Patent Publication Number: US-7216776-B2

Title: Child-resistant pill dispenser

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
   This application is a continuation of International Application No. PCT/US03/029237, filed Sep. 19, 2003, which claims priority to U.S. Provisional Application No. 60/412,512 filed Sep. 20, 2002. The aforementioned applications are herein incorporated by reference. 

   FIELD OF THE INVENTION 
   The present invention relates generally to an apparatus and a method of packaging and dispensing a product, and more specifically, the present invention is directed to a child-resistant pill dispenser for dispensing pills and a method of packaging pills therein. 
   BACKGROUND OF THE INVENTION 
   Various bottles and other pill containers have been developed to include a variety of security features making it difficult for a child to open. For example, pills are commonly packaged in a bottle having a cap that can only be removed by pressing down on the cap while twisting it. However, this type of bottle has a number of disadvantages. First, if a child manages to open the bottle, the child has immediate access to the entire contents of the bottle. Second, if an adult user of the bottle fails to properly close the bottle after opening it, the security feature may be completely defeated. Third, a child-proof cap typically provides only a single line of security. If there is a structural failure of the locking cap, no other mechanism is typically provided to prevent a child from gaining access to the contents of the bottle. 
   According, there remains in the art a need for an apparatus and method for packaging and dispensing a product that provides easy access for the intended user, such as an adult, while providing a high degree of security against the unintended user, such as a child. 
   SUMMARY OF THE INVENTION 
   The present invention overcomes the deficiencies of the known art and the problems that remain unsolved by providing a child-resistant pill dispenser comprising a pill conveyor including a locking mechanism wherein pressure must be exerted to both the pill conveyor and the locking mechanism in order to pivot the pill conveyor open so as to gain access to at least one pill from the pill dispenser. The child-resistant pill dispenser includes security features which mandate the necessary coordination and combination of simultaneous actions by a user to open the pill dispenser. 
   In accordance with one embodiment of the present invention, there is provided a dispenser for dispensing pills comprising a chassis including a reservoir for holding pills, a pill conveyor pivotably mounted within the chassis, where the pill conveyor includes a pocket for receiving at least one pill, a pathway positioned between the reservoir and the pocket where the pathway includes a chute for holding at least one pill, the chute correspondingly aligned with the pocket for guiding said at least one pill into the pocket and a locking mechanism for releasably locking the pill conveyor in a closed position. Advantageously, the locking mechanism may comprise a resiliently deformable strap that is affixed to a rear plate of the pill conveyor where the strap butts up against a ledge on the chassis to hold the pill conveyor in a closed position. 
   Regarding the embodiments described herein, as well as those covered by the claims, the child-resistant pill dispenser may include other locking mechanisms without departing from the scope of the claims. In addition, the child-resistant pill dispenser may or may not include indicia or indicators, such as, an arrow or directives, for indicating to a user where a user should apply pressure to the pill conveyor in order to open the pill conveyor. Advantageously, the child-resistant pill dispenser may further include a pair of ridges for supporting the dispenser in an upright position and a panel for receiving a label containing product information, directions for use, text, graphics, or other printed material. In addition, the child-resistant dispenser may or may not be transparent. 
   In another embodiment of the present invention, there is provided a method for packaging pills in a child-resistant dispenser, the method comprising the steps of pivotably mounting a pill conveyor to a chassis where the pill conveyor includes a pocket for holding at least one pill, configuring a pathway between a reservoir and the pocket, where the pathway includes a chute for holding at least one pill where the chute is correspondingly aligned with the pocket for guiding at least one pill into the pocket, loading a plurality of pills into the reservoir, attaching an end cap to the chassis for securely holding the plurality of pills within the reservoir, attaching a bottom plate to the chassis and releasably locking the pill conveyor in a closed position. Regarding the embodiments described herein, as well as those covered by the claims, the plurality of pills are either manually loaded or automatically loaded into the reservoir of the chassis. The child-resistant pill dispenser may be loaded at the place of manufacture, by the user at home, or at any location by a health care professional. The end cap may be permanently or releasably attached to the chassis defining whether the child-resistant pill dispenser will be either reusable or disposable. 
