Devices for capping vials useful in system and method for dispensing prescriptions

A method for securing a closure on a cylindrical container (such as a pharmaceutical vial) includes: positioning a closure in a first position, the closure being substantially centered via a centering assembly along an axis that is generally normal to the closure; translating the substantially centered closure along the axis to a second position; positioning a cylindrical container, the container being substantially centered via the centering assembly along the axis; translating the substantially centered closure along the axis to a third position in which it is adjacent the substantially centered container; and relatively rotating the closure and the container to secure the closure to the container. With such a method, both the closure and the cylinder can be centered along the axis, thereby registering them with each other for reliable securing.

FIELD OF THE INVENTION

The present invention is directed generally to the dispensing of prescriptions of pharmaceuticals, and more specifically is directed to the automated dispensing of pharmaceuticals.

BACKGROUND OF THE INVENTION

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.

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. The Williams system conveys a bin with tablets to a counter and a vial to the counter. The counter dispenses tablets to the vial. Once the tablets have been dispensed, the system returns the bin to its original location and conveys the vial to an output device. Tablets may be 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.

One additional 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, certain of the operations may be improved. For example, the reliability of the capping operation may be improved and desirable. Also, the ability to accommodate multiple styles and sizes of vials and caps with a single mechanism may also be desirable.

SUMMARY OF THE INVENTION

As a first aspect, embodiments of the present invention are directed to a method for securing a closure on a cylindrical container (such as a pharmaceutical vial). The method comprises: positioning a closure in a first position, the closure being substantially centered via a centering assembly along an axis that is generally normal to the closure; translating the substantially centered closure along the axis to a second position; positioning a cylindrical container, the container being substantially centered via the centering assembly along the axis; translating the substantially centered closure along the axis to a third position in which it is adjacent the substantially centered container; and relatively rotating the closure and the container to secure the closure to the container. With such a method, both the closure and the cylinder can be centered along the axis, thereby registering them with each other for reliable securing.

In some embodiments, the method includes positioning the closure and the container on a positioning stage. Also, in some embodiments the closure and the container are substantially centered via centering members of the centering assembly.

As a second aspect, embodiments of the present invention are directed to an apparatus for securing a closure on a cylindrical container. The apparatus comprises a centering assembly having a main stage and an elevator. The main stage includes a receiving region for separately receiving a closure and a container and further comprises centering members that are configured to substantially center the closure and the container sequentially along a first axis generally normal to the stage. The elevator is positioned such that a lifting member thereof is disposed over the main stage. The elevator includes a capture member that is configured to capture a closure and is configured to move between a lowered position, in which the capture member can capture the closure from the main stage, a raised position, in which a container can be received on the main stage below the captured closure, and an intermediate securing position, in which the closure is lowered to contact an upper edge of the container. The main stage and the capture member are configured to rotate relative to each other about the first axis, such that a closure captured with the capturing member can be rotatably secured to a container positioned on the main stage when the elevator is in the securing position.

As another aspect, embodiments of the present invention are directed to an apparatus for centering an object, comprising: a main stage; a plurality of centering members pivotally interconnected with the main stage, each of the centering members being rotatable about a respective axis of rotation, the axes of rotation being substantially parallel with each other, wherein rotation of the centering members about their respective axes of rotation causes the centering members to contact an object positioned on the main stage, and wherein contact with each of the centering members indicates that the object is centered on the stage; and a shield overlying at least one of the centering members, the shield being pivotable about the axis of rotation of the underlying centering member relative to the main stage and relative to the centering member, the shield having a contact edge that overhangs an edge of the centering member. The shield is configured to rotate with the centering member when no force above a predetermined level is applied to the contact edge of the shield, and wherein the shield is configured to rotate relative to the centering member when a force above a predetermined level is applied to the contact edge of the shield.

