Method of loading a multi-dose blister card using intermediate blister cards

• US 7,779,614 B1
• Filed: 05/30/2008
• Issued: 08/24/2010
• Est. Priority Date: 05/30/2007
• Status: Active Grant

• Current Assignee: Walgreen Co. (Walgreens Boots Alliance Incorporated)
• Original Assignee: Walgreen Co. (Walgreens Boots Alliance Incorporated)
• Inventors: Pankow, Greg, McGonagle, Sean, Lewis, J. Randolph, Lee, Victor
• Primary Examiner(s): GERRITY, STEPHEN FRANCIS
• Application Number:
  US12/130,140
• Time in Patent Office: 816 Days
• Field of Search: 533/96, 534/43, 534/45, 534/48, 53473-475, 534/92, 531/47, 531/54, 531/55, 531/58, 535/39, 531/68, 532/37, 532/38, 532/40, 532/44, 532/46, 532/47, 532/58, 533/811, 533/812, 221/87, 221/88, 414/412
• US Class Current: 53/474
• CPC Class Codes: A61J 1/035 Blister-type containers blisters in general B65D75/36
• CPC Class Codes: B65B 1/22 by vibration
• CPC Class Codes: B65B 11/50 Enclosing articles, or quantities of material, by disposing contents between two sheets, e.g. pocketed sheets, and securing their opposed free margins apparatus or devices for forming pockets in or from sheets, blanks or webs B65B47/00
• CPC Class Codes: B65B 2039/009 Multiple outlets
• CPC Class Codes: B65B 39/007 Guides or funnels for introducing articles into containers or wrappers
• CPC Class Codes: B65B 5/103 for packaging pills or tablets
• CPC Class Codes: B65B 5/106 by pushers B65B5/12 and B65B5/108 take precedence
• CPC Class Codes: B65B 69/0041 by puncturing
• CPC Class Codes: B65B 69/0058 Solid contents

Abstract

A method of filling a multi-dose blister card first includes selecting a first intermediate blister card comprising a plurality of tablets of a first product stored within a first plurality of intermediate blisters. Additionally, a multi-dose blister card including a plurality of multi-dose blisters that are empty is selected. The plurality of tablets of the first product from the first plurality of intermediate blisters are transferred into the plurality of multi-dose blisters. Next, a second intermediate blister card including a plurality of tablets of a second product stored within a second plurality of intermediate blisters is selected. The plurality of tablets of the second product are then transferred into the plurality of multi-dose blisters such that at least one of the multi-dose blisters contains one tablet of the first product and one product of the second product.

Claims

1. A method of filling a multi-dose blister card, the method comprising:

selecting a first intermediate blister card comprising a plurality of tablets of a first product stored within a first plurality of intermediate blisters, the first plurality of intermediate blisters arranged in a matrix of a plurality of columns and a plurality of rows;

selecting a multi-dose blister card comprising a plurality of multi-dose blisters that are empty;

transferring the plurality of tablets of the first product from the first plurality of intermediate blisters into the plurality of multi-dose blisters;

selecting a second intermediate blister card comprising a plurality of tablets of a second product stored within a second plurality of intermediate blisters, the second plurality of intermediate blisters arranged in a matrix of a plurality of columns and a plurality of rows, the second product different than the first product; and

transferring the plurality of tablets of the second product from the second plurality of intermediate blisters into the plurality of multi-dose blisters such that at least one of the multi-dose blisters contains one tablet of the first product and one tablet of the second product.

2. The method of claim 1, wherein selecting the first and second intermediate blister cards comprises selecting the first and second intermediate blister cards from a plurality of possible intermediate blister cards, each of the possible intermediate blister cards comprising a plurality of tablets of a distinct product stored within a plurality of intermediate blisters.

3. The method of claim 1, wherein transferring the plurality of tablets of the second product from the second intermediate blister card to the multi-dose blister card comprises depositing the plurality of tablets of the second product into a group of the multi-dose blisters that is identical to a group of the multi-dose blisters occupied by the plurality of tablets of the first product.

