Abstract:
An automated vial label assembly for three-sided pharmaceutical vials includes a conveyor assembly, an elevator assembly, and a printer assembly. The labeling process may be controlled and programmed by a computing device with sensors present at deliberate points throughout the assembly to communicate and transmit information back to the computing device. Such information may include the location and position of the vial, the status of the printed label, and the rotational speed of the container and label assembly. This system may be used to label any size or shape of bottle, including more traditional cylindrical or square shaped containers. The labeling module may be used as a stand-alone labeling system or may be a module used in combination with a larger system such as a pharmaceutical dispensing assembly whereby vials may be sorted, labeled, and filled with the appropriate medications.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    The present invention generally relates to an apparatus and method for applying labels to items such as containers, vials, bottles, etc. More specifically, the present invention relates to an apparatus and method of labeling of three-sided pharmaceutical vials. This labeling system may be used as a stand-alone module, or may be used in conjunction with automated prescription filling devices and systems. 
         [0002]    When considering the existing methods of a prescription order fulfillment process, it is necessary to affix patient-specific information to the pharmaceutical container. This is typically accomplished by affixing an adhesive-backed label to a container; this label typically being printed with any commercially-available printer. The patient-specific information affixed to the label will include important information such as the patient name, medication type, medication strength and description, physician information, signa, instructions for taking the medication and one or more types of machine-readable information, such as a bar code. 
         [0003]    Three-sided bottles have more surface area than a traditional cylindrical bottle of the same volumetric size, and considering the amount of patient and prescription-related information that is required to be affixed to a pharmaceutical bottle when filling a prescription, it would be advantageous to dispense medication in a bottle that has a larger surface area for displaying the required information. However, three-sided bottles (or even four-sided bottles) prove to be more difficult to label, both by hand and by automation. In contrast with a cylindrical bottle, whereby a single label can quickly be wrapped around the circumference of the bottle, a three-sided bottle requires much more precision when applying a label; typically, more than one label needs to be applied (one for each side), and the edges and corners of the bottle must be taken into consideration when applying the label. 
         [0004]    A typical label applicator applies one or more labels to an article as the article is conveyed past the label applicator. For example, a label applicator may include a label dispenser, which dispenses a label onto a label receiver or applicator section. The applicator section then transfers the label to the article. This transfer is often accomplished by a blast of gas, typically air, under pressure. Labels used in these applicators are usually secured to a backing strip or release liner by an adhesive, and the backing strip is wound onto a supply reel, fan-folded, or held in some other manner. The backing strip and labels are moved from a holding area through a printing area by a take-up mechanism, such as a reel, and the labels are peeled off of the backing strip by a peel bar, and momentarily retained at an applicator or label receiver. The applicator or label receiver then transfers the label to a passing article. 
         [0005]    Known types of label applicators include, but are not limited to, air-jet, synchronous (wipe-on), tamp, corner wrap, flag (wiring cable) and round product applicators. However, typically in these systems there is a measurable gap between the peel bar and the applicator, such as a tamp or transfer head, and the printed adhesive-backed label is removed completely from the backing strip, thereby losing the accurate positioning. 
         [0006]    To meet the different requirements of manufacturers and packagers of such products, many types of apparatus and systems have been proposed and are used. U.S. Pat. No. 8,733,416 describes a method for positioning an article within a label applicator and securing the article between a first roller, a second roller, and a moveable contact member. A label is received for application to the article by delivering the label between the article and at least one of the first roller, second roller, and the moveable contact member. 
         [0007]    U.S. Pat. No. 6,451,149 describes an apparatus and method for the accurate positioning of die cut printed labels on a backing strip by ensuring that a trailing portion of the printed label remains attached to the backing strip at a pickup point. The apparatus includes a label leading edge indicating sensor and an adjustable peel bar held at a pickup position. The label remains in its die cut position on the backing strip until a vacuum head removes the label and applies it to a product. Therefore, accurate positioning of the printed label is maintained. 
         [0008]    U.S. Pat. No. 4,844,771 describes a label applicator and method which can label the forward and rear faces of an article, as well as the other exposed faces of the article, with a printer that can be located immediately adjacent the peeler bar. This apparatus dispenses a printed label onto a label receiver and moves the label receiver along a path toward the article to be labeled, and pivots the label receiver as the label receiver moves along the path. 
         [0009]    U.S. Patent Publication No. 2007/0102109 A1 describes an automated pharmaceutical dispensing system with a retrieval subsystem for retrieving a pharmaceutical pack and delivering the pack to a labelling station. The labelling station comprises a label printer and a label applicator subsystem for applying the label to the pack. The system further comprises a delivery subsystem for delivering the pack from the labelling station to a user-accessible point. The label applicator can apply the label at a predetermined position, predetermined orientation or across two discrete planes of the pack. 
         [0010]    U.S. Pat. No. 8,986,476 describes an apparatus and method for fulfillment of patient prescription orders by adapting a stock container pre-filled with medication for use as a patient-specific container through precise application of patient-specific information to the pre-filled container. In general, preferred embodiments comprise a control apparatus and information-application apparatus. A printer applies patient-specific information on a label. A positioner orients the pre-filled container to receive the label from the printer such that information provided with the container is available for use. 
         [0011]    All of the above-referenced U.S. patents are hereby incorporated by reference, in their entirety. 
         [0012]    Disadvantages of the use of known label applicators or hand application of labels include indiscriminate application of the labels, the amount of time required to apply labels by hand, and errors that could occur through improper or inaccurate labeling. Indiscriminate application of a pharmaceutical label represents a problem to pharmacy management because some of the information provided on the containers may be covered and obscured by the label. As a result, the information provided with the container may be rendered unusable to pharmacy management, patient or others in the prescription order fulfillment chain. Furthermore, when using a label applicator to apply a label to a three-sided container, the timing of the steps in the labeling process is very important. The timing of printing the label, transporting the label to the container, and the positioning of the container must all be synchronous. If the timing is off for any one step, the label will not be applied properly. 
         [0013]    It would therefore be advantageous to provide an automated, streamlined apparatus and process for labeling containers, specifically pharmaceutical containers of different sizes and shapes. It would be particularly advantageous to provide a product and method that employs the use of sensors and computer feedback to eliminate the need to precisely time each step in the labeling process. It would be further advantageous to provide an apparatus and method for labeling containers that could be used alone or adapted to be used in conjunction with current pharmaceutical dispensing systems. 
       BRIEF SUMMARY OF THE INVENTION 
       [0014]    In one aspect of the present invention, an automated vial label assembly is provided. A preferred embodiment of the present invention comprises a conveyor assembly, an elevator assembly, and a printer assembly. During the labeling process, a vial or container may travel from the conveyor assembly to the elevator assembly, where a label printed by the printer assembly is applied to the container. The labeling process may be controlled and programmed by a computer or another suitable information processing device. Sensors are present at deliberate points throughout the assembly to communicate and transmit information back to the computing device. Such information may include the location and position of the vial, the location and status of the printed label, and the rotational speed of the container and label assembly. 
         [0015]    The label assembly system of the present invention is fully automated and is described herein in terms of labeling a three-sided, triangular shaped pharmaceutical vial; however, this system may be used to label any size or shape of bottle, including more traditional cylindrical and square shaped containers, which may or may not be used for pharmaceutical purposes. 
         [0016]    The present invention may be used as a stand-alone labeling system or may be a module used in combination with a larger system such as a pharmaceutical dispensing assembly whereby vials may be sorted, labeled, and filled with the appropriate medications, for example. 
     
    
     
       DESCRIPTION OF THE DRAWINGS 
         [0017]    These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where: 
           [0018]      FIG. 1 a    illustrates a perspective view of a preferred embodiment of the label assembly system, wherein a vial has been transported from the conveyor assembly to the cup of the elevator assembly. 
           [0019]      FIG. 1 b    illustrates a perspective view of a preferred embodiment of the label assembly, wherein a vial is raised in position to be labeled. 
           [0020]      FIG. 2  illustrates a perspective view of one embodiment of the conveyor assembly, whereby a vial is shown traveling down the conveyor toward the sensor. 
           [0021]      FIG. 3  illustrates a perspective view of a preferred arrangement of the conveyor assembly adjacent to the elevator assembly of the present invention. 
           [0022]      FIG. 4 a    illustrates a perspective view of one embodiment of the elevator assembly with the platform in the lowered position and a vial present in the cup. 
           [0023]      FIG. 4 b    illustrates a perspective view of one embodiment of the elevator assembly with the platform raised and a vial positioned between the platform and the pilot. 
           [0024]      FIG. 5  illustrates a perspective view of one embodiment of the printer assembly. 
           [0025]      FIG. 5 a    illustrates a close-up perspective view of inset “A”, showing one embodiment of the label transfer assembly. 
           [0026]      FIG. 6  illustrates a perspective view of one embodiment of the printer assembly showing a printed label rolling onto the label transfer assembly and triggering the label sensor. 
           [0027]      FIG. 6 b    illustrates a close-up perspective view of inset “B”, showing a printed label rolling onto the label transfer assembly and triggering the label sensor. 
           [0028]      FIG. 7 a    illustrates a perspective view of one embodiment of the elevator assembly and adjacent printer assembly, showing a vial present in the cup of the elevator assembly. 
           [0029]      FIG. 7 b    illustrates a perspective view of one embodiment of the elevator assembly and adjacent printer assembly, showing a vial in position for labeling. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0030]    A preferred embodiment of the automated vial label assembly  10  of the present invention comprises an optional conveyor assembly  11 , an elevator assembly  12 , and a printer assembly  13 , as shown in  FIGS. 1 a   - 7   b.    FIG. 1 a    shows one arrangement of a vial labeling assembly  10  wherein a three-sided vial  14  (also referred to herein as a container) has already passed through the conveyor system  11  and into the cup  19  of the elevator assembly  12 .  FIG. 1 b    shows this same arrangement of the overall vial label assembly  10 ; however, in this illustration the vial  14  and label transfer assembly  33  are in position for the label  38  to be readily applied. 
         [0031]    Preferred embodiments of the components of the vial label assembly are outlined below, followed by a detailed description of a preferred contemplation of the entire labeling process. 
       Conveyor Assembly 
       [0032]    The conveyor assembly  11 , as shown in  FIG. 2 , preferably comprises a belt  15  or belts driven by a motor  16 , and may be designed in any length or size suitable for the module. When in use, a vial or container  14  is dropped on the conveyor assembly  11  in an orientation such that the closed bottom of the container  14  is traveling toward the end of the conveyor  15 . A proximity sensor  17  may be present at the end of the conveyor assembly  11  to sense when a vial  14  is nearing the edge or has reached the end of the conveyor  15 . This sensor  17  may be any suitable sensor, such as a LED light-based sensor. 
       Elevator Assembly 
       [0033]    Shown in  FIG. 3 , the conveyor assembly  11  is preferably adjacent to the elevator assembly  12 . In one embodiment, the elevator assembly  12  comprises components such as a receptacle or cup  19  for catching the vial  14  as it falls from the conveyor belt  15 , a rotatable platform  20 , a pilot  30  for aligning and rotating the vial  14 , a motor  25  for raising and lowering the platform  20 , a motor  25  for driving the rotation of the vial  14 , and sensors  21 ,  22  to communicate and transmit information to be used in the labeling process. As previously described, the labeling process may be controlled and programmed by a computer or another suitable information processing device. This computing device will compile the information provided by the assembly sensors for use in an algorithm that runs the vial labeling process. 
         [0034]    The conveyor  11  and elevator assembly  12  are positioned such that the end of the conveyor belt  15  may accurately drop the container  14  into a cup  19  preferably present on lower portion of the elevator assembly  12 . This cup  19  is for receiving the container  14  as it drops off the conveyor belt  15 . The elevator assembly  12  also includes a platform  20  that raises and lowers in response to where the container  14  is located on the elevator assembly  12 . For instance, once the container  14  passes through the light beam  18  of the sensor  17  on the conveyor assembly  11 , thus triggering the sensor  17  that the container  14  has reached the end of the conveyor  15 , the platform  20  on the elevator assembly  12  may lower down into the bottom of the cup  19 . In this way, the container  14  drops off the conveyor  15  and into the cup  19 , landing open side up on top of the platform  20 , as seen in  FIG. 4 a   . In a preferred embodiment, the platform  20  on elevator assembly  12  moves up and down in a vertical direction, contrary to most label applicators which proceed through a labeling process in a horizontal direction; however, it is to be noted that the elevator assembly of the present invention may be designed to move in any direction as desired and may not be limited to only vertical movement. 
         [0035]    In a preferred embodiment, the platform  20  is spring-loaded and rotatable and may be raised and lowered through mechanical means such as a motor  25  driven belt system  24 .  FIG. 4 a    shows the platform  20  lowered into the cup  19 , while  FIG. 4 b    shows the elevator assembly  12  with the platform  20  in a raised position. When a container  14  is loaded onto the platform  20 , the platform  20  can be raised to meet a pilot  30  preferably on the upper portion of the elevator assembly  12 . The pilot  30  serves to align the container  14  for labeling (see  FIG. 4 b   ) and rotates the container  14  on axis for labeling. The pilot  30  may be powered by a motor and shaft assembly  29  or other suitable means that rotates the pilot  30 ; the container  14  is aligned by the pilot  30  and rotates on axis with the pilot  30  for application of the label  38 . The optional spring portion  26  of the platform  20  allows for the container  14  to be pushed tightly around the pilot  30  for a secure fit. 