As a further aspect, embodiments of the present invention are directed to an apparatus for centering and gripping an object, comprising: a main stage rotatable via a drive unit about a first axis of rotation; a plurality of centering members pivotally interconnected with the main stage, each of the centering members being rotatable about a respective axis of rotation, the axes of rotation being substantially parallel with each other, wherein rotation of the centering members about their respective axes of rotation causes the centering members to contact an object positioned on the main stage such that contact with each of the centering members centers the object on the stage. The centering assembly includes a central sun gear that rotates with the main stage about the first axis, and wherein each of the clamps is connected to and rotatable with a respective clamp gear, each of the clamp gears engaging and being driven by the sun gear. The sun gear is coupled to a drive unit via a clutch. The clutch is configured such that, when the centering members are free to rotate relative to the main stage, the clutch engages the sun gear, such that sun gear remains stationary and the clamp gears rotate relative to the main stage, and wherein when the centering members are prevented from rotating, the sun gear rotates with the main stage.

As an additional aspect, embodiments of the present invention are directed to a method for securing a closure on a cylindrical container, comprising: positioning a closure in a first position, the closure being substantially centered via a centering assembly along an axis that is generally normal to the closure; translating the substantially centered closure along the axis to a second position; positioning a cylindrical container, the container being substantially centered via the centering assembly along the axis; translating the substantially centered closure along the axis to a third position in which it is adjacent the substantially centered container; and relatively rotating the closure and the container to secure the closure to the container, wherein rotating the container comprises gripping the container with a plurality of centering members, each of the centering members being rotatable about a respective axis of rotation. The closure and centering members are configured such that, when each of the centering members is in contact with the container, an angle defined between each of the respective axes of rotation, a contact point between the contact member and the container, and the axis normal to the closure is between about 140 and 178 degrees.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

The present invention will now be described more fully hereinafter, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in 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. In the drawings, like numbers refer to like elements throughout. Thicknesses and dimensions of some components may be exaggerated for clarity.

As described above, the invention relates generally to a system and process for dispensing pharmaceuticals. An exemplary process is described generally with reference toFIG. 1. The process begins with the identification of the proper container, tablets or capsules and closure to be dispensed based on a patient's prescription information (Box20). A container of the proper size is dispensed at a container dispensing station (Box22), then grasped and moved to a labeling station (Box24). The labeling station applies a label (Box26), after which the container is transferred to a tablet dispensing station (Box28), from which the designated tablets are dispensed in the designated amount into the container (Box30). The filled container is then moved to a closure dispensing station (Box32), where a closure of the proper size has been dispensed (Box34). The filled container is secured with a closure (Box36), then transported to an offload station and offloaded (Box38).

A system that can carry out this process is illustrated inFIGS. 2 and 3and designated broadly therein at40. The system40includes a support frame44for the mounting of its various components. The system40generally includes as operative stations a controller (represented herein by a graphics user interface monitor42), a container dispensing station58, a labeling station60, a tablet dispensing station62, a closure station100, and an offloading station66. In the illustrated embodiment, containers, tablets and closures are moved between these stations with two different conveying devices: a labeling carrier68and a dispensing carrier70; however, in some embodiments only a single carrier may be employed, or one or more additional carriers may be employed. With the exception of the closure station100, which is described in detail below, each of the other operative stations and the conveying devices is described in detail in U.S. Pat. No. 6,971,541 to Williams et al., the disclosure of which is hereby incorporated herein in its entirety.

Referring now toFIG. 4, general operations of the closure station100are illustrated in the form of a flow chart. The closure station100can address situations that can arise with prior art systems in which a filled pharmaceutical vial may not be properly aligned with a cap or closure in order for the closure to be applied. According to embodiments of the present invention, a closure is centered along an axis at a first position (Block80), then translated along that axis to a second position (Block82). A filled vial or other container is then centered along the axis (Block84). The centered closure is translated along the axis to a third position adjacent the container (Block86), and the container is rotated relative to the closure about the axis to secure the closure to the container (Block88). This method can assure that the closure and container are both centered about the same axis, which in turn can improve the reliability of the process of securing the closure onto the container.

