U.S. patent application number 12/904858 was filed with the patent office on 2011-02-10 for methods and apparatus for dispensing solid pharmaceutical articles.
This patent application is currently assigned to PARATA Systems, LLC. Invention is credited to David Alan Calderwood, Andrew Kirk Dummer, Bryan Patrick Farnsworth, Richard D. Michelli, Jeffrey P. Williams.
Application Number | 20110031262 12/904858 |
Document ID | / |
Family ID | 39619259 |
Filed Date | 2011-02-10 |
United States Patent
Application |
20110031262 |
Kind Code |
A1 |
Dummer; Andrew Kirk ; et
al. |
February 10, 2011 |
Methods and Apparatus for Dispensing Solid Pharmaceutical
Articles
Abstract
An apparatus for dispensing pharmaceutical articles includes a
housing and a gas source to provide a positive pressure supply gas
flow. The housing defines a hopper chamber to hold the articles, a
dispensing channel fluidly connected to the hopper chamber, a drive
jet outlet, and an agitation outlet. The dispensing channel has an
inlet and an outlet and defines a flow path therebetween. The gas
source is fluidly connected to each of the drive jet outlet and the
agitation outlet to provide: a pressurized drive jet gas flow
through the drive jet outlet to convey articles through the
dispensing channel along the flow path; and a pressurized agitation
gas flow through the agitation outlet to agitate articles in the
hopper chamber.
Inventors: |
Dummer; Andrew Kirk; (Chapel
Hill, NC) ; Farnsworth; Bryan Patrick; (Wake Forest,
NC) ; Michelli; Richard D.; (Raleigh, NC) ;
Williams; Jeffrey P.; (Hillsborough, NC) ;
Calderwood; David Alan; (Chapel Hill, NC) |
Correspondence
Address: |
MYERS BIGEL SIBLEY & SAJOVEC
PO BOX 37428
RALEIGH
NC
27627
US
|
Assignee: |
PARATA Systems, LLC
|
Family ID: |
39619259 |
Appl. No.: |
12/904858 |
Filed: |
October 14, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11750710 |
May 18, 2007 |
7837061 |
|
|
12904858 |
|
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Current U.S.
Class: |
221/1 ;
221/278 |
Current CPC
Class: |
G07F 11/44 20130101;
G07F 17/0092 20130101 |
Class at
Publication: |
221/1 ;
221/278 |
International
Class: |
B65D 83/04 20060101
B65D083/04; B65H 3/08 20060101 B65H003/08 |
Claims
1. An apparatus for dispensing pharmaceutical articles, the
apparatus comprising: a) a housing defining: a hopper chamber to
hold the articles; a dispensing channel fluidly connected to the
hopper chamber, the dispensing channel having an inlet and an
outlet and defining a flow path therebetween; a drive jet outlet;
and an agitation outlet; and b) a gas source to provide a positive
pressure supply gas flow, wherein the gas source is fluidly
connected to each of the drive jet outlet and the agitation outlet
to provide: a pressurized drive jet gas flow through the drive jet
outlet to convey articles through the dispensing channel along the
flow path; and a pressurized agitation gas flow through the
agitation outlet to agitate articles in the hopper chamber; wherein
the apparatus is configured to generate the drive jet gas flow and
the agitation gas flow simultaneously using the same gas
source.
2. The apparatus of claim 1 including an air amplifier interposed
and fluidly connected between the gas source and the agitation
outlet, and wherein the agitation gas flow has a greater mass flow
rate than the supply gas flow.
3. The apparatus of claim 1 wherein: the housing further includes a
second agitation outlet; and the gas source is fluidly connected to
the second agitation outlet to provide a second pressurized
agitation gas flow through the second agitation outlet to agitate
articles in the hopper chamber.
4. The apparatus of claim 3 wherein: the housing includes a divider
wall configured to define, in the hopper chamber, a front region
between the inlet and the divider wall and a rear region on a side
of the divider wall opposite the front region, and to further form
a choke passage between the front and rear regions; the agitation
outlet is a first agitation outlet and the agitation gas flow is a
first agitation gas flow; the first agitation outlet is positioned
and configured to direct the first agitation gas flow into the
front region to agitate articles in the front region; and the
second agitation outlet is positioned and configured to direct the
second agitation gas flow into the rear region to agitate articles
in the rear region; the housing is configured to direct tablets
through the choke passage from the rear region to the front
region.
5. The apparatus of claim 4 wherein: the drive jet gas flow is
operative to convey the articles through the dispensing channel in
a forward direction toward the outlet; and the apparatus includes
at least one valve operable to simultaneously provide the drive jet
gas flow through the drive jet outlet and the first agitation gas
flow through the first agitation outlet to dispense articles from
the hopper chamber.
6. The apparatus of claim 4 wherein: the drive jet gas flow is
operative to convey the articles through the dispensing channel in
a reverse direction toward the inlet; and the apparatus includes at
least one valve operable to simultaneously provide the drive jet
gas flow through the drive jet outlet and the second agitation gas
flow through the second agitation outlet.
7. The apparatus of claim 4 wherein the housing further includes a
second divider wall configured to divide the rear region into a
first rear region between the first and second divider walls and a
second rear region on a side of the second divider wall opposite
the first rear region, the second divider wall forming a second
choke passage between the first and second rear regions, wherein
the housing is configured to direct tablets through the second
choke passage from the second rear region to the first rear region
and thereafter from the first rear region to the front region.
8. The apparatus of claim 4 wherein a spacing between the divider
wall and a floor of the housing is adjustable to adjust the size of
the choke passage.
9. The apparatus of claim 1 wherein: the drive jet gas flow is
operative to convey the articles through the dispensing channel in
a reverse direction toward the inlet; and the apparatus includes a
controller operative to simultaneously provide the drive jet gas
flow through the drive jet outlet and the agitation gas flow
through the agitation outlet responsive to a tablet jam
condition.
10. A method for dispensing pharmaceutical articles, the method
comprising: a) providing an apparatus including: 1) a housing
defining: a hopper chamber to hold the articles; a dispensing
channel fluidly connected to the hopper chamber, the dispensing
channel having an inlet and an outlet and defining a flow path
therebetween; a drive jet outlet; and an agitation outlet; and 2) a
gas source to provide a positive pressure supply gas flow, wherein
the gas source is fluidly connected to each of the drive jet outlet
and the agitation outlet; and b) providing the positive pressure
supply gas flow from the gas source to each of the drive jet outlet
and the agitation outlet to simultaneously generate, using the same
gas source, each of a pressurized drive jet gas flow through the
drive jet outlet and a pressurized agitation gas flow through the
agitation outlet, wherein the drive jet gas flow conveys articles
through the dispensing channel along the flow path and the
agitation gas flow agitates articles in the hopper chamber.
11. The method of claim 10 wherein the agitation gas flow has a
greater mass flow rate than the supply gas flow.
12. The method of claim 10 further including providing the positive
pressure gas from the gas source to a second agitation outlet in
the housing to generate a second pressurized agitation gas flow
through the second agitation outlet to agitate articles in the
hopper chamber.
13. The method of claim 12 wherein the agitation gas flow is a
first agitation gas flow, the method including: providing a divider
wall configured to define, in the hopper chamber, a front region
between the inlet and the divider wall and a rear region on a side
of the divider wall opposite the first region, and to further form
a choke passage between the front and rear regions; directing the
first agitation gas flow into a front region to agitate articles in
the front region; and directing the second agitation gas flow into
the rear region to agitate articles in the rear region.
14. The method of claim 13 including: conveying the articles
through the dispensing channel in a forward direction toward the
outlet using the drive jet gas flow; and providing the drive jet
gas flow through the drive jet outlet and the first agitation gas
flow through the first agitation outlet simultaneously to dispense
articles from the hopper chamber.
15. The method of claim 13 including: conveying the articles
through the dispensing channel in a reverse direction toward the
inlet using the drive jet gas flow; and providing the drive jet gas
flow through the drive jet outlet and the second agitation gas flow
through the second agitation outlet simultaneously.
16. The method of claim 10 including: detecting a tablet jam
condition; and in response to the tablet jam condition, generating
the drive jet gas flow and the agitation gas flow, wherein the
drive jet gas flow is operative to convey the articles through the
dispensing channel in a reverse direction toward the inlet.
17. The method of claim 10 wherein: the housing includes a divider
wall configured to define, in the hopper chamber, a front region
between the inlet and the divider wall and a rear region on a side
of the divider wall opposite the front region, and to further form
a choke passage between the front and rear regions; the housing
further includes a second agitation outlet and the gas source is
fluidly connected to the second agitation outlet to provide a
second pressurized agitation gas flow through the second agitation
outlet to agitate articles in the hopper chamber; the drive jet
outlet is a forward drive jet outlet and the drive jet gas flow is
a forward drive jet gas flow; the housing further includes a
reverse drive jet outlet and the gas source is fluidly connected to
the reverse drive jet outlet to provide a reverse drive jet gas
flow through the reverse drive jet outlet to convey articles
through the dispensing channel along the flow path; the agitation
outlet is a first agitation outlet and the agitation gas flow is a
first agitation gas flow; the first agitation outlet is positioned
and configured to direct the first agitation gas flow into the
front region to agitate articles in the front region; the second
agitation outlet is positioned and configured to direct the second
agitation gas flow into the rear region to agitate articles in the
rear region; the forward drive jet gas flow is operative to convey
the articles through the dispensing channel in a forward direction
toward the outlet; the reverse drive jet gas flow is operative to
convey the articles through the dispensing channel in a reverse
direction toward the inlet; and the method includes alternating
between a forward mode and a reverse mode, wherein: in the forward
mode, the apparatus simultaneously provides the forward drive jet
gas flow through the forward drive jet outlet and the first
agitation gas flow through the first agitation outlet to dispense
articles from the hopper chamber while not providing the reverse
drive jet gas flow and the second agitation gas flow; and in the
reverse mode, the apparatus simultaneously provides the reverse
drive jet gas flow through the reverse drive jet outlet and the
second agitation gas flow through the second agitation outlet to
return articles to the hopper chamber while not providing the
forward drive jet gas flow and the first agitation gas flow.
18. An apparatus for dispensing pharmaceutical articles, the
apparatus comprising: a dispensing channel having an inlet and an
outlet and defining a flow path therebetween; a housing defining a
hopper chamber to hold the articles, wherein the hopper chamber is
in fluid communication with the inlet of the dispensing channel,
the housing including a floor and a divider wall configured to
define, in the hopper chamber: a front region between the inlet and
the divider wall; a rear region on a side of the divider wall
opposite the front region; and a choke passage between the front
and rear regions and between the divider wall and the floor;
wherein a spacing between the divider wall and the floor is
adjustable to adjust the size of the choke passage.
19. The apparatus of claim 18 wherein the housing further includes
a second divider wall configured to divide the rear region into a
first rear region between the first and second divider walls and a
second rear region on a side of the second divider wall opposite
the first rear region, the second divider wall forming a second
choke passage between the first and second rear regions and between
the second divider wall and the floor, wherein the housing is
configured to direct tablets through the second choke passage from
the second rear region to the first rear region and thereafter from
the first rear region to the front region.
20. The apparatus of claim 18 including an agitation outlet in the
housing and a gas source fluidly connected to the agitation outlet,
wherein the agitation outlet is positioned and configured to direct
a gas flow from the gas source into at least one of the front
region and the rear region to agitate articles therein.
21. The apparatus of claim 18 wherein the divider wall is angled
with respect to vertical to support a load of the articles in the
rear region.
Description
RELATED APPLICATION(S)
[0001] The present application is a continuation patent application
of and claims priority from U.S. patent application Ser. No.
11/750,710, filed May 18, 2007, the disclosure of which is hereby
incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention is directed generally to the
dispensing of solid pharmaceutical articles and, more specifically,
is directed to the automated dispensing of solid pharmaceutical
articles.
BACKGROUND OF THE INVENTION
[0003] Pharmacy generally began with the compounding of medicines
which entailed the actual mixing and preparing of medications.
Heretofore, pharmacy has been, to a great extent, a profession of
dispensing, that is, the pouring, counting, and labeling of a
prescription, and subsequently transferring the dispensed
medication to the patient. Because of the repetitiveness of many of
the pharmacist's tasks, automation of these tasks has been
desirable.
[0004] Some attempts have been made to automate the pharmacy
environment. Different exemplary approaches are shown in U.S. Pat.
No. 5,337,919 to Spaulding et al. and U.S. Pat. Nos. 6,006,946;
6,036,812 and 6,176,392 to Williams et al. These systems utilize
robotic arms to grasp a container, carry it to one of a number of
bins containing tablets (from which a designated number of tablets
are dispensed), carry it to a printer, where a prescription label
is applied, and release the filled container in a desired location.
Tablets are counted and dispensed with any number of counting
devices. Drawbacks to these systems typically include the
relatively low speed at which prescriptions are filled and the
absence in these systems of securing a closure (i.e., a lid) on the
container after it is filled.
[0005] One automated system for dispensing pharmaceuticals is
described in some detail in U.S. Pat. No. 6,971,541 to Williams et
al. This system has the capacity to select an appropriate vial,
label the vial, fill the vial with a desired quantity of a selected
pharmaceutical tablet, apply a cap to the filled vial, and convey
the labeled, filled, capped vial to an offloading station for
retrieval. Although this particular system can provide automated
pharmaceutical dispensing, it may be desirable to modify certain
aspects of the system to address particular needs.
SUMMARY OF THE INVENTION
[0006] According to embodiments of the present invention, an
apparatus for dispensing pharmaceutical articles includes a housing
and a gas source to provide a positive pressure supply gas flow.
The housing defines a hopper chamber to hold the articles, a
dispensing channel fluidly connected to the hopper chamber, a drive
jet outlet, and an agitation outlet. The dispensing channel has an
inlet and an outlet and defines a flow path therebetween. The gas
source is fluidly connected to each of the drive jet outlet and the
agitation outlet to provide: a pressurized drive jet gas flow
through the drive jet outlet to convey articles through the
dispensing channel along the flow path; and a pressurized agitation
gas flow through the agitation outlet to agitate articles in the
hopper chamber.
[0007] According to some embodiments, the agitation gas flow has a
greater mass flow rate than the drive jet gas flow. According to
some embodiments, the agitation gas flow has a greater mass flow
rate than the supply gas flow. According to some embodiments, an
air amplifier is interposed and fluidly connected between the gas
source and the agitation outlet. The air amplifier may be
configured to utilize the Coanda Effect.
[0008] According to method embodiments of the present invention, a
method is provided for dispensing pharmaceutical articles using an
apparatus including a housing defining a hopper chamber to hold the
articles, a dispensing channel fluidly connected to the hopper
chamber, a drive jet outlet, and an agitation outlet, the
dispensing channel having an inlet and an outlet and defining a
flow path therebetween, the apparatus further including a gas
source fluidly connected to each of the drive jet outlet and the
agitation outlet. The method includes providing a positive pressure
supply gas flow from the gas source to each of the drive jet outlet
and the agitation outlet to generate each of a pressurized drive
jet gas flow through the drive jet outlet and a pressurized
agitation gas flow through the agitation outlet. The drive jet gas
flow conveys articles through the dispensing channel along the flow
path and the agitation gas flow agitates articles in the hopper
chamber.
[0009] According to some embodiments, the agitation gas flow has a
greater mass flow rate than the drive jet gas flow. According to
some embodiments, the agitation gas flow has a greater mass flow
rate than the supply gas flow. According to some embodiments, the
supply gas flow is provided from the gas source to the agitation
outlet via an air amplifier interposed and fluidly connected
between the gas source and the agitation outlet. The air amplifier
may be configured to utilize the Coanda Effect.
[0010] According to further embodiments of the present invention,
an apparatus for dispensing pharmaceutical articles includes a
dispensing channel having an inlet and an outlet and defining a
flow path therebetween, and a housing defining a hopper chamber to
hold the articles. The hopper chamber is in fluid communication
with the inlet of the dispensing channel. The housing includes a
floor and a divider wall configured to define, in the hopper
chamber: a front region between the inlet and the divider wall; a
rear region on a side of the divider wall opposite the front
region; and a choke passage between the front and rear regions and
between the divider wall and the floor. According to some
embodiments, a spacing between the divider wall and the floor is
adjustable to adjust the size of the choke passage.
[0011] Further features, advantages and details of the present
invention will be appreciated by those of ordinary skill in the art
from a reading of the figures and the detailed description of the
preferred embodiments that follow, such description being merely
illustrative of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a flow chart illustrating methods according to
embodiments of the present invention.
[0013] FIG. 2 is a perspective view of a pharmaceutical tablet
dispensing system including a sensor clearing system according to
embodiments of the present invention.
[0014] FIG. 3 is a cutaway view of the tablet dispensing system of
FIG. 2 illustrating a container dispensing station, a labeling
carrier, a dispensing carrier, and a closure dispensing station
thereof.
[0015] FIG. 4 is a top, front perspective view of a dispensing bin
according to embodiments of the present invention.
[0016] FIG. 5 is a bottom perspective view of the bin of FIG.
4.
[0017] FIG. 6 is a cross-sectional, perspective view of the bin of
FIG. 4.
[0018] FIG. 7 is a cross-sectional view of the bin of FIG. 4.
[0019] FIG. 8 is a cross-sectional view of the bin of FIG. 4
wherein tablets contained therein are at rest.
[0020] FIG. 9 is a cross-sectional view of the bin of FIG. 4
wherein tablets contained therein are being agitated and
dispensed.
[0021] FIG. 10 is a cross-sectional view of the bin of FIG. 4
wherein tablets contained therein are being agitated and returned
to a hopper chamber of the bin.
[0022] FIG. 11 is an enlarged, exploded, top perspective view of an
air amplifier of the bin of FIG. 4.
[0023] FIG. 12 is a cross-sectional view of the air amplifier of
FIG. 10.
[0024] FIG. 13 is a block diagram representing gas supply flow
paths of the bin of FIG. 4.
DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION
[0025] The present invention now will be described more fully
hereinafter with reference to the accompanying drawings, in which
illustrative embodiments of the invention are shown. In the
drawings, the relative sizes of regions or features may be
exaggerated for clarity. This invention may, however, be embodied
in many different forms and should not be construed as limited to
the embodiments set forth herein; rather, these embodiments are
provided so that this disclosure will be thorough and complete, and
will fully convey the scope of the invention to those skilled in
the art.
[0026] It will be understood that when an element is referred to as
being "coupled" or "connected" to another element, it can be
directly coupled or connected to the other element or intervening
elements may also be present. In contrast, when an element is
referred to as being "directly coupled" or "directly connected" to
another element, there are no intervening elements present. Like
numbers refer to like elements throughout.
[0027] In addition, spatially relative terms, such as "under",
"below", "lower", "over", "upper" and the like, may be used herein
for ease of description to describe one element or feature's
relationship to another element(s) or feature(s) as illustrated in
the figures. It will be understood that the spatially relative
terms are intended to encompass different orientations of the
device in use or operation in addition to the orientation depicted
in the figures. For example, if the device in the figures is turned
over, elements described as "under" or "beneath" other elements or
features would then be oriented "over" the other elements or
features. Thus, the exemplary term "under" can encompass both an
orientation of over and under. The device may be otherwise oriented
(rotated 90 degrees or at other orientations) and the spatially
relative descriptors used herein interpreted accordingly.
[0028] The terminology used herein is for the purpose of describing
particular embodiments only and is not intended to be limiting of
the invention. As used herein, the singular forms "a", "an" and
"the" are intended to include the plural forms as well, unless the
context clearly indicates otherwise. It will be further understood
that the terms "comprises" and/or "comprising," when used in this
specification, specify the presence of stated features, integers,
steps, operations, elements, and/or components, but do not preclude
the presence or addition of one or more other features, integers,
steps, operations, elements, components, and/or groups thereof. As
used herein the expression "and/or" includes any and all
combinations of one or more of the associated listed items.
[0029] Unless otherwise defined, all terms (including technical and
scientific terms) used herein have the same meaning as commonly
understood by one of ordinary skill in the art to which this
invention belongs. It will be further understood that terms, such
as those defined in commonly used dictionaries, should be
interpreted as having a meaning that is consistent with their
meaning in the context of the relevant art and will not be
interpreted in an idealized or overly formal sense unless expressly
so defined herein.
[0030] In accordance with embodiments of the present invention,
apparatus and methods are provided for dispensing solid
pharmaceutical articles. In particular, such methods and apparatus
may be used to dispense pharmaceuticals. With reference to FIG. 1,
methods according to embodiments of the present invention may be
executed using an apparatus including a housing defining a hopper
chamber to hold the articles, a dispensing channel fluidly
connected to the hopper chamber, a drive jet outlet, and an
agitation outlet, the dispensing channel having an inlet and an
outlet and defining a flow path therebetween, the apparatus further
including a gas source fluidly connected to each of the drive jet
outlet and the agitation outlet. A positive pressure supply gas
flow is provided from the gas source to each of the drive jet
outlet and the agitation outlet to generate each of a pressurized
drive jet gas flow through the drive jet outlet and a pressurized
agitation gas flow through the agitation outlet such that the
pressurized drive jet gas flow conveys articles through the
dispensing channel along the flow path and the pressurized
agitation gas flow agitates articles in the hopper chamber (Block
20). According to some embodiments, the articles are pharmaceutical
tablets or pills.
[0031] According to some embodiments, the agitation gas flow has a
higher or greater mass flow rate than the drive jet gas flow.
According to some embodiments, the agitation gas flow has a greater
mass flow rate than the supply gas flow. The supply gas flow may be
provided from the gas source to the agitation outlet via an air
amplifier interposed and fluidly connected between the gas source
and the agitation outlet. According to some embodiments, the drive
jet outlet and the agitation outlet are supplied by the same gas
source. According to some embodiments, the drive jet gas flow and
the agitation gas flow are provided simultaneously. The air
amplifier may be configured to utilize the Coanda Effect.
[0032] A dispensing system according to embodiments of the present
invention and that can carry out the foregoing methods is
illustrated in FIGS. 2-13 and designated broadly therein at 40
(FIGS. 2 and 3). The system 40 includes a support frame 44 for the
mounting of its various components. Those skilled in this art will
recognize that the frame 44 illustrated herein is exemplary and can
take many configurations that would be suitable for use with the
present invention. The frame 44 provides a strong, rigid foundation
to which other components can be attached at desired locations, and
other frame forms able to serve this purpose may also be acceptable
for use with this invention.
[0033] The system 40 generally includes as operative stations a
controller (represented herein by a graphics user interface 42), a
container dispensing station 58, a labeling station 60, a tablet
dispensing station 62, a closure dispensing station 64, and an
offloading station 66. In the illustrated embodiment, containers,
tablets and closures are moved between these stations with a
dispensing carrier 70; however, in some embodiments, multiple
carriers are employed. The dispensing carrier 70 has the capability
of moving the container to designated locations within the cavity
45 of the frame 44. Except as discussed herein with regard to the
dispensing station 62, each of the operative stations and the
conveying devices may be of any suitable construction such as those
described in detail in U.S. Pat. No. 6,971,541 to Williams et al.
and/or U.S. Patent Publication No. US-2006-0241807-A1, the
disclosures of which are hereby incorporated herein in their
entireties.
[0034] The controller 42 controls the operation of the remainder of
the system 40. In some embodiments, the controller 42 will be
operatively connected with an external device, such as a personal
or mainframe computer, that provides input information regarding
prescriptions. In other embodiments, the controller 42 may include
a stand-alone computer that directly receives manual input from a
pharmacist or other operator. An exemplary controller may include a
conventional microprocessor-based personal computer. The controller
42 may be a centralized computer or portions thereof may be
physically and/or functionally distributed or divided into multiple
controllers. For example, according to some embodiments, the
controller is embodied in part in each tablet dispensing bin
assembly.