         [0036]    It is contemplated in an alternative embodiment that, rather that the container  14  being raised to the pilot  30  by a spring-loaded platform  20 , instead the container  14  may remain stationary at a receiving point and the pilot  30  may be lowered down to meet the container  14 . In this embodiment, the pilot  30  may be spring-loaded to allow for the container  14  to be pushed tightly around the pilot  30  as the pilot  30  is lowered into the opening of the container  14 . In this embodiment, the container  14  still remains capable of being rotated on axis for label application. 
         [0037]    In a preferred embodiment, the pilot  30  is conical shaped and may include different steps or grooves  27  to accommodate different diameters of bottle openings (see  FIG. 4 a   ); a container  14  with an opening of a smaller diameter would be stopped shorter on the pilot  30  than a container  14  with a larger diameter opening. Additionally, the pilot  30  may include at least one rubber gasket  28  or O-ring to facilitate frictional engagement between the container  14  and the pilot  30 . 
         [0038]    Preferably, at least two sensors may be present on the platform  20  component of the elevator assembly  12  for 1) sensing when a container  14  is present on the platform  20 , and 2) sensing proper alignment of the container  14 , as well as determining the edges and sides of the container  14  prior to labeling. The sensors may be mechanical, acoustic, photo, or any other suitable type of sensor. The first sensor  21  is a proximity sensor for sensing the presence of a container  14  on the platform  20 , preferably a fiber optic sensor or LED light sensor. The second sensor  22  (also referred to herein as an “alignment sensor”) is preferably a LED light sensor. Any person skilled in the art would know what type of sensor may be best suited for a particular function. 
         [0039]    In one embodiment, the alignment sensor  22  may be mounted adjacent to the platform  20 , preferably directly adjacent to or in close proximity to where the container  14  will sit on the platform  20 . The vial rotation motor  29 , or another suitable rotation means, rotates the container  14  while the alignment sensor  22 , determines the edges and the sides of the container  14  to verify the position of the vial  14 . This determination process, described in greater detail below, is performed to ensure the container  14  is positioned properly prior to applying the label  38 . The alignment sensor data is sent to a computer where a computer algorithm is used to control the labeling process. 
       Printer Assembly 
       [0040]    Adjacent to the elevator assembly  12  is the printer assembly  13 , as illustrated in  FIGS. 5-6   b.  In a preferred arrangement, the printer assembly  13  comprises a printer  31 , a label transfer assembly  33  with sensor  39 , and ready to print or pre-printed labels or spools  32  of labels. The printer  31  may be any suitable printer as desired for a particular machine and/or use. Labels  38  may be chosen based on the size and shape of the container to which they are being affixed. 
         [0041]    As shown in  FIGS. 5 a  and 6 b   , the label transfer assembly  33  includes a means for rolling  34 ,  35 ,  36  the label  38  across the transfer assembly  33  and a means for providing vacuum force  37  as the label  38  travels across the transfer assembly  33 . In a preferred arrangement illustrated by  FIG. 6 b   , the label transfer assembly  33  is comprised of at least two shafts  35  with a series of pulleys  34  encircling each shaft  35 . In one embodiment, the shaft  35  may be stationary, while the pulleys  34  may be connected in series around a cylindrical tube that may rotate around the stationary shaft  35  through means such as ball bearings. In this way, the pulleys  34  may rotate together as one piece around the shaft  35 . Or in an alternative embodiment, the shaft  35  may rotate in conjunction with the pulleys  34 . A series of belts, cables, O-rings, or the like, may be arranged around each pulley such that each belt  36  connects the pulleys  34  of the adjacent shaft  35 . And, a fan  37  may be provided either between or behind the belts  36  to provide vacuum force so that as the label  38  travels across the label transfer assembly  33  to meet the container  14 , the label  38  remains upright and held in position against the belts  36  as it is dispatched from the printer  31  to the container  14 . 
         [0042]    A proximity sensor  39 , shown in  FIG. 5 a   , may be present on the label transfer assembly  33 , preferably positioned at the edge of the label transfer assembly  33  adjacent to the printer  31 , such that the label  38  passes by the sensor  39  (see  FIG. 6 b   ) as soon as the label  38  comes in contact with the belts  36  of the label transfer assembly  33 . This sensor  39  may tell the vial rotation motor  29  that a label  38  is ready for application. For simplification of the assembly, in a preferred embodiment, the pulleys  34  and belts  36  of the label transfer assembly  33  may be passive and, therefore, not require a motor for movement. Instead, the rotation of the container  14  via the vial rotation motor  29  can drive the rotation of the transfer assembly belts  36 . However, it is contemplated that the label transfer assembly may be powered by other means such as a motor, if so desired. 
         [0043]      FIG. 7 a    illustrates the printer assembly  13  and elevator assembly  12  adjacent to one another. A label  38  has been dispatched from the printer  31  and is passing through a light beam  18  of the proximity sensor  39  on the label transfer assembly  33 .  FIG. 7 b    illustrates the same arrangement shown by  FIG. 7 a   , except the container  14  is now in position and driving the rotation of the transfer assembly belts  36 . 
       Preferred Labeling Process 
       [0044]    A preferred process is described herein. The vial label assembly of the present invention is not to be limited to this process; it is to be understood that this process may be altered or adjusted as required or desired. 
         [0045]    In one preferred process, a container  14  may be dispensed onto the conveyor assembly  11  in such a way that the bottom or closed end of the container  13  travels in the direction of the belts  15 , toward the end of the conveyor assembly  11 . As the container  14  reaches the end of the conveyor  15 , it triggers a proximity sensor  17  present at the end of the conveyor belt  15 . The triggering of the conveyor sensor  17  alerts the platform  20  to lower into the cup  19  of the elevator assembly  12 . The container  14  continues to move past the sensor  17  until the container  14  is dropped into the cup  19  and onto the platform  20 . 
         [0046]    It is contemplated that the container  14  may be transported to the elevator assembly  12  through methods other than the conveyor assembly  11 . For example, in an alternative process, the container  14  may be transported to the elevator assembly  12  by hand, robotic arm, or another suitable method. 
         [0047]    When a first proximity sensor  21  on the platform  20  senses the presence of a container  14 , the elevator platform motor  25  triggers the belt  24  that raises the platform  20  and container  14  up to a pilot  30 , where the pilot  30  centers the container  14  for labeling. When the container  14  is engaged with the pilot  30 , a vial rotation motor  29  drives the rotation of the container  14  while the alignment sensor  22 , locates or determines the edges and sides of the container  14  to ensure proper vial positioning for label application. For example, in the case of a three-sided container, when the alignment sensor  22  senses a corner or edge of the container  14 , it then looks for another corner at 120 degrees from the first corner; once that corner is determined, the sensor looks for a third corner at 120 degrees from the second corner; once the third corner is determined, the sensor again looks for the original (first) corner at 120 degrees from the third corner. If the sensor determines more or less than 120 degrees (for example, if the sensor begins measuring degrees at a seam or artifact of the container rather than an actual corner or edge), then the determination of each edge may start over at the next detectable corner to ensure that all sides of the container have been properly detected. The number of degrees measured per side is dependent upon the shape of the container. For example: if the container is four-sided, the sensor may count 90 degrees from a detectable edge; if the container is cylindrical, the sensor may detect a point on the container and count 360 degrees back to the original point. As the alignment sensor  22  detects the sides and corners of the container  14 , it sends this information back to the computing device, where it can be compiled in the algorithm of the labeling process. 
         [0048]    Once the container  14  is properly aligned by the proximity and alignment sensors  21 ,  22 , the control computer transmits to the printer assembly  13  that the container  14  is ready for labeling. The label transfer assembly  33  moves into place, coming into contact with the side of the container  14 , and printer  31  prints the label(s)  38 . The vial rotation motor  29  spins the container  14  as directed by the control computer using encoder feedback to control speed, which in turn moves or spins the belts  36  on the label transfer assembly  33 . The printed label  38  is dispatched from the printer  31  and rolls along the belts  36  of the transfer assembly  33 . The label  38  is held against the belts  36  by a vacuum force created by the fan  37  of the transfer assembly  33  until the label  38  passes through the proximity sensor  39  and reaches the container  14 . The container  14  begins to rotate and the first edge of the label is applied to the first edge of the container. The rotation of the container  14  drives the rest of the label  38  to be applied to the first side of the container  14 . The container  14  continues to rotate as the label  38  rolls along the belts  36 , until the entire label  38  is applied to the first side of the container  14 , at which point the container  14  has rotated beyond the starting point of the next label. The vial rotation motor  29  then reverses the rotation of the container  14  to an extent whereby the container  14  is now in proper position for the labeling of the second (next) side of the container. The same rotation/reverse rotation process may repeat until the container  14  has been labeled as desired by the end user, at which point the label transfer assembly  33  opens away from the container  14 , and the elevator assembly  12  lowers the container  14  so that it may be removed or transported to the next step in an automated pharmaceutical dispensing process. 
         [0049]    Although the present invention has been described in considerable detail with reference to certain preferred versions thereof, other versions are possible. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred versions contained herein. All features disclosed in this specification may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.