Referring now toFIG. 5, the structure of the closure station100(which is capable of carrying out the method described inFIG. 4) is illustrated in some detail therein. The closure station100includes a frame102upon which other components are mounted. The frame102comprises a lower platform104that is mounted to the support frame44of the system40(seeFIG. 3for mounting orientation). An upright support106extends upwardly from one end of the lower platform104. An upper platform108extends in cantilever fashion from the upper end of the support106over the lower platform104. An elevator mounting member109is fixed to the support106and extends upwardly therefrom.

As used herein to describe the relative positions of various components, the terms “front,” “forward”, and derivatives thereof refer to the direction in which the upper and lower platforms108,104extend away from the support106. The terms “rear”, “back” and derivatives thereof refer to the direction opposite the forward direction. The terms “outward,” “outer,” “lateral” and derivatives thereof refer to the direction beginning at a vertical plane parallel to the forward direction that divides the frame102in the center and extending toward its periphery; the terms “inner,” “inward” and derivatives thereof refer to the direction opposite the outer direction.

Referring again toFIG. 5and more particularly toFIGS. 6 and 7, an elevator110is mounted to the rear surface of the support106. The elevator110has a base member111that extends vertically and generally parallel to the elevator mounting member109. A floor112merges with the lower end of the base member111and extends forwardly over the upper platform108of the frame102. Rails114a,114bare formed in the outer edges of the elevator mounting member109and extend for virtually its entire height. The rails114a,114bengage bearings116that are mounted to the rear surface of the base member111. A drive pinion118is rotatably mounted on the rear side of the base member111. A drive motor119(FIG. 7) is mounted on the front side of the base member111opposite the drive pinion118to rotate the drive pinion118about the axis A1. A toothed rack120with outwardly-facing teeth extends vertically on the back side of the elevator mounting member109.

Referring toFIGS. 5 and 7, a suction block127is mounted to the floor112. The block127includes an air intake bore126that leads from the upper surface of the block127to its lower surface, where a suction pad128is mounted. An air hose (not shown) is inserted into the bore126and is attached to a suction source (also not shown) to apply suction to the suction pad128.

Referring now toFIGS. 5,6,8,9aand9b, a centering assembly130is mounted to the upper platform108and support106of the frame102. A mounting bracket133is mounted to the underside of the upper platform108. A motor134is mounted to the underside of the mounting bracket133. A shaft136having a shoulder136ais coupled to the motor134via a coupling135and extends upwardly therefrom through a bore in a bearing137that is fixed to the upper platform108. The shaft136also extends through a spring142that is positioned above and rests on the shoulder136a, a thrust bearing139aagainst which the upper end of the spring142presses, a sun gear140with teeth140tthat is separated from the top surface of the bearing137via a clutch washer141, and a second thrust bearing139b. The shaft136terminates at a fixed joint with a main stage138that is positioned above the thrust bearing139b. The shaft136, the sun gear140, and the main stage138are all rotatable about an axis of rotation A2.

Referring once again toFIGS. 6,8,9a-9cand12a, three clamp gears144a,144b,144care mounted via rotating shafts145to the underside of the main stage138for rotation about respective axes of rotation A3, A4, A5. The clamp gears144a,144b,144care mounted near the periphery of the main stage138at 120 degree intervals about the axis A2, such that their teeth144t engage the teeth140aof the sun gear140. A respective clamp146a,146b,146cis mounted on each shaft145above the upper surface of the main stage138.

Referring now toFIGS. 9a-9cand12a-12c, each clamp146a,146b,146cis generally teardrop-shaped, with a long straight edge147a, a shorter curved edge147bthat meets the edge147anear the axis of rotation of the clamp, and an arcuate edge147c. Three sets of teeth148a,148b,148care located about the arcuate edge147cof each clamp. A thin shield150of similar but slightly larger shape overlies each clamp146a,146b,146c. The shields150are attached magnetically to the clamps and also rotate about their respective axes of rotation with the clamps, but are also free to rotate independently of the clamps if an independent horizontal force is applied thereto. The magnetic interaction between the shields and the clamps can be created by, for example, employing a sheet metal shield and a magnet in each clamp, a plastic shield with a molded-in magnet and a metal clamp, or other variations. A stop151is positioned adjacent each of the clamps146a,146b,146c.

Referring again toFIG. 5, an upper stage152is fixed to the upper surface of the main stage138above the clamps146a,146b,146c. The upper stage152includes a large central aperture154that is bounded by sloping surfaces155that drain into the aperture154.

Operation of the closure station100can be understood with reference toFIGS. 10-21. As shown inFIG. 10, the closure station100can begin in an intermediate position, in which the suction pad128located beneath the suction block127of the elevator110is located just above the upper stage152. In this position, the closure station100is free to receive a closure (i.e., a lid for a vial) from, for example, a closure dispensing station similar to that shown in U.S. Pat. No. 6,971,541 to Williams et al., or one similar to that shown in co-pending and co-assigned U.S. patent application Ser. No. 11/693,929, filed Mar. 30, 2007. In some embodiments, the closure is automatically dispensed and travels down a chute (not shown) to the closure station100. The gap between the suction pad128and the upper stage152is such that a closure can enter the upper stage152, but cannot escape.

The controller42signals the closure station100that a vial is to be filled, which causes a closure C to be dispensed from the closure dispenser. Because receipt of the closure C is facilitated with the clamps146a,146b,146cretracted as far as possible, the controller42signals the drive motor134to rotate the drive motor shaft136(in a clockwise direction from the vantage point ofFIG. 12c). Rotation of the drive motor shaft135rotates the main stage138(also in a clockwise direction from the vantage point ofFIG. 12c) about the axis A2. However, compression in the spring142draws the main stage138against the thrust bearing139b, which in turn forces the thrust bearing139binto the sun gear140and the sun gear140against the clutch washer141. Friction between the sun gear140and the clutch washer141prevents the sun gear140from rotating about the axis A2. As a result, as the main stage138rotates, the engagement of each of the clamp gears144a,144b,144cwith the sun gear140rotates the clamp gears144a,144b,144cin a clockwise direction (from the vantage point ofFIGS. 9cand12a-12c) about, respectively, the axes A3, A4, A5, which in turn rotates the clamps146a,146b,146cclockwise about the same axes. As the clamps146a,146b,146crotate, their arcuate edges147crotate to face generally outwardly from the axis A2. This disposition opens the main stage138to receive a closure C from the closure dispenser. Clamp rotation ceases when each clamp146a,146b,146cstrikes its respective stop151. Continued rotation of the main stage138causes the sun gear140to slip and rotate with respect to the clutch washer141. Regardless of additional rotation of the main stage138, relative rotation of the main stage138, the sun gear140and the clamps146a,146b,146cceases (seeFIGS. 12a-12c).

As shown inFIG. 10, upon arriving at the closure station100, the closure C is received in the aperture154of the upper stage152. The sloping surfaces155assist in decelerating the closure C as it exits the chute and urge the closure C to come to rest in the aperture154.

Once the closure C has been deposited in the aperture154(the presence of the closure C can be determined in different ways, such as detection by a sensor located in a closure delivery chute, the passage of a predetermined period of time, or the like), the controller42reverses the direction of the drive motor134. Thus, the motor134rotates the main stage138counterclockwise (from the vantage point ofFIG. 12c) about the axis A2. Again, the compression in the spring142generates sufficient force on the shaft136that the clutch washer141prevents rotation of the sun gear140. Consequently, rotation of the main stage138rotates the clamp gears144a,144b,144cand the clamps146a,146b,146ccounterclockwise (from the vantage point ofFIGS. 12c,13aand13b) and out from under the upper stage152. Thus, the arcuate edges147cof the clamps146a,146b,146c, which begin facing radially outwardly from the center of the main stage138, rotate to face inwardly toward axis A2(seeFIGS. 13aand13b).

