cartons to an order,

d) an ability to hold, sequence and sort orders.

22. The system according to claim 21, wherein the system has the ability to perform two of said tasks.

23. The system according to claim 21, wherein the system has the ability to perform three of said tasks.

24. The system according to claim 21, wherein the system has the ability to perform all of said tasks.