   In a further embodiment of the present invention, there is provided a method of dispensing a pill from a child-resistant dispenser comprising the steps of sealing a plurality of pills within a reservoir of a chassis, guiding a pill from the reservoir of the chassis into a pocket of a pill conveyor where the pill conveyor is pivotably mounted to the chassis, unlocking the pill conveyor by applying pressure to a resiliently deformable strap affixed to the pill conveyor, where the pressure causes the resiliently deformable strap to flatten against a rear plate of the pill conveyor away from a ledge of the chassis, pivoting the pill conveyor from a closed position in which the pocket is inaccessible from outside the dispenser to an open position in which the pocket is accessible from outside the dispenser, and removing at least one pill from the pocket of the pill conveyor. Advantageously, the step of unlocking the pill conveyor further includes applying pressure to the pill conveyor to cause a second pill protruding within the pocket to move away from the pocket. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIGS. 1–3  are perspective views of an embodiment of the present invention. 
       FIG. 4  is a top transparent view of the embodiment shown in  FIG. 1 . 
       FIG. 5  is a cross-sectional view of an embodiment of the present invention. 
       FIGS. 6–8  are exploded views of embodiments of the present invention. 
       FIGS. 9–10  are cross-sectional views of embodiments of the present invention. 
       FIG. 11  is a flowchart of a method for dispensing pills from the pill dispenser according to an embodiment of the present invention. 
   

   DETAILED DESCRIPTION 
   As required, detailed embodiments of the present invention are disclosed herein. It will be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale, and some features may be exaggerated or minimized to show details of particular components. In other instances, well-known materials or methods have not been described in detail in order to avoid obscuring the present invention. Therefore, specific structural and functional details disclosed herein are not limiting but serve as a basis for the claims and for teaching one skilled in the art to variously employ the present invention. 
   Further, it will be understood that the present invention is taught in terms of a pill dispenser, but the invention is applicable to the packaging, storing, and dispensing of various items or products. Accordingly, the term “pill” as used herein includes all manner of small and portable items or products that a user may wish to keep secure and dispense in a regulated manner. 
   Referring now to the drawings, wherein like elements are represented by like numerals,  FIGS. 1–3  show perspective views of a child-resistant pill dispenser  10  according to a first embodiment of the present invention. The pill dispenser  10  includes a chassis  12 . Although the chassis  12  is shown as a substantially rectangular profile, it will be noted that the shape and size of the chassis  12  is merely a design choice. The pill dispenser  10  further includes a pill conveyor  14 , generally referred to as a “coin”, which is mounted within chassis  12 . The pill conveyor  14  includes a pill conveyor pocket  18  dimensioned to receive at least one pill  16 . 
   The pill conveyor  14  is pivotable between a first, closed position and a second, open position. As illustrated in  FIGS. 2 and 3 , the pill conveyor  14  is pivoted to an open position in order to release at least one pill  16  from the pill dispenser  10 . The pill conveyor pocket  18  is accessible from the outside of the dispenser  10  only when the pill conveyor  14  is in an open position. When the pill conveyor  14  is in a closed position, the pill conveyor pocket  18  is enclosed within the dispenser  10 , thus, making the pill conveyor pocket  18  inaccessible from the outside of the dispenser  10 . 
   The pill conveyor  14  further includes a locking mechanism which releasably locks the pill conveyor  14  in a closed position. According to one embodiment of the present invention, the locking mechanism includes a resiliently deformable latching strap  20  that is affixed to a rear plate  62  of the pill conveyor  14 , best illustrated in  FIG. 7  below. When the pill conveyor  14  is closed in a resting position, the latching strap  20  bows outward and overhangs ledge  22  of chassis  12  so as to prevent the pill conveyor  14  from pivoting in an open position. 
   In the illustrated embodiments the pill conveyor  14  is unlocked by applying sufficient pressure to the latching strap  20  to cause the latching strap  20  to flatten against the rear wall of pill conveyor  14 . Once flattened, the latching strap  20  clears ledge  22 , allowing pill conveyor  14  to pivot in an open position. In one embodiment of the present invention, the latching strap  20  is recessed in a hollowed-out portion  28  of chassis  12 . The hollowed-out portion  28  receives latching strap  20  and protects the latching strap  20  from damage, or from being accidentally unlocked. 
   The deformable latching strap  20  is a means for locking as are all selectively moveable structural configurations that prohibit the movement of the pill conveyor  14 , such as but not limited to pins, latches, spring loaded stops, catches, nubs, interfacing protrusions and depressions, and the like as well as parts thereof. Further means for locking may be provided through additional or alternative security features, such as, adding structural elements to the dispenser  10  requiring additional steps be taken before being able to unlock the pill conveyor  14  and gaining access to at least one pill  16 . One example of such means for locking includes modifying the dispenser  10  so that the pill conveyor  14  must be first rotated in a particular orientation before the pill conveyor  14  can be pivoted upward from chassis  12  of pill dispenser  10 . 
   The dispenser  10  may further include indicators or indicia, such as, an arrow  24  which may be formed within or on pill conveyor  14  for indicating to a user what location and/or direction a user should apply pressure on the pill conveyor  14  so as to open the pill conveyor  14 . One non-limiting example of indicia  26  may include the word “PUSH”, which may be formed on or attached to pill conveyor  14 . 
   Dispenser  10  may further include a pair of ridges  30  and  32  that are shaped to allow the dispenser  10  to stand on end. This feature could be used, for example, in a counter display or to store the dispenser in an upright position in a medicine cabinet. It will be noted that ridges  30 ,  32  may be manufactured in any suitable size and shape, the configuration being merely a design choice. 
   As illustrated in  FIGS. 1–3 , the dispenser  10  may further include a panel  34  that can be used to receive a stick-on label containing product information, directions for use, text, graphics, or other printed material. The panel  34  may be opaque or transparent thereby allowing a user to view the contents of the dispenser  10 . It will be understood that other portions of the dispenser  10  may also be made transparent, or the entire dispenser  10  may be made transparent, if desired. 
   Referring to  FIGS. 4 and 5 , there is shown a top transparent view and a cross-sectional view of dispenser  10 , respectively.  FIGS. 4 and 5  illustrate how pills  16  are loaded into the pill conveyor pocket  18  of pill conveyor  14 . As shown, chassis  12  includes a pill reservoir  40  for holding pills  16 . The pill conveyor  14  is pivotably mounted into a compartment  42  of chassis  12 . The dispenser  10  includes a number of interior surfaces  44  that together define a pathway between the pill reservoir  40  and the pill conveyor pocket  18 . The pathway comprises a generally funnel-like shape, ending in a straight chute  46  leading to the pill conveyor pocket  18 . The chute  46  is dimensioned to receive and hold at least one pill  16   b.    
   With regard to operation of the illustrated embodiment, when the pill conveyor  14  is in a closed position a first pill  16   a  is loaded into the pill conveyor pocket  18  and a second pill  16   b  is subsequently guided into chute  46  via the pathway. As will be described below in reference to  FIGS. 9–10 , the second pill  16   b  in chute  46  cooperates with the first pill  16   a  in the pill conveyor pocket  18  to provide additional security. Individual pills  16  contained within the dispenser  10  are extracted, one at a time, from dispenser  10 , by tilting the dispenser  10 , when the pill conveyor  14  is in a closed position, causing a pill  16   a  to be loaded into pill conveyor pocket  18  of the pill conveyor  14 . A gentle shaking of dispenser  10  may help to load pill  16   a  into the pill conveyor pocket  18 . It will be seen that the same actions used to load a first pill  16   a  into the pill conveyor pocket  18  will also cause a second pill  16   b  to be guided into chute  46  and butt-up against pill  16   a.    
   A user may unlock the pill conveyor  14  in order to gain access to a pill  16   a  by applying pressure to both the latching strap  20 , to cause the latching strap  20  to flatten against the rear plate  62  of the pill conveyor  14 , and to the pill conveyor  14  generally in the location of the arrow  24 , thereby permitting the latching strap  20  to clear ledge  22  and rest in the hollowed-out portion  28  of dispenser  10 . The pill conveyor  14  is subsequently pivoted in an open position, causing the pill conveyor pocket  18  to be exposed to the exterior of the dispenser  10  and allowing the user to remove pill  16   a  from the pill conveyor pocket  18 . If a user wishes to extract another pill  16  from the dispenser  10 , the user must pivot the pill conveyor  14  back in a closed position, reload the pill conveyor pocket  18  with a pill  16   a , and again unlock the pill conveyor  14  by applying pressure to both the latching strap  20  and the pill conveyor  14 . 
     FIGS. 6–8  are a series of exploded views of dispenser  10 , showing the various components used to construct the illustrated embodiment. According to one aspect of the present invention, dispenser  10  includes a chassis  12 , a pill conveyor  14 , an end cap  50 , and a bottom plate  52 . The chassis  12 , pill conveyor  14 , and end cap  50  may be, but are not necessarily, fabricated using an injection molding technique and the bottom plate  52  may be trimmed from a larger sheet of plastic. If desired, some or all of the components of the dispenser  10  can be designed so that they snap and lock securely to each other without the need for additional fastening. Alternatively, a suitable adhesive or welding technique may be used to attach the components to each other. As understood by those skilled in the art, the pill dispenser  10  may be a single-use disposable unit or may be designed for multiple uses. 
   As shown in  FIG. 6 , chassis  12  is formed such that the pill reservoir  40  is open at the rear of the dispenser  10  allowing pills  16  to be quickly loaded into the pill reservoir  40 . The loading operation may be performed by hand, or by machine. Once a desired number of pills  16  have been loaded into reservoir  40 , the end cap  50  is subsequently attached to the chassis  12  in order to seal the pills  16  inside the reservoir  40 . As mentioned above, the end cap  50  and the chassis  12  may be designed so that the end cap  50  releaseably snaps into position. Alternatively, the end cap  50  may be permanently attached by a suitable adhesive or welding technique. 
   According to an alternative embodiment of the present invention, the pill dispenser  10  is provided to a pharmacy with the end cap  50  not yet attached to the chassis  12 . A pharmacist may load the pills  16  within the dispenser  10  at the pharmacy, and then snap the end cap  50  to chassis  12  and into place sealing the pills  16  inside the dispenser  10 . Prescription information may be printed onto a stick-on label that is affixed to the square panel  34 , or some other suitable location on or within the dispenser  10 . 
   The pill conveyor  14  further includes a cover plate  54 . In the illustrated embodiments the cover plate  54  is disc-shaped; however, other shapes may be used without departing from the scope of the claims. Further, a gripping surface, here shown as a dome  56 , is formed on the cover plate  54 . The dome  56  provides a gripping surface that may be used to hold the pill conveyor  14  in an open position. The dome  56  generally provides some indication of where to apply the necessary pressure on the pill conveyor  14  for pivoting the pill conveyor  14  to an open position. As with other exterior characteristics of the present invention, the gripping surface is not limited to a particular design choice. 
   Extending downward from cover plate  54  is a face plate  58 . The pill pocket  18  is formed within face plate  58 . The face plate  58  is dimensioned such that its bottom edge  60  rests on the bottom of the conveyor compartment  42  when the pill conveyor  14  is in a closed position. This arrangement prevents the pill conveyor  14  from being pivoted in the wrong direction. In addition the face plate  58  serves to block chute  46 , connecting the pill reservoir  40  and the pill conveyor pocket  18 , when the pill conveyor  14  is in an open position. 
   As illustrated in  FIG. 7 , the pill conveyor  14  further includes a rear plate  62  extending downward from the cover plate  54 . As described earlier, here the latching strap  20  is affixed to the rear plate  62 . The pill conveyor  14  further includes a pair of ears  64  on which are formed nubs  66  that lock into receiving apertures  68  disposed within the conveyor compartment  42 . As shown, the pair of ears  64  are positioned between the face plate  58  and the rear wall  62  and the nubs  66  serve as pivot points for the pill conveyor  14 . The latching strap  20  may be located at various positions proximate to or integral to the conveyor  14 . Further, part or all of the pill conveyor  14  itself may be made resiliently deformable, while being sufficiently rigid to prevent failure of the security function, thereby functioning of and by itself as a means for locking. 
   As shown in  FIGS. 7 and 8 , the bottom side of the chassis  12  is irregularly shaped. Accordingly, a bottom plate  52  may be attached to cover the bottom side of the chassis  12 . In addition to giving the bottom side of the assembled dispenser  10  a finished appearance, the bottom plate  52  may serve to prevent a child from gaining access to the underside of the pill conveyor  14  and possibly interfering with the security function. 
   Referring to  FIGS. 9 and 10  there are shown cross-sectional views of dispenser  10 , illustrating the operation of one embodiment of the present invention. As shown, pills  16  are guided within a pathway and travel along chute  46  to pill conveyor pocket  18 . The pill conveyor pocket  18  is shaped and sized to hold a single pill  16   a . If desired, the pill conveyor pocket  18  may be modified to hold two or more pills  16  without departing from the scope of the claims. 
   According to an embodiment of the present invention, the pill conveyor pocket  18  is dimensioned to be slightly deeper than the diameter of a pill  16 . Thus, after a first pill  16   a  has been loaded into the pill conveyor pocket  18 , a second pill  16   b , which has entered chute  46 , will protrude slightly into the pill conveyor pocket  18 . The portion of the second pill  16   b  protruding into the pill conveyor pocket  18  makes it difficult to pivot the pill conveyor  14 , even when the latching strap  20  has been pushed clear of ledge  22  of dispenser  10 . To overcome this difficulty, pressure must also be applied to the pill conveyor  14 . Applying pressure to the pill conveyor  14 , causes the front face  58  of the pill conveyor  14  to deform slightly, thereby securing pill  16   a  within the pill conveyor pocket  18  and pushing pill  16   b  back in chute  46  and out of the way, thus, allowing the pill conveyor  14  to be pivoted in an open position. Even if the security feature of the latching strap  20  fails, it can be seen that it is difficult for a child to extract a pill  16  from the dispenser  10 , because the child must also exert pressure on the pill conveyor  14  in order to push pill  16   b  back in the chute  46  and out of the way to allow the pill conveyor  14  to open. 
   Referring now to  FIG. 11 , there is shown a flowchart  100  illustrating one method of dispensing pills  16  from the child-resistant dispenser  10  according to an embodiment of the present invention. In step  102 , pills  16  are loaded and sealed within the pill compartment  40  of the dispenser  10 . Step  102  may be performed at a manufacturing facility, at home by the user, or at any location by a health care professional. Further, sealing comprising both permanent and temporary closing of the pill compartment. In step  104 , a pill  16   a  is guided to enter chute  46  and is loaded within the pill conveyor pocket  18  while the pill conveyor  14  is in a closed position. In step  106 , the pill conveyor  14  is unlocked. The pill conveyor  14  is locked using a means for locking, which in the illustrated embodiments comprises a deformable latching strap  20  that engages a ledge  22 . As described earlier, the pill conveyor  14  is unlocked by applying pressure against the latching strap  20 , however, because an additional locking feature is provided by a second pill  16   b  protruding into pill conveyor pocket  18 , additional pressure must also be applied to the pill conveyor  14  in order to push the second pill  16   b  back in chute  46  and out of the way. After completing step  106 , the pill conveyor  14 , as illustrated in step  108 , is pivoted upward from a closed position to an open position. In step  110 , the pill  16   a  is removed from the pill conveyor pocket  18  of the dispenser  10 . In step  112 , the pill conveyor  14  is pivoted to a closed position, which subsequently causes the pill conveyor  14  to re-lock due to the resilient latching strap  20  protruding outwards and overhanging ledge  22  of the dispenser  10 . Steps  104 – 112  are repeated, as necessary, to extract additional pills  16 . 
   It will be seen that the pill dispenser  10  has a number of aspects that make it difficult for a child to gain access to the packaged pills  16 . First, the child must maneuver a pill  16  into a pill conveyor pocket  18 , which requires a certain amount of coordination. Then, the child must maintain the position of the pill  16   a  in the pill conveyor pocket  18  while attempting to unlock the pill conveyor  14 . Unlocking the pill conveyor  14  requires manipulating the means for locking, maintaining that position while also applying pressure on the pill conveyor  14 , and then pivoting the pill conveyor  14  to an open position all while taking care to make sure that the pill  16   a  continues to be held in the pill conveyor pocket  18 . If a child somehow manages to release a pill  16 , the child must re-lock the pill conveyor  14  and repeat steps  104 – 112 , as illustrated in  FIG. 11  in order to release a second pill  16 . Thus, accidental access to pills  16  in the dispenser  10  is limited to one pill at a time, and not the entire contents of the dispenser  10 . Even if a child somehow can repeat the skills required to remove a pill  16  from the dispenser  16 , the time and effort required for a child to remove multiple pills  16  from the dispenser  10  may increase the probability that an adult will notice what the child is doing and timely intervene. Also, a child may become bored or frustrated and give up before removing too many pills  16  from the dispenser  10 . 
   If the means for locking fails to operate, the dispenser  10  includes a fallback protection feature which is provided by the use of a deformable pill conveyor  14 . As described above, in addition to applying pressure to the latching strap  20  so as to release the pill conveyor  14  from ledge  22 , additional pressure must also be applied to the pill conveyor  14  in order to cause the front face of the pill conveyor  14  to deform and push a second pill  16   b  in the chute  46  away from the pill conveyor pocket  18 . Also, if an adult accidentally leaves the dispenser  10  open, or fails to close the dispenser  10  properly, a child will have to complete the necessary steps  102 – 112 , as illustrated above, thus, making it very difficult for a child to gain access to a pill  16 . 
   It must be emphasized that the law does not require and it is economically prohibitive to illustrate and teach every possible embodiment of the present claims. Hence, the above-described embodiments are merely exemplary illustrations of implementations set forth for a clear understanding of the principles of the invention. Many variations and modifications may be made to the above-described embodiments without departing from the scope of the claims. All such modifications, combinations, and variations are included herein by the scope of this disclosure and the following claims.