As the clamps146a,146b,146ccontinue to rotate counterclockwise, each of the shields150resting atop each clamp146a,146b,146crotates also. Because the shields150overhang the arcuate edges147cof the clamps146a,146b,146c, the edge of the shield150strikes the closure C first. Contact with the shield150urges the closure C toward the center of the aperture154. The presence of the shields150can prevent the closure C, which may have ridges to facilitate gripping by someone subsequently attempting to unscrew the closure C or other childproofing features, from becoming snagged or caught on one of the sets of teeth148a,148b,148cof the arcuate edge147cas it is being urged to the center of the aperture154.

Once each shield150has contacted the closure C, the shields150are forced by the closure C to rotate clockwise relative to their respective clamps146a,146b,146cuntil the arcuate edges147cof the clamps146a,146b,146ccontact and grip the edges of the closure C (seeFIG. 14a). The rotation of the shields150ceases after each of the clamps146a,146b,146chas contacted the closure C; this can be determined based on a predetermined time period, a torque or position sensor, or the like. Through the action of the slip clutch described above with respect toFIGS. 9a-9cand12a-12c, continued rotation of the main stage138will not produce additional relative rotation of the main stage138, the sun gear140, or the clamps146a,146b,146c. At this point the closure C should be centered in the aperture154(FIGS. 14aand14b).

Once the closure C is centered and rotation of the main stage138ceases, the controller42actuates the drive motor119, which rotates the drive gear118(the rotation is clockwise from the vantage point ofFIGS. 10 and 15). Rotation of the drive gear118as its teeth engage the teeth of the rack120drives the elevator110downward (FIG. 15). The elevator110ceases its downward movement when the suction cup128positioned beneath suction block127contacts the closure C (movement of the elevator110ceases responsive to position sensors, force sensors, or the like). At this point the controller42signals the suction source to apply suction to the suction cup128, thereby attaching the closure C thereto.

After the closure C is attached to the suction cup128(this can be verified with a vacuum contact switch or the like), the controller42activates the drive motor119, which drives the drive gear118in a counterclockwise direction and raises the elevator110, thereby translating the closure C along the axis A2to a raised position (FIG. 16). In addition, the controller42signals the drive motor134to reverse direction (i.e., the shaft136rotates clockwise from the vantage point ofFIGS. 14aand14b), which action rotates the clamps146a,146b,146cslightly clockwise toward their original positions to release the substantially centered closure C (FIG. 16).

When the elevator110has completed its ascension (FIG. 16), having translated the closure C along the axis A2while maintaining it in a centered condition, the closure station100is then free to receive a filled vial V from the dispensing carrier70(FIG. 17). The dispensing carrier70conveys the filled vial V to the aperture154of the upper stage152, deposits it there, and withdraws. The controller42then signals the drive motor134to rotate the main stage138counterclockwise (from the vantage point ofFIG. 12a). As described above, this rotation rotates the clamps146a,146b,146cand the shields150counterclockwise such that they contact and substantially center the lower end of the filled vial V (FIG. 18). As a result, both the closure C and the filled vial V are substantially centered by the same components. This should register the closure C and the filled vial V along the axis A2for subsequent securing of the closure C on the filled vial V.

At the same time, the controller42activates the drive motor119to lower the elevator110and translate the closure C along the axis A2until the closure C is in position just above the top of the filled vial V (FIG. 19). The main stage138continues to rotate, and the elevator110descends until the closure C encloses the perimeter of the upper edge of the filled vial V (movement of the elevator110continues responsive to position sensors, force sensors, or a combination thereof). The elevator110maintains a downwardly-directed force to urge the closure C against the upper edge of the vial V.

Once the closure C is in position for securing, the main stage138continues its counterclockwise rotation (with the closure C remaining stationary due to friction between it and the suction cup128). Because the clamps146a,146b,146care clamped against the vial V, they are prevented from further counterclockwise rotation. Accordingly, the clamp gears144a,144b,144care also prevented from rotating counterclockwise. As a result, the clamp gears144a,144b,144capply a counterclockwise torque to the sun gear140(seeFIGS. 20,20aand20b). This torque overcomes the friction between the sun gear140and the clutch washer141, thereby enabling the sun gear140to rotate counterclockwise with the shaft136and the main stage138(and the vial V clamped thereon) to continue to rotate counterclockwise. This counterclockwise rotation of the vial V relative to the stationary closure C twists the closure C onto the vial V (seeFIG. 20). Rotation can be halted based on a predetermined time period, a position sensor, a torque sensor, or the like.

It is also notable that, in the illustrated embodiment, the positions of the teeth148a,148b,148con the arcuate edge147cof each clamp146a,146b,146care selected such that, as the closure C is centered, the angle between the respective axis A3, A4, A5of each clamp146a,146b,146c, the point of contact of the teeth148a,148b,148cwith the vial V, and the axis A2approaches, but does not exceed, 180 degrees (an angle of between about 140 and 178 degrees is typical—seeFIG. 20b). This angular relationship can provide a high gripping force for the clamps146a,146b,146con the vial V and can generate a high reactive torque in the clamping gears144a,144b,144cto assist the sun gear140in overcoming the friction provided by the clutch washer141. In the illustrated embodiment, the positions of the teeth148a,148b,148care selected to correspond to three popular vial sizes, but other embodiments may employ teeth in different locations, may omit them entirely, may have a different number of sets of teeth, or may have virtually the entire arcuate edge147ccovered with a continuous set of teeth.

Once securing of the closure C is complete, the controller42signals the suction source to deactivate, activates the drive motor119to raise the elevator110, and activates the drive motor134to rotate the main stage clockwise to release the clamps146a,146b,146cfrom the now-capped filled vial V. The controller42then signals the dispensing carrier70(FIG. 21) to retrieve the capped, filled vial V for subsequent operations (such as offloading). The clamps146a,146b,146crotate clockwise until their straight edges147acontact the stops151, which action slides the shields150back to their original positions atop their respective clamps.

Those skilled in this art will recognize that other configurations of the closure station100may also be employed with the present invention. For example, delivery of the closure C to the closure station100may be carried out with any number of techniques, including through the use of chutes, channels, belts or other conveying devices of different configurations, robotic or “pick and place” delivery, or other methods known to those skilled in this art.

As another example, in some embodiments, and as shown inFIG. 10a, the floor112may include wings112a,112bon either side thereof. The wings112a,112bare mounted on upwardly-turned flanges112c,112d. The wings112a,112bare formed of flexible sheets of polymeric material. In this embodiment, when the closure C is released from a chute (not shown), the gap between the suction pad128and the upper stage152is such that the wings112a,112bare positioned in the chutes and are deflected slightly. The wings112a,112bcan act as gates that stop the movement of the closure C in the chute. Subsequent elevation of the elevator110raises the wings112a,112bout of the chutes so that the closure C can continue to the main stage138. Inclusion of the wings112a,112bcan prevent the closure C from “overshooting” the main stage138as it descends in the chute and can also help to control the final position of the closure C on the main stage by controlling the speed of the closure C.

In other embodiments, the centering assembly130may have a different configuration. For example, the sun gear140may be omitted, and a drive motor or similar drive unit may be attached to the central shaft136that depends from the main stage, such that the main stage138is driven directly by the shaft136. The shields150may be omitted in some embodiments, or friction between the shields150and the clamps146a,146b,146cmay be created via a clutch or similar mechanism. Also, in certain embodiments, the upper stage152may be omitted, and the main stage138may have a concave upper surface, such that a closure entering the closure station is centered generally by the contour of the upper surface of the main stage prior to clamping with the clamps146a,146b,146c. Alternatively, the main stage138may be stationary (as would the vial captured thereby) as a component of the elevator rotates a closure held by the elevator. As another alternative, the capped vial may arrive unlabeled for capping and the label may be applied as the vial rotates during or after capping.