(12)
`
`United States Patent
`Felder et al.
`
`(10) Patent N0.:
`(45) Date of Patent:
`
`US 6,581,395 B2
`Jun. 24, 2003
`
`US006581395B2
`
`(54) AUTOMATED STORAGE AND RETRIEVAL
`APPARATUS FOR FREEZERS AND
`RELATED METHOD THEREOF
`
`(75) Inventors: Robin A. Felder, Charlottesville, VA
`(US)_ B Sean Graves charlottesv?le
`VA iJS'_
`P G’ d
`’
`(
`)> E‘mes - “n “501%
`Charlotteswna VA (Us)
`
`_
`(73) Ass1gnee: University of Virginia Patent
`Foundation, Charlottesville, VA (US)
`
`4,870,829 A * 10/1989 Oullette et al. ............ .. 62/51.1
`4,969,336 A * 11/1990 Knippscheer et al. ....... .. 62/266
`5,125,240 A * 6/1992 Knippscheer et al. ....... .. 62/266
`5,176,202 A * 1/1993 Richard ................... .. 165/481
`5’233’844 A * 8/1993 Kmppscheer et a1‘ """" " 62/440
`5,498,116 A * 3/1996 Woodruff et al. ......... .. 414/331
`5,628,197 A * 5/1997 Rada ........................... .. 62/62
`5,638,686 A * 6/1997 Coelho et al.
`.. 62/51.1
`5,921,102 A * 7/1999 Vago .................. .. 62/337
`6,068,437 A * 5/2000 Boje et al. ........... .. 414/331.02
`
`FOREIGN PATENT DOCUMENTS
`
`EP
`
`0411224 A2 * 2 1991
`
`........... .. F25D 3 11
`
`( T ) Notice:
`
`
`
`Subjectto any disclaimer, the term Of Pawnt is amended or adlllsted under 35
`
`
`
`W0 W0
`
`
`
`WO 91/02202 WO 98/58215
`
`
`
`* 2’1991 * 12/1998
`
`
`
`" ......... .. F25D/19/0O
`
`U.S.C. 154(b) by 0 days.
`
`(21) Appl. N0.: 10/263,910
`_
`_
`(22) Flled'
`(65)
`
`Oct‘ 3’ 2002
`Prior Publication Data
`
`_
`_
`* cited by examiner
`Primary Examiner—Denise L. Esquivel
`Assistant Examiner—Marc Norman
`(74) Attorney, Agent, or Firm—Robert J. Decker
`(57)
`ABSTRACT
`
`Us 2003/0037556 A1 Feb‘ 27’ 2003
`Related U S A “cation Data
`'
`' pp
`(63) Continuation of application No. 09/935,488, ?led on Aug.
`23, 2001, now Pat, No_ 6,467,285'
`(60) Provisional application No. 60/227,166, ?led on Aug. 23,
`2000, and Provisional application NO- 60/229597, ?led 0n
`Jun‘ 20’ 2001'
`(51) Im. c1.7 ........................ .. F25D 17/00; F25D 25/02
`(52) US. Cl. .......................................... .. 62/177, 62/381
`-
`(58) Field of Search ........................ .. 62/177 381 382
`
`(56)
`
`’
`’
`’
`’
`References Cited
`
`’
`
`’
`
`Us PATENT DOCUMENTS
`62/218
`3 163 994 A * 1/1965 Haumann et al
`62681
`3,782,133 A * 1/1974 Desperier et a1:
`250/507
`3:787:699 A * 1/1974 Menaehem et a1_ __
`. 62/514 R
`4,485,641 A * 12/1984 Angelier et al.
`4,799,358 A * 1/1989 Knopf et al. .................. .. 62/3
`
`An automated cold storage apparatus, and related method
`thereof, provides a sample process management system that
`is a revolutionary approach to the storage and retrieval
`regar‘lmg Cntlcal Sample?‘ The system—a slgnl_?cant_ tech
`nologrcal breakthrough in laboratory automat1on—1s the
`?rst ultra loW temperature robotic system capable of being
`validated. Samples in containers are stored and retrieved
`robotically through an airlock climate-control chamber that
`is automatically dahumidi?ad by a dry gas purge, such as a
`9
`d'
`'d
`'_ g
`P_ g
`h 1'1; Th' p g
`car on 10x1 e or mtro en ur e or t e 1 e.
`is ur e
`rapldly reduces amblent humldlty to a deslrable relanve
`€.g., less than about
`virtually
`eliminating the accumulation of frost. Microplates are sys
`tematically identi?ed using barcode technology, for
`example. Once through the climate-controlled chamber, the
`containers (i.e., samples) are robotically transferred to the
`rotary mechanism. This mechanism transports the containers
`to a derived nest location upon the storage means, such as a
`carousel or to one of the stationary addresses.
`
`37 Claims, 26 Drawing Sheets
`
`1
`
`10—\
`
`20\
`
`m 0 23
`
`27
`
`28
`
`/
`43
`/’
`
`ROTARY
`
`@ @ h TRANSPORTER
`m
`TRANSPORTER
`
`'
`
`VERTICAL
`
`CONTROL _
`SYSTEM
`
`1..
`
`a ‘
`
`4o
`
`PICKING
`MECHANISM
`
`42
`
`L
`
`CLIMATE
`CONTROL
`
`Hamilton Ex. 1002
`Page 1
`
`

`

`U.S. Patent
`
`Jun. 24, 2003
`
`Sheet 1 0f 26
`
`US 6,581,395 B2
`
`F
`
`1O '\__
`
`23
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`f’ 27
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`
`f 43
`
`CONTROL
`
`SYSTEM
`@
`
`FIG. 1
`
`Hamilton Ex. 1002
`Page 2
`
`

`

`U.S. Patent
`
`Jun. 24, 2003
`
`Sheet 2 0f 26
`
`US 6,581,395 B2
`
`FIG. 2A
`
`Hamilton Ex. 1002
`Page 3
`
`

`

`U.S. Patent
`
`Jun. 24, 2003
`
`Sheet 3 0f 26
`
`US 6,581,395 B2
`
`FIG. 2B
`
`Hamilton Ex. 1002
`Page 4
`
`

`

`U.S. Patent
`
`Jun. 24, 2003
`
`Sheet 4 0f 26
`
`US 6,581,395 B2
`
`FIG. 3
`
`63
`
`67
`
`68
`
`I'll-I LlLl
`
`FIG. 4A
`
`68 \
`
`f 63
`
`Hamilton Ex. 1002
`Page 5
`
`

`

`U.S. Patent
`
`Jun. 24, 2003
`
`Sheet 5 0f 26
`
`US 6,581,395 B2
`
`mv
`
`
`
`Nd 6220i
`
`om / or
`/
`
`Hamilton Ex. 1002
`Page 6
`
`

`

`U.S. Patent
`
`Jun. 24, 2003
`
`Sheet 6 0f 26
`
`US 6,581,395 B2
`
`mw
`
`0220i
`
`JOEPZOO
`
`1/ or
`
`/
`
`om
`
`Hamilton Ex. 1002
`Page 7
`
`

`

`U.S. Patent
`
`Jun. 24, 2003
`
`Sheet 7 0f 26
`
`US 6,581,395 B2
`
`mq
`
`>I<POE
`
`mmkmomwzgmk
`
`@ZZOE
`
`mm
`
`JOEL-ZOO
`
`Hamilton Ex. 1002
`Page 8
`
`

`

`U.S. Patent
`
`Jun. 24, 2003
`
`Sheet 8 0f 26
`
`US 6,581,395 B2
`
`mv
`
`Nw
`
`6220K
`
`mmkmOmwz/iup
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`mwFEOmwZxEP
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`mm
`
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`{ON
`
`Hamilton Ex. 1002
`Page 9
`
`

`

`U.S. Patent
`
`Jun. 24, 2003
`
`Sheet 9 0f 26
`
`US 6,581,395 B2
`
`EXTERIOR DOOR OPENS AND TRANSPORT TRAY
`EXITS, AND STORAGE CONTAINER IS PLACED IN CHAMBER
`
`601
`
`‘J- 600
`
`EXTERIOR DOOR CLOSES, TRANSPORT TRAY RETURNS TO CHAMBER
`AND STORAGE CONTAINER'S BARCODE IS SCANNED BY READER
`DEVICE, AND STORAGE LOCATION IS ASSIGNED
`
`EXTERIOR DOOR AND INTERIOR 000R ARE IN CLOSED POSITION WHILE
`AIR PURGING SYSTEM COOLS AND DEHUMIDIFIES AIR IN CHAMBER
`
`603
`
`INTERIOR DOOR OPENS, TRANSPORT TRAY TRANSPORTS THE
`CONTAINER INWARD, A PICKING MECHANISM IS ADVANCED INTO THE
`CHAMBER TO PICK UP STORAGE CONTAINERS AND THEN RETRACTS
`TO PLACE CONTAINER ON INTERCHANGE TRAY, INTERIOR DOOR CLOSES
`
`THE STORAGE CAROUSEL IS ROTATED TO ROTATIONALLY ALIGN
`CORRECT VERTICAL RACK WITH THE FUTURE POSITION OF THE
`INTERCHANGE MECHANISM
`
`INTERCHANGE MECHANISM IS ACTUATED VERTICALLY BY A VERTICAL
`TRANSPORTER TO VERTICALLY ALIGN WITH CORRECT HEIGHT OF
`TARGETED STORAGE TRAY
`
`604
`
`605
`
`606
`
`A ROTARY TRANSPORTER ROTATES THE INTERCHANGE MECHANISM
`TO ROTATIONALLY ALIGN WITH CORRECT VERTICAL RACK
`
`607
`
`TO 608
`FIG. 68
`
`FIG. 6A
`
`Hamilton Ex. 1002
`Page 10
`
`

`

`U.S. Patent
`
`Jun. 24, 2003
`
`Sheet 10 0f 26
`
`US 6,581,395 B2
`
`FROM 607
`FIG. 6A
`
`I
`
`6CD
`4/
`
`PICKING MECHANISM IS ADVANCED SUBSTANTIALLY HORIZONTALLY TO
`PLACE THE STORAGE CONTAINER ON STORAGE TRAY
`
`608
`
`PICKING MECHANISM IS VERTICALLY LOWERED A NOMINAL HEIGHT AND
`RETRACTED SUBSTANTIALLY HORIZONTALLY TO DISENGAGE THE
`STORAGE CONTAINER
`
`609
`
`PROCESSOR RECORDS RELEVANT STORAGE CONTAINER INFORMATION
`IN DATABASE
`
`‘510
`
`INTERCHANGE MECHANISM IS ROTATED TO ROTATIONALLY ALIGN WITH
`INTERIOR DOOR OF THE CHAMBER AND THE INTERCHANGE MECHANISM
`IS VERTICALLY ACTUATED TO VERTICALLY ALIGN WITH INTERIOR
`DOOR, FOR A RESTING STATE
`
`611
`
`FIG. 6B
`
`Hamilton Ex. 1002
`Page 11
`
`

`

`U.S. Patent
`
`Jun. 24, 2003
`
`Sheet 11 0f 26
`
`US 6,581,395 B2
`
`700 j
`
`STORAGE CONTAINER ID FOR DESIRED OR TARGETED
`CONTAINER IS ENTERED ELECTRONICALLY
`
`CENTRAL PROCESSOR LOCATES RELEVANT STORAGE CONTAINER
`INFORMATION IN THE DATABASE AND LOCATION OF STORAGE
`CONTAINER IN STORAGE CAROUSEL IS DETERMINED
`
`IF SECURITY IS REQUIRED, THEN AN ACCESS CODE IS ENTERED VIA DATA
`INPUT DEVICE AND CONFIRMED BY PROCESSOR TO ALLOW ACCESS
`TO THE DESIRED STORAGE CONTAINER
`
`STORAGE CAROUSEL IS ROTATED TO ROTATIONALLY ALIGN THE
`CORRECT VERTICAL RACK, CONTAINING THE DESIRED STORAGE
`CONTAINER, WITH THE FUTURE POSITION INTERCHANGE MECHANISM
`
`INTERCHANGE MECHANISM IS ACTUATED VERTICALLY BY A VERTICAL
`TRANSPORTER TO VERTICALLY ALIGN WITH THE CORRECT HEIGHT OF A
`DESIRED STORAGE TRAY
`
`ROTARY TRANSPORTER ROTATES THE INTERCHANGE MECHANISM
`TