ELECTRICAL CONNECTOR INTERFACED WITH CONDUCTIVE INK ON A

CARDBOARD SUBSTRATE

[0001] The present invention is directed to a dispensing apparatus, and specifically to a dispensing apparatus that tracks the dispensed product, the dispensing apparatus having a disposable dispensing portion and a reusable portion

[0002] Certain products have sufficient value that their distribution must be carefully controlled, monitored and recorded. To prevent unauthorized distribution of such products, they are kept under lock and key with limited access until time for distribution, use or sale. There are many products that fall within this description. As an example, one category of products that falls within this description is pharmaceuticals.

[0003] Certain pharmaceuticals are maintained in blister packs in a locked area until ready for distribution. When ready for distribution, the blister packs containing the products are removed from locked area. The individual product is removed from the blister pack by the professional responsible for its distribution, and the product is distributed by the professional to the patient. The professional responsible for distribution of the product must maintain meticulous records regarding access and distribution of the product. Nevertheless, despite the procedures for accountability, the current system is subject to mistake, fraud or theft. The problem to be solved is a need for an improved system for tracking access and distribution of valuable products to minimize losses due to mistake, fraud or theft.

[0004] The solution is provided by an inventory control system for tracking distribution of valuable or important articles that are sufficiently small that they can be assembled into a blister pack and then dispensed in units from the blister pack. The invention includes the blister pack, a connector assembly mounted to the blister pack and to a header, the header releasably connected

to the connector assembly, the header further in communication with a microprocessor-controlled device having a memory.

[0005] The invention will now be described by way of example with reference to the accompanying drawings in which:

[0006] Figure 1 depicts a schematic of the inventory control system of the present invention.

[0007] Figure 2 depicts a blister pack with a connector assembly mounted thereon.

[0008] Figure 3 depicts a second side of blister pack covered with a pierceable sheet having circuits printed on the sheet.

[0009] Figure 4 depicts a connector assembly mounted on a blister board.

[0010] Figure 5 is an unassembled view of a header and connector assembly mounted on a blister board.

[0011] Figure 6 depicts a preferred embodiment of the connector of the present invention.

[0012] Figure 7 depicts a preferred embodiment of the connector of the present invention with one of the covers removed.

[0013] Figure 8 depicts a blister pack assembly assembled over a circuit board in a cover of the present invention.

[0014] Figure 9 depicts a preferred embodiment of the connector assembly disassembled from the blister pack.

[0015] Figure 10 is an exploded view of the connector assembly of the present invention.

[0016] Figure 11 depicts the assembly of the blister pack and header to the connector assembly, with the covers of the connector assembly shown in phantom.

[0017] The connector assembly and header test the continuity of each circuit printed on the blister pack of the present invention and transmit information about the status of each circuit to the microprocessor device. Because the connector assembly and header are releasably connected, the connector assembly and blister pack can be separated from the header to facilitate use or movement of the blister pack. Articles can be removed from the blister pack for distribution or use as is well-known. The articles are removed by piercing the backing material on the blister pack, which not only liberates the article within the blister pack, but also breaks a circuit for each unit article removed. The breaking of this circuit is only of significance to the connector assembly of the present invention. When the connector assembly is reconnected to the header, a continuity check can be run through the circuits. The continuity check entails attempting to pass a current through each of the circuits to determine which circuits remain intact and which circuits have been broken. In this manner the number of articles removed from the blister pack from the time that it was removed from the header can be determined and the number or articles still in inventory can also be determined.

[0018] The present invention can be used for automated inventory control of valuable, small articles that are conducive to packaging in blister packs by determining through continuity checks, the number of circuits broken, and thus, the number of articles removed.

[0019] The present invention advantageously can be used to eliminate errors, theft and fraud in distribution or administration of small valuable articles in blister packs that are otherwise difficult to inventory because of their

large numbers and small sizes, yet is reusable with new blister packs once the disposable blister packs are spent.

[0020] The present invention is broadly directed to an inventory control system for articles capable of being packaged in blister packs. Broadly, the inventory control system is shown schematically in Figure 1. The system 2 comprises a blister pack 4, a removable connector assembly 6 attached to blister pack, 4, a header 8 releasably attached to connector assembly 6, and a microprocessor-controlled device having a memory 10 in communication with header 8. An ubiquitous microprocessor-controlled device having a memory usable with the present invention is a computer.

[0021] Figure 2 depicts blister pack 4 having a first side 20 and an opposed second side 22. In accordance with current blister pack technology, compartments 24 of predetermined size extend away from the first side 20. The compartments are sized to hold an article or unit of material. The compartments can be formed integral with a backing material or can be assembled onto a firm or stiff backing material, such as cardboard. Preferably, the article or unit of material held in the blister pack can be seen through the compartments 24, so that the compartments ideally comprise a transparent or translucent plastic.

[0022] Figure 3 depicts the second side 22 of blister pack 4. The second side 22 is covered with a pierceable sheet 26. However, this pierceable sheet 26 differs from pierceable sheets commonly found on blister packs in that the pierceable sheet 26 of the present invention includes a plurality of circuits 28 printed on it, a circuit being located over each of the compartments 24. The circuits can be printed using a conductive ink. Each of the circuits 28 extends in an electrically continuous manner toward an edge of the blister pack, preferably a corner 30. As shown in Figure 1 , the portion of the blister pack, here a corner 30, receives a connector 6 such as shown in Figure 1. As will be developed below, the connector 6 attached to the blister pack 4, connects

to the plurality of circuits 28. Referring again to Figure 3, the plurality of circuits 28 preferably terminate in a landing 32, which facilitates connection to a connector. Like the circuits, the landing also may be printed on the pierceable sheet with a conductive ink.

[0023] The blister pack 4 functions similarly to prior art blister packs in dispensing an article or a unit of material. A quick view of either side of the blister pack will disclose which compartments contain an article or a unit of material. Individual compartments are breached by piercing the pierceable sheet and removing the article or unit of material from the blister pack. This is most conveniently done for an article by applying pressure on a selected compartment from the first side in the direction of the second side of the blister pack 4, causing the article to pierce the pierceable sheet. Alternatively, an instrument can be used to pierce the pierceable sheet. Blister pack 4 differs from prior art blister packs in that piercing the pierceable sheet to remove an article also break the circuit printed on the pierceable sheet and overlying the selected compartment.

[0024] The pierceable sheet can be any material that can be overlaid onto the blister pack and onto which a circuit can be printed. The current material of choice for pierceable sheet for a blister pack is metal foil. This requires application of a thin layer of a dielectric material between the plurality of circuits and the metal foil in order for the circuit to function properly. However, the material for the pierceable sheet is not limited to foil, as a non-conductive material onto which a circuit can be applied or printed directly may be used.

[0025] Figure 4 depicts a connector assembly 6 mounted on a blister pack 4. The connector assembly 6 is mounted over the landing 32, which therefore is not visible, on the corner 30 of blister pack. In this embodiment, the backing material for the blister pack 4 is a tablet with laminate filler to further stiffen the tablet. Although the internal layout of the connector assembly 6 is not visible in this view, the housing 34 of the connector assembly slides over

the corner 30 to establish contact with landing 32. Leads 36 in communication with landing 32 extend from connector assembly for connection (directly or indirectly) with the microprocessor device having memory 10, see Figure 1). The housing 34 is a dielectric material, such as a plastic, while the leads 36 are conductive,

[0026] Figure 5 depicts a header 8 and connector assembly 6, the header 8 separated from connector assembly 6 so that the header internals are visible. The header includes a housing 38. Header 8 includes a pocket 40 that mates with connector assembly 6 by sliding over connector assembly housing 34. Header 8 also includes a plurality of contacts, preferably pins 42, projecting into the pocket 40, the pocket protecting the pins from damage. When assembled the plurality of pins mate with the leads 36, the pins 42 preferably corresponding on a one to one basis with the leads 36. In this embodiment, the header 8 includes a second set of connections (not shown in Figure 5) for communication with a microprocessor device having a memory. The second set of connections is in communication with pins 42. Preferably, the second set of connections is positioned on the side of the header housing 44 opposite the pocket 40 that protects the plurality of pins. The header 8 is readily assembled and disassembled from the connector assembly by any well known means. For example, a push button/detent arrangement may be used. As a further example, not meant to be limiting, a lever attachment/detachment arrangement may be used. In fact, a friction fit of the header 8 over the connector assembly 6 or the connector assembly over the header may be used.

[0027] The header 8 is connected to microprocessor device having a memory 10, but which can be remote from the microprocessor device. The header can be permanently positioned in a secure location. Because the connector assembly 6 can be removed readily from the header 8 as previously discussed, the blister pack 4 to which the connector assembly 6 is attached can be retained in a secure location until ready for use. There are

many ways to make the blister pack ready for use. However, when ready for use, the connector assembly 6 is removed from the header 8 to allow transport of the blister pack if desired, and an article or unit of material is removed from the blister pack. On removal of the connector assembly 6 from the header 8, the circuit between the header 8 and connector assembly 6 is broken. When blister pack usage is complete, connector assembly 6 is reconnected to header 8. On reconnection, the circuit is restored. A signal sent out through the header 8, and the connector assembly 6 to the blister pack 4 can test the continuity of the circuits on the blister pack. The signal passes through the circuits and determines the number of circuits that have been broken, or alternatively, the number of circuits still intact. The microprocessor device having memory 10 compares the number of circuits remaining after return with the number of circuits that were intact before removal and determines how many articles or unit doses of material were removed while the blister pack was removed from the header 8 This information can then be stored in the microprocessor memory. In this way, the inventory of the articles or unit doses of material in a blister pack can be continuously tracked. By providing additional appropriate software requiring identification for access, the system can identify who had access to one or more blister packs, when and for how long. Furthermore, the system can restrict access to blister packs if appropriate identification is not provided. In this manner, responsibility for removal of the contents can also be assigned. Furthermore, if the article or unit dose of material is to be distributed to a third person such as for example a patient, the software can allow, or require the accessing person to identify the ultimate recipient of the article or unit dose of material. Clearly, the system permits various levels of complexity, all of which is enabled by the header/connector assembly/blister pack combination.

[0028] Figures 6 and 7 depict a preferred embodiment of the connector assembly 6 of the present invention. Figure 6 depicts the top cover 60 and bottom cover 62 forming the housing 34 of the connector assembly 6

assembled together. When assembled, a first gap or aperture 64 is located between the top and bottom covers. This first gap or aperture 64 receives a portion of the blister pack, preferably the blister pack corner 30. A second gap or aperture 66 is provided that optionally accepts a positive assembly/removal feature in the form of a button or a lever to facilitate assembly and removal of the header 8 from the connector assembly 6. In Figure 7, the top cover 60 is removed, disclosing a circuit board 68 residing in a cavity 70 in the bottom cover. The circuit board 68 includes a first set of contacts 72 that reside within the cavity 70 and are enclosed within the housing 34 of the connector assembly when top cover 60 and bottom cover 62 are assembled together. Leads 74 extend to the exterior of the housing 34, or are readily accessible from the exterior of the housing, when the covers 60 and 62 are assembled together. Leads 74 and first set of contacts 72 are electrically connected to one another, each of the leads 74 electrically connected to a contact of the first set of contacts 72. The circuit board 68, as shown in Figure 9, or the bottom cover 62 as shown in Figure 7, further includes locating features, posts 76 in the preferred embodiment, that extend upward that are also visible in the assembled connector assembly, Figure 6. As the locating features are used for location of the components during assembly, the specific component on which they are fabricated is not critical, as long as the top cover, bottom cover and blister board can be correctly located in relationship to one another. In a preferred embodiment, apertures 78 on bottom cover are also visible. A second cavity 80 in the bottom cover 62 lies adjacent leads.

[0029] Figure 8 depicts a partial assembled connector assembly in the sequence of assembly operations. A blister pack 4 is assembled onto a bottom cover 62 and partially over circuit board 68 of connector assembly 6. The blister pack corner 30 is depicted having a plurality of apertures 82. The first side of blister pack 20 from which a plurality of compartments 24 extend is opposite the circuit board 68, while second side of blister pack 22 is placed

down onto circuit board 68. Locating features, preferably apertures 82 on the blister pack corner 30, are dimensioned so that they mate with the locating features, preferably posts 76 on connector assembly bottom cover 62. The posts and apertures align the blister pack 4 with the circuit board 68 so that the pads on landing 32 on second side of blister pack 22 (not visible in Figure 8) are brought into alignment with first set of contacts 72 within connector assembly 6. The blister pack corner 30 is captured in first gap 64 when top cover 60 is assembled over posts 76, thereby attaching it to bottom cover 62. The top cover and bottom cover can be attached by any convenient means. Top cover 60 can include apertures permitting it to be snap fit over the bottom cover 62 using posts 76 and the apertures. Alternatively other snap means can be molded into the top and bottom covers. If desired, a separate fastener can be assembled through mating apertures in the top and bottom covers to hold the top and bottom covers together. In this embodiment, the leads 74 are external to the connector assembly 6 so that a header 8 can be assembled to it.

[0030] In another embodiment, the top cover and bottom cover can be molded as a single plastic piece with a plastic hinge intermediate the top cover and the bottom cover. The top cover can be folded along a bend line to bring the top cover proximate to the bottom cover to form a "living hinge." The circuit board and blister pack can be located on features preformed onto the single plastic piece and then fastened together as described above. However, to further simplify the assembly of the top and bottom cover, a retaining device can be molded into the single plastic piece to secure the top cover to the bottom cover when brought into mating engagement. Any interference fit would supply the engagement, such as a snap fitting.

[0031] Figure 10 is an exploded view of the connector assembly 6 of the present invention with the top cover 60 being assembled to the bottom cover 62. The blister board has been removed for clarity. Only Figure 10A depicts separate fasteners 84, here snap fittings, used to fasten the connector

assembly together while capturing the blister board therebetween. The use of fasteners is a significant aspect, since this permits the connector assembly 6 to be removed from an exhausted blister pack and reassembled to a new blister pack by simply removing and replacing fasteners 84. Leads 74 are positioned on the outside of the connector assembly 6.

[0032] Figure 11 depicts a blister pack 4 assembled to the connector assembly 6, and a header 8 assembled to the connector assembly 6 in accordance with the present invention. The top cover and bottom cover of the connector assembly 6 are shown in phantom so that interaction of the circuit board 68 with both the landing 32 on the blister pack and the header 8 can be viewed clearly. The pins 42 of header 8 contact the leads (not shown in Figure 11), and header housing is removably attached to connector assembly while pins 42 are urged into contact with leads 74. The header housing can be assembled to the connector assembly, preferably by a friction fit, and pulled from it. Preferably, a latch is positioned in cavity 80. When the blister pack 4 is required to be removed from the header, pressure is applied to the latch, which in turn transfers the force to the header housing 38 and urges the header 8 out of engagement with the connector assembly 6, so that the blister pack 4 can be removed and the header 8, which remains in place.

[0033] It will be understood in the art that the present invention discloses wired communications between the header 8 and the microprocessing unit with memory 10, the invention is not so limited. The header 8 and microprocessing unit with memory 10 can be provided with radio communications and the header, being provided with an appropriate power source, can be in two way RF communications using a transmitter /receiver (transceiver) with the microprocessor-controlled device having a memory 10. Alternatively, the header 8 can be provided with a microprocessor, a power source and a transmitter. On reconnection of the header 8 with the connector assembly 6, an electrical signal can be sent through the connector assembly

6 and blister pack circuits by the header 8, which determines the number of open (or closed) circuits.

[0034] The header transmits information indicative of the presence or absence of electrical signals, that is, the number of circuits 28 present and/or broken, which is an indication of the number of compartments 24 from which contents have been removed.