[0035] In operation, the controller 42 signals the container
dispensing station 58 that a container of a specified size is
desired. In response, the container dispensing station 58 delivers
a container for retrieval by the carrier 70. From the container
dispensing station 58, the container is moved to the labeling
station 60 by the carrier 70. The labeling station 60 includes a
printer that is controlled by the controller 42. The printer prints
and presents an adhesive label that is affixed to the
container.
[0036] Filling of labeled containers with tablets is carried out by
the tablet dispensing station 62. The tablet dispensing station 62
comprises a plurality of tablet dispensing bin assemblies or bins
100 (described in more detail below), each of which holds a bulk
supply of individual tablets (typically the bins 100 will hold
different tablets). Referring to FIGS. 2 and 4-7, the dispensing
bins 100, which may be substantially identical in size and
configuration, are organized in an array mounted on the rails of
the frame 44. Each dispensing bin 100 has a dispensing channel 116
with an outlet 116B (FIG. 7) that faces generally in the same
direction, to create an access region for the dispensing carrier
70. The identity of the tablets in each bin is known by the
controller 42, which can direct the dispensing carrier 70 to
transport the container to the proper bin 100.
[0037] The dispensing bins 100 are configured to singulate, count,
and dispense the tablets contained therein, with the operation of
the bins 100 and the counting of the tablets being controlled by
the controller 42. According to some embodiments, each bin 100
includes its own dedicated controller that is operative to execute
a dispensing run upon receiving a command from a central controller
or the like. Some embodiments may employ the controller 42 as the
device which monitors the locations and contents of the bins 100;
others may employ the controller 42 to monitor the locations of the
bins, with the bins 100 including indicia (such as a bar code or
electronic transmitter) to identify the contents to the controller
42. In still other embodiments, the bins 100 may generate and
provide location and content information to a central controller,
with the result that the bins 100 may be moved to different
positions on the frame 44 without the need for manual modification
of the central controller (i.e., the bins 100 will update the
central controller automatically).
[0038] Any of a number of dispensing units that singulate and count
discrete objects may be employed if suitably modified to include
the inventive aspects disclosed herein. In particular, dispensing
units that rely upon targeted air flow and a singulating nozzle
assembly may be used, such as the devices described in U.S. Pat.
No. 6,631,826 to Pollard et al. and/or U.S. Patent Publication No.
US-2006-0241807-A1, each of which is hereby incorporated herein by
reference in its entirety. Bins of this variety may also include
additional features, such as those described below.
[0039] After the container is desirably filled by the tablet
dispensing station 62, the dispensing carrier 70 moves the filled
container to the closure dispensing station 64. The closure
dispensing station 64 may house a bulk supply of closures and
dispense and secure them onto a filled container. The dispensing
carrier 70 then moves to the closed container, grasps it, and moves
it to the offloading station 66.
[0040] Turning to the bins 100 in more detail, an exemplary bin 100
is shown in more detail in FIGS. 4-13. The bin 100 includes a
housing 110 having a hopper portion 112 and a nozzle 114. The bin
100 is fluidly connected with a pressurized gas source 136 as
discussed in more detail below.
[0041] Referring to FIGS. 6-8, the hopper portion 112 defines a
hopper chamber 120 that can be filled with tablets T (FIG. 8). The
bin 100 can be filled or replenished with tablets through an
opening 130 located at the upper rear portion of the bin 100. The
opening 130 is selectively accessible via a pivoting door 132, for
example.
[0042] The nozzle 114 defines the dispensing channel 116 through
which the tablets T can be dispensed one at a time into the
container C, for example (FIGS. 9 and 10). The dispensing channel
116 has an inlet 116A opposite the outlet 116B and fluidly connects
the channel 116 to the chamber 120. As disclosed in U.S. Patent
Publication No. US-2006-0241807-A1, the bin 100 may include
components that permit the entry to the dispensing channel 116 to
be adjusted in size to complement the size and configuration of the
tablet to be dispensed. For example, an upper wall 118 defining a
portion of the dispensing passage 116 may be slid able up and down
to selectively adjust the height of the passage 116 and/or the
inlet 116A. A side wall may be similarly movable to adjust the
width of the passage 116 and/or the inlet 116A.
[0043] With reference to FIG. 6, the hopper portion 112 has a
bottom wall defining a floor 122. The floor 122 has a sloped rear
portion 122A that slopes downwardly toward the inlet 116A. The
floor 122 also has a funnel-shaped front portion 122B. A front
agitation port or outlet 122C and a rear agitation port or outlet
122D are provided in the floor 122. As discussed below, air or
other pressurized gas can be flowed through the outlets 122C, 122D
and into the chamber 120 to agitate the tablets T contained
therein.
[0044] With reference to FIG. 7, a front partition or divider wall
124 extends through the hopper chamber 120 and forms a gap or choke
point 124A between the lower edge of the wall 124 and the floor
122. According to some embodiments, the choke point 124A has a gap
spacing or height G1 (FIG. 7) of between about 0.25 and 0.75 inch.
The position of the wall 124, and thereby the gap spacing G1, may
be selectively adjusted using an adjustment mechanism 124B (FIG.
4).
[0045] A rear partition or divider wall 126 extends through the
hopper chamber 120 and forms a gap or choke point 126A between the
lower edge of the wall 126 and the floor 122. According to some
embodiments, the choke point 126A has a gap spacing or height G2
(FIG. 7) of between about 0.6 and 1 inch. The position of the wall
126, and thereby the gap spacing G2, may be selectively adjusted
using an adjustment mechanism 126B (FIG. 4). According to some
embodiments, the rear divider wall 126 forms an angle A (FIG. 7) of
at least about 30 degrees with respect to horizontal and, according
to some embodiments, between about 30 and 45 degrees with respect
to horizontal.
[0046] The front divider wall 124 and rear divider wall 126 divide
the hopper chamber 120 into subchambers or regions. More
particularly and referring to FIG. 7, a front region or subchamber
120A is defined between the divider wall 124 and the inlet 116A, an
intermediate region or subchamber 120B is defined between the front
divider wall 124 and the rear divider wall 126, and a rear region
or subchamber 120C is defined between the rear divider wall 126 and
the rear wall of the bin 100.
