System, Method, and Apparatus for Forming and Filling Pill Compartments

Abstract

A method and apparatus for forming and filling blister packs is disclosed. The method includes receiving a substantially sheet of material and forming a plurality of compartments in the sheet of material. Next, at least one of the compartments is filled with at least two pills. The at least two pills include a first type of pill and a different second type of pills. The method continues with sealing the compartments and optionally dividing the sheet of material into blister packs.

What is claimed is: 
     
         1 . A method of forming and filling blister packs, the method comprising:
 receiving a substantially sheet of material;   forming a plurality of compartments in the sheet of material;   filling at least one of the compartments with at least two pills, the at least two pills comprising a first type of pill and a second type of pills; and   sealing the blister pack.   
     
     
         2 . The method of  claim 1 , wherein the step of forming includes positioning a section of the sheet of material over a first side of a mold, the mold having openings, and vacuuming from a distal second side of the mold, thereby drawing portions of the sheet of material into the openings and forming the compartments in the sheet of material. 
     
     
         3 . The method of  claim 2 , wherein the step of forming further includes the step of heating the sheet of material before the step of vacuuming. 
     
     
         4 . The method of  claim 1 , wherein the step of forming includes positioning a section of the sheet of material over a first side of a mold, the mold having openings, and pressing a stamp onto the mold, the stamp having protrusions that align with the openings, thereby forming the compartments in the sheet of material. 
     
     
         5 . The method of  claim 4 , wherein the step of forming further includes the step of heating the sheet of material before the step pressing. 
     
     
         6 . The method of  claim 1 , wherein the step of filling comprises moving each of a plurality of canisters in an X direction and/or Y direction to position the each canister over one of the compartments and dropping at least one pill from the canister into the one of the compartments. 
     
     
         7 . The method of  claim 1 , wherein the step of filling comprises moving the compartments in an X direction and/or Y direction to position one of the compartments beneath one of the canisters and dropping at least one pill from the one of the canisters into the one of the compartments. 
     
     
         8 . The method of  claim 1 , further comprising a step of sealing the compartments after the step of filling. 
     
     
         9 . The method of  claim 1 , further comprising a step of cutting the sheet of material after the step of filling. 
     
     
         10 . A form and fill machine comprising:
 means for forming a plurality of compartments in a sheet of material;   means for filling at least one of the compartments with a plurality of pills, the plurality of pills including at least two types of pills;   means for sealing the compartments;   means for dividing the sheet of materials into individual blister packs.   
     
     
         11 . The form and fill machine of  claim 10 , wherein the means for forming comprises a mold, the mold having openings, whereas the sheet of material is positioned over the mold and a vacuum is drawn from under the mold, thereby forming the compartments within the openings. 
     
     
         12 . The form and fill machine of  claim 11 , wherein the means for forming further comprises a heater, whereas the heater heats the sheet of material before the vacuum is drawn from under the mold. 
     
     
         13 . The form and fill machine of  claim 10 , wherein the means for forming comprises a mold, the mold having openings, whereas the sheet of material is positioned over the mold and a stamp having protrusions that align with the openings is forced onto the mold, thereby forming the compartments within the openings. 
     
     
         14 . The form and fill machine of  claim 13 , wherein the means for forming further comprises a heater, whereas the heater heats the sheet of material before the stamp is forced down onto the mold. 
     
     
         15 . The form and fill machine of  claim 10 , wherein the means for filling comprises a plurality of canisters and at least a first canister of the canisters contains a first pill type and at least a second canister of the canisters contains a second pill type, wherein the first pill type is different from the second pill type. 
     
     
         16 . The form and fill machine of  claim 10 , wherein the means for sealing comprises affixing a label over the compartments. 
     
     
         17 . The form and fill machine of  claim 10 , wherein the means for dividing comprises a cutting device. 
     
     
         18 . A form and fill machine comprising:
 a mold for forming a plurality of compartments in a sheet of material, the mold having openings, whereas the sheet of material is positioned over the mold and a vacuum is drawn from under the mold, thereby forming the compartments in the sheet of material at the openings;   a plurality of canisters, at least a first canister of the canisters contains a first pill type and at least a second canister of the canisters contains a second pill type, wherein the first pill type is different from the second pill type;   a drive mechanism, the drive mechanism selectively positions the first canister of the plurality of canisters over a selected compartment of the compartments and drops a selected quantity of the first type of pill into the selected compartment, and the drive mechanism selectively positions the second canister of the plurality of canisters over the selected compartment and drops a selected quantity of the second type of pill into the selected compartment;   a sealing mechanism, the sealing mechanism seals the compartments after the compartments are filled;   a cutting mechanism, the cutting mechanism divides the sheet of material with compartments into blister packs.   
     
     
         19 . The form and fill machine of  claim 18 , wherein the mold further comprises a heating element to heat the sheet of material before the vacuum is drawn. 
     
     
         20 . The form and fill machine of  claim 18 , wherein the drive mechanism moves a selected canister of the canisters in an X direction and/or in a Y direction.