4. The method of claim 1, wherein transferring the plurality of tablets of the second product from the second intermediate blister card to the multi-dose blister card comprises depositing the plurality of tablets of the second product into a group of the multi-dose blisters that is different than a group of the multi-dose blisters occupied by the plurality of tablets of the first product.

5. The method of claim 1, wherein transferring the plurality of tablets of the first product from the first intermediate blister card to the multi-dose blister card comprises transferring a first quantity of tablets, and transferring the plurality of tablets of the second product from the second intermediate blister card to the multi-dose blister card comprises transferring a second quantity of tablets that is different than the first quantity of tablets.

6. The method of claim 1, further comprising loading the first and second intermediate blister cards into a filling machine prior to transferring the pluralities of tablets of the first and second products to the multi-dose blister card.

7. The method of claim 6, further comprising storing the selected first and second intermediate blister cards in a tote prior to loading the first and second intermediate blister cards into the filling machine.

8. The method of claim 7, wherein storing the selected first and second intermediate blister cards in the tote comprises storing the first and second intermediate blister cards in sequential order in the tote.

9. The method of claim 1, wherein

transferring the plurality of tablets of the first product from the first intermediate blister card comprises simultaneously discharging each of the plurality of tablets of the first product from the first intermediate blister card;

and

transferring the plurality of tablets of the second product from the second intermediate blister card comprises simultaneously discharging each of the plurality of tablets of the second product from the second intermediate blister card.

10. The method of claim 9, further comprising:

collapsing each of the first plurality of intermediate blisters of the first intermediate blister card with a movable press plate simultaneously while discharging the plurality of tablets of the first product from the first intermediate blister card; and

collapsing each of the second plurality of intermediate blisters of the second intermediate blister card with the movable press plate simultaneously while discharging the plurality of tablets of the second product from the second intermediate blister card.

11. The method of claim 10, further comprising:

cutting a backing material of the first intermediate blister card at locations adjacent the first plurality of intermediate blisters simultaneously with collapsing the first plurality of intermediate blisters; and

cutting a backing material of the second intermediate blister card at locations adjacent the second plurality of intermediate blisters simultaneously with collapsing the second plurality of intermediate blisters.

12. A method of filling a multi-dose blister card, the method comprising:

loading a multi-dose blister card into a filling machine, the multi-dose blister card comprising a plurality of multi-dose blisters that are empty;

loading a first intermediate blister card into the filling machine, the first intermediate blister card comprising a plurality of tablets of a first product stored within a first plurality of intermediate blisters, the first plurality of intermediate blisters arranged in a matrix of a plurality of columns and a plurality of rows;

transferring the plurality of tablets of the first product from the first plurality of intermediate blisters into the plurality of multi-dose blisters;

loading a second intermediate blister card into the filling machine, the second intermediate blister card comprising a plurality of tablets of a second product stored within a second plurality of intermediate blisters, the second plurality of intermediate blisters arranged in a matrix of a plurality of columns and a plurality of rows; and

transferring the plurality of tablets of the second product from the second plurality of intermediate blisters into the plurality of multi-dose blisters such that at least one of the multi-dose blisters contains at least one tablet of the first product and at least one tablet of the second product.

13. The method of claim 12, further comprising selecting the first intermediate blister card from a plurality of possible intermediate blister cards prior to loading the first intermediate blister card into the filling machine, wherein each of the plurality of possible intermediate blister cards comprises a plurality of tablets of a distinct product stored in a plurality of intermediate blisters.

14. The method of claim 13, further comprising selecting the second intermediate blister card from the plurality of possible intermediate blister cards prior to loading the second intermediate blister card into the filling machine.

15. The method of claim 12, wherein transferring the plurality of tablets of the second product from the second intermediate blister card to the multi-dose blister card comprises depositing the plurality of tablets of the second product into a group of the multi-dose blisters that is identical to a group of the multi-dose blisters occupied by the plurality of tablets of the first product.

16. The method of claim 12, wherein transferring the plurality of tablets of the second product from the second intermediate blister card to the multi-dose blister card comprises depositing the plurality of tablets of the second product into a group of the multi-dose blisters that is at least partially different than a group of the multi-dose blisters occupied by the plurality of tablets of the first product.

17. The method of claim 12, wherein transferring the plurality of tablets of the first product from the first intermediate blister card to the multi-dose blister card comprises transferring a first quantity of tablets, and transferring the plurality of tablets of the second product from the second intermediate blister card to the multi-dose blister card comprises transferring a second quantity of tablets that is different than the first quantity of tablets.

18. The method of claim 12, further comprising storing the selected first and second intermediate blister cards in a tote prior to loading the first and second intermediate blister cards into the filling machine.

19. The method of claim 18, wherein storing the selected first and second intermediate blister cards in the tote comprises storing the first and second intermediate blister cards in sequential order in the tote.

20. The method of claim 12, wherein

transferring the plurality of tablets of the first product from the first intermediate blister card comprises simultaneously discharging the plurality of tablets of the first product from the first intermediate blister card;

and

transferring the plurality of tablets of the second product from the second intermediate blister card comprises simultaneously discharging the plurality of tablets of the second product from the second intermediate blister card.

21. The method of claim 12, further comprising:

collapsing each of the first plurality of intermediate blisters of the first intermediate blister card with a movable press plate simultaneously while discharging the plurality of tablets of the first product from the first intermediate blister card; and

collapsing each of the second plurality of intermediate blisters of the second intermediate blister card with the movable press plate simultaneously while discharging the plurality of tablets of the second product from the second intermediate blister card.

22. The method of claim 12, further comprising:

cutting a backing material of the first intermediate blister card at locations adjacent the first plurality of intermediate blisters simultaneously with collapsing the first plurality of intermediate blisters; and

cutting a backing material of the second intermediate blister card at locations adjacent the second plurality of intermediate blisters simultaneously with collapsing the second plurality of intermediate blisters.

23. A method of filling a multi-dose blister card, the method comprising:

selecting a multi-dose blister card comprising a plurality of multi-dose blisters;

selecting a first intermediate blister card comprising a plurality of tablets of a first product stored within a first plurality of intermediate blisters, the first plurality of intermediate blisters arranged in a matrix of a plurality of columns and a plurality of rows;

loading the multi-dose blister card into a filling machine;

loading the first intermediate blister card into the filling machine;

actuating a press of the filling machine into engagement with the first intermediate blister card, thereby discharging the plurality of tablets of the first product out of the plurality of first intermediate blisters and into the plurality of multi-dose blisters;

removing the first intermediate blister card from the filling machine;

selecting a second intermediate blister card comprising a plurality of tablets of a second product stored within a second plurality of intermediate blisters, the second plurality of intermediate blisters arranged in a matrix of a plurality of columns and a plurality of rows;

loading the second intermediate blister card into the filling machine; and

actuating the press of the filling machine into engagement with the second intermediate blister card, thereby discharging the plurality of tablets of the second product out of the plurality of second intermediate blisters and into the plurality of multi-dose blisters of the multi-dose blister card.

24. The method of claim 23, wherein selecting the first and second intermediate blister cards comprises selecting the first and second intermediate blister cards from a plurality of possible intermediate blister cards, each comprising a plurality of tablets of a distinct product stored within a plurality of intermediate blisters.

25. The method of claim 23, wherein discharging the plurality of tablets of the second product from the second intermediate blister card into the multi-dose blister card comprises depositing the plurality of tablets of the second product into a group of the multi-dose blisters that is identical to a group of the multi-dose blisters occupied by the plurality of tablets of the first product.

26. The method of claim 23, further comprising storing the selected first and second intermediate blister cards in sequential order within a tote prior to loading the first and second intermediate blister cards into the filling machine.

27. The method of claim 23, further comprising:

cutting a backing material of the first intermediate blister card at locations adjacent the first plurality of intermediate blisters simultaneously with collapsing the first plurality of intermediate blisters; and

cutting a backing material of the second intermediate blister card at locations adjacent the second plurality of intermediate blisters simultaneously with collapsing the second plurality of intermediate blisters.