[0047] With reference to FIG. 8, the housing 110 further includes a
high pressure supply port or nozzle 134. In use, the pressurized
gas source 136 is fluidly connected to the high pressure nozzle 134
via a manifold, fitting, flexible or rigid conduit 134A, or the
like. The gas source 136 may include a compressor or a container of
compressed gas, for example. The high pressure gas source 136 is
operative to provide a supply gas flow of a suitable working gas at
a high pressure to the nozzle 134. According to some embodiments,
the supplied gas is or includes air. According to some embodiments,
the pressure of the supplied gas at the nozzle 134 is at least
about 10 psi and, according to some embodiments, between about 10
and 60 psi. A flowpath network for the supplied gas is
schematically illustrated in FIG. 13 and described below.
[0048] With reference to FIGS. 7, 9 and 13, a gas supply passage or
conduit 140A (FIG. 7) fluidly connects the high pressure nozzle 134
to a forward control valve 142. Two forward jet supply passages
140C (FIG. 9) fluidly connect the forward control valve 142 to
respective forward drive jet apertures or outlets 146. The forward
jet outlets 146 are positioned and configured to direct air or
other supplied gas into the dispensing channel 116. A front
agitation supply passage 140E (FIG. 9) fluidly connects the forward
control valve 142 to a front air amplifier 150. The front air
amplifier 150 is positioned and configured to direct air or other
supplied gas into the hopper chamber 120 through the front
agitation outlet 122C. The forward control valve 142 is operable to
control airflow to the forward jet outlets 146 and the front air
amplifier 150.
[0049] With reference to FIGS. 7, 10 and 13, a gas supply passage
or conduit 140B (FIG. 7) fluidly connects the high pressure nozzle
134 to a reverse control valve 144. A reverse jet supply passage
140D (FIG. 10) fluidly connects the reverse control valve 144 to a
reverse drive jet aperture or outlet 148. The reverse jet outlet
148 is positioned and configured to direct air or other supplied
gas into the dispensing channel 116. A rear agitation supply
passage 140F (FIG. 10) fluidly connects the reverse control valve
144 to a rear air amplifier 160. The rear air amplifier 160 is
positioned and configured to direct air or other supplied gas into
the hopper chamber 120 through the rear agitation outlet 122D. The
reverse control valve 144 is operable to control airflow to the
reverse jet outlet 148 and the rear air amplifier 160.
[0050] The gas supply passages 140A-F may be of any suitable
construction and configuration. According to some embodiments, some
or all of the passages 140A-F are defined in whole or in part by
channels formed in the housing 110. These channels may be machined
or molded into the housing 110.
[0051] Each of the air amplifiers 150, 160 is secured to the
housing 110. The air amplifiers 150, 160 may be of any suitable
construction to effect the functionality described herein.
According to some embodiments, the air amplifiers 150, 160 are
constructed as described below with regard to the air amplifier
150. The air amplifiers 150, 160 may be constructed in the same or
similar manners and it will therefore be appreciated that this
description can likewise apply to the air amplifier 160 (and/or any
additional air amplifiers).
[0052] With reference to FIGS. 11 and 12, the air amplifier 150
includes an outer body 152, an inner body 154 and a gasket or shim
153. The components 152, 153, 154 may be formed of any suitable
material(s). According to some embodiments, the bodies 152, 154 are
formed of a rigid polymeric material, which, according to some
embodiments, is molded. The shim 153 may also be formed of a rigid
polymeric material or, according to other embodiments, an
elastomeric material. The bodies 152, 154 may each be unitarily
formed as illustrated or may each comprise assembled subcomponents.
Moreover, the bodies 152, 154 may be unitarily formed together.
[0053] The outer body 152 includes an annular center wall 152A, an
annular inner wall 152B, and an annular channel 152C defined
therebetween. A feed opening 152D is defined in the wall 152A and
fluidly communicates with the channel 152C. When the air amplifier
150 is installed in the housing 110, the gas supply passage 140D
(FIG. 7) is fluidly connected to the feed opening 152D to supply
the gas from the gas source 136 to the channel 152C. Similarly,
when the air amplifier 160 is installed in the housing 110, the gas
supply passage 140F is fluidly connected to the feed opening of the
air amplifier 160 to supply the gas from the gas source 136 to the
annular channel of the air amplifier 160. The body 152 defines a
central passage 152E extending up through the wall 152B. The body
152 has a relatively sharp or squared, annular upper edge or corner
surface 152F defining a portion of the passage 152E. According to
some embodiments, the side and bottom surfaces forming the edge
152F form an angle of about 90 degrees.
[0054] The inner body 154 has an upstanding projection or collar
154A. A central passage 154B extends through the inner body 154.
The body 154 has a relatively rounded or arcuate, annular lower
edge or corner surface 154C defining a portion of the passage
154B.
[0055] The components 152, 153, 154 are assembled as shown in FIG.
12 such that the shim 153 is interposed or sandwiched between the
bodies 152, 154. The assembled air amplifier 150 has an inlet 156A,
an interior chamber 156B, a central passage 156C and an outlet
156D. The interior chamber 156B includes the channel 152C.
[0056] In use and with reference to FIG. 12, the air amplifier 150
(and likewise the air amplifier 160) can be used to convert a
supplied pressurized gas flow having a given pressure, velocity and
mass flow rate into an exiting or output air flow having a
comparatively lower pressure, higher velocity, and higher mass flow
rate. More particularly, the valve 142 can be opened to supply a
flow FS of pressurized gas to the channel 152C via the opening
152D. The supplied gas flows around the channel 152C, into the
chamber 156B, and into the central passage 156C (as indicated by
the arrows FC). The gas flow FC responding to the juxtaposition of
the rounded surface 156C opposite and adjacent the sharp corner
152F generally and preferentially follows the rounded surface 154C
up through the passage 154B and out through the outlet 156D as a
result of the Coanda effect. Due to the Coanda effect, a vacuum or
low pressure region is established on or adjacent to the surface
154C. This low pressure region draws a flow of ambient air FE
through the inlet 156A. The flow FE is drawn up through the passage
156C and out through the outlet 156C. The two flows FC and FE
thereby combine to provide an exit gas flow FAF. The exit gas flow
FAF has a pressure that is less than the pressure of the supplied
gas FS and a mass flow rate that is greater than that of the
supplied gas FS.
[0057] The outlet 156D of the air amplifier 150 is positioned in or
adjacent the agitation outlet 122C so that the exit gas flow FAF
enters the hopper chamber 120 through the outlet 122C. Similarly,
the corresponding outlet of the air amplifier 160 is positioned in
or adjacent the agitation outlet 122D so that an exit gas flow FAR
exiting the air amplifier 160 enters the hopper chamber 120 through
the outlet 122D (FIG. 10).
[0058] According to some embodiments and as illustrated, one or
both of the air amplifiers 150, 160 are mounted on or integrated
into the housing 110. The air amplifiers 150, 160 may be separately
formed from the housing 110 and secured to the housing by adhesive,
fasteners, integral mechanical structures, or the like. All or a
portion of each air amplifier 150, 160 may be integrally molded
into the housing 110. Each amplifier 150, 160 can be separately
formed from the housing 110 and insert molded into the housing
110.
[0059] One or more sensors 115 are operatively positioned in the
dispensing channel 116. According to some embodiments, the sensors
115 are counting sensors and are operably connected to associated
sensor receiver/processor electronics. As further discussed below,
the sensors 115 are configured and positioned to detect the tablets
T as they pass through the dispensing channel 116. According to
some embodiments, the sensors 115 are photoelectric sensors.
According to some embodiments, at least one of the sensors includes
a photoemitter and the other sensor includes a photodetector that
receives photoemissions from the photoemitter of the first
sensor.
[0060] A connector circuit board or other electrical connector may
be mounted on the bin 100 to provide an electrical connection
between an external controller and a bin-controlling circuit board
or other electronic component of the bin 100 for power and data
signals from the external controller and the counting sensors
115.
[0061] Exemplary operation of the dispensing system 40 will now be
described. The bin 100 is filled with tablets T to be dispensed.
The tablets T may initially be at rest as shown in FIG. 8. At this
time, the valves 142, 144 are closed so that no gas flow is
provided through the jet outlets 146, 148 or the agitation outlets
122C, 122D.
[0062] When is it desired to dispense the tablets T to fill the
container C, the dispensing carrier 70, directed by the controller
42, moves the container C to the exit port 116B of the selected
dispensing bin 100. The controller 42 signals the forward valve 142
to open (while the rearward valve 144 remains closed). The opened
valve 142 permits the pressurized gas from the gas source 136 to
flow through the passages 140C and out through the forward drive
jet outlets 146. The pressurized flow from the jet outlets 146
creates high velocity gas jets that generate suction that causes a
forward flow FF of high pressure, high velocity air to be drawn
outwardly through the dispensing channel 116 (FIG. 9). Tablets T
are oriented into a preferred orientation by the shape of the inlet
116A to the dispensing channel 116 and dispensed into the container
C through the dispensing channel 116 and the outlet 116B under the
force of the forward flow FF. The counting sensors 115 count the
tablets T as they pass through a predetermined point in the
dispensing channel 116.
[0063] The opening of the valve 142 also simultaneously permits the
pressurized supply gas from the gas source 136 to flow through the
passage 140E, through the front air amplifier 150 and out through
the front agitation outlet 122C as an air flow FAF having a
relatively low velocity and high mass flow rate as compared to the
gas flow from the jet outlets 146 (FIG. 9). The air flow FAF flows
through and lofts or otherwise displaces (i.e., agitates) the
tablets T in the front subchamber 120A proximate the inlet 116A.
This agitation of the tablets T helps to orient the tablets T for
singulated entry into the dispensing channel 116 and to prevent
tablet jams. According to some embodiments, the forward jet gas
flows and the agitation flow FAF are provided simultaneously.
[0064] Once dispensing is complete (i.e., a predetermined number of
tablets has been dispensed and counted), the controller 42
activates the forward valve 142 to close and the reverse valve 144
to open. The opened valve 144 permits the pressurized gas from the
gas source 136 to flow through the passage 140D and out through the
reverse drive jet outlet 148. The pressurized flow from the jet
outlet 148 creates a high velocity gas jet that generates suction
that causes a reverse (i.e., rearward) flow FR of high pressure air
to be drawn inwardly through the dispensing channel 116 toward the
chamber 120. In this manner, the airflow is reversed and any
tablets T remaining in the channel 116 are returned to the chamber
120 under the force of the reverse flow (FIG. 10).
[0065] The opening of the valve 144 also simultaneously permits the
pressurized supply gas from the gas source 136 to flow through the
passage 140F, through the rear air amplifier 160 and out through
the rear agitation outlet 122D as the air flow FAR which has a
relatively low velocity and high mass flow rate as compared to the
gas flow from the jet outlet 148 (FIG. 10). The air flow FAR flows
through and lofts or otherwise displaces (i.e., agitates) the
tablets T in the front subchamber 120A and/or the intermediate
subchamber 120B proximate the choke point 124A. This agitation of
the tablets T helps to loosen the tablets T to permit return of the
tablets T and to prevent or break tablet jams. According to some
embodiments, the reverse jet gas flow and the agitation flow FAR
are provided simultaneously. According to some embodiments, the
reverse valve 144 is opened and then closed after a relatively
short period to provide the reverse flow FR and the agitation flow
FAR as short bursts.
[0066] During a dispensing cycle, the controller 42 may determine
that a tablet jam condition is or may be present. Tablets may form
a jam at the nozzle inlet 116A, the choke point 124A or the choke
point 126A, so that no tablets are sensed passing through the
dispensing passage 116 for a prescribed period of time while the
forward air flow FF is being generated. In this case, the
controller 42 will issue a "backjet" by closing the forward valve
142 and opening the reverse valve 144 as described above for
generating the air flows FR, FAR. The air flows FR, FAR may serve
to dislodge any jams at the inlet 116A, the choke point 124A, or
the choke point 126A as well as to loosen the tablets in the
subchamber 120C.
[0067] According to some embodiments and as illustrated, the drive
jet outlets 146 and the agitation outlet 122C (and/or the drive jet
outlet 148 and the agitation outlet 122D) are fluidly connected to
the pressurized gas source via the same intake (i.e., the nozzle
134). According to some embodiments and as illustrated, only a
single gas source 136 is used to supply both the drive jet outlets
146 and the agitation outlet 122C or both the drive jet outlet 148
and the agitation outlet 122D. According to some embodiments, a
single gas source is used to supply all drive jet outlets and
agitation outlets.
[0068] According to some embodiments, the pressure of the gas
supplied to the feed inlet 152D of each air amplifier 150, 160 is
substantially the same as the pressure of the gas supplied to each
drive jet outlet 146, 148.
[0069] In the foregoing manner, agitation air flows FAF, FAR can be
provided to facilitate effective and reliable dispensation and
return of the tablets T. The air amplifiers 150, 160 may enable
effective agitation of tablets in the hopper 120 using a supplied
gas flow that would otherwise be insufficient. For example, a
compressor having a lower mass flow rate supply capacity may be
used for the gas source 136. This may be particularly beneficial
where a smaller or quieter compressor may be needed or desired
(e.g., in a pharmacy).
[0070] Because the air flows FAF, FAR are supplied from a high
pressure source suitable to supply the drive jet outlets 146, 148,
it is not necessary to provide a separate low pressure, high mass
flow rate air supply to perform tablet agitation and, therefore,
the associated apparatus (e.g., manifolds, pumps, etc.) can be
omitted. Moreover, because the air flows FAF, FAR are supplied from
a common (i.e., the same) high pressure gas source 136 as the jets
144, 146, the number of supplies and connections required can be
reduced or minimized. As a result, dispensing systems and bins
according to embodiments of the present invention may be less
expensive and complicated to manufacture and operate.
[0071] The divider walls 124, 126 and choke points 124A, 126A may
further facilitate smooth and reliable operation of the bin 100,
while also allowing for filling the bin 100 with a greater number
of tablets. With reference to FIG. 8, the choke points 124A, 126A
limit or reduce the weight load that tends to push the tablets
forward into the front or staging region 120A. As a result, fewer
tablets T tend to collect in the region 120A so that fewer tablets
T must be displaced by the air flow FAF from the air amplifier 150.
Thus, by reducing the tablet load, the bin 100 may be able to
effectively agitate the tablets and prevent jams with lower air
flow energy from the air amplifier 150. The sizes of the choke
points 124A, 126A may be selectively adjusted by raising and
lowering the divider walls 124, 126 to customize the bin 100 for
dispensing tablets of different sizes, for example.
[0072] The angled orientation of the divider wall 126 with respect
to vertical also serves to reduce the forward loading on the
tablets T. The angled divider wall 126 may thereby permit a larger
amount of tablets to be stored in the hopper chamber 120.
[0073] The arrangement of the divider walls 124, 126 may also serve
to promote dispensing of the oldest tablets (i.e., the tablets that
have been in the hopper chamber 120 longest) first. Generally,
newer tablets are added on top of older tablets in the subchamber
120C. Once the bottommost tablets pass through the choke point
126A, they tend not to return to the subchamber 120C even when a
backjet is executed.
[0074] The air amplifiers 150, 160 can be tuned or adjusted to
provide the desired performance in view of other operating
parameters (e.g., tablet size, supplied gas flow rate, etc.). One
method in accordance with the present invention for adjusting an
air amplifier 150, 160 is to replace the shim 153 with a shim that
is thicker or thinner, depending on the desired adjustment. The
described methods of assembly and adjustment may allow for a
relatively low profile air amplifier.
[0075] While the bin 100 has been illustrated and described herein
with only one front air amplifier 150 and one rear air amplifier
160, fewer or greater numbers of front and rear air amplifiers may
be provided. For example, there may be two or more front air
amplifiers 150 and/or two or more rear air amplifiers 160.
According to some embodiments, the bin may include only a front air
amplifier or air amplifiers 150 or, alternatively, only one or more
rear air amplifiers 160. The air amplifiers may be arranged and
configured in any suitable manner. For example, a row or rows of
air amplifiers may extend across the width of the floor 122.
[0076] While the bin 100 has been illustrated and described herein
with the air amplifier 150 being supplied from the same valve 142
and controlled in group fashion with the drive jet outlets 146 and
the air amplifier 160 being supplied from the same valve 144 and
controlled in group fashion with the drive jet outlet 148, one or
both of the air amplifiers 150, 160 can be separately controlled
from the associated jet outlets. For example, a further valve may
be provided that controls the gas supply to the air amplifier 150
independently of the jet outlets 146, whereby the tablets T may be
agitated via the air amplifier 150 prior to providing the
dispensing draw via the jet outlets 146.
[0077] According to some embodiments, the agitation outlets 122C,
122D are each sized and shaped such that tablets of the size and
shape intended to be dispensed using the bin cannot fall through
the outlet 122C, 122D. According to some embodiments and as
illustrated, one or both of the agitation outlets 122C, 122D is an
elongated slot. Such a shape may serve to prevent a tablet from
settling over so much of the area of the outlet 122C, 122D that the
Coanda effect is defeated. According to some embodiments, each
elongated outlet 122C, 122D has a width of no more than about 2 mm.
According to some embodiments, each elongated outlet 122C, 122D has
an area of at least about 0.24 in.sup.2.
[0078] While, in the foregoing description, the valves 142, 144 are
controlled by the controller 42, the valves 142, 144 may
alternatively be controlled by a local controller unique to each
bin 100.
[0079] The foregoing is illustrative of the present invention and
is not to be construed as limiting thereof. Although a few
exemplary embodiments of this invention have been described, those
skilled in the art will readily appreciate that many modifications
are possible in the exemplary embodiments without materially
departing from the novel teachings and advantages of this
invention. Accordingly, all such modifications are intended to be
included within the scope of this invention. Therefore, it is to be
understood that the foregoing is illustrative of the present
invention and is not to be construed as limited to the specific
embodiments disclosed, and that modifications to the disclosed
embodiments, as well as other embodiments, are intended to be
included within the scope of the invention.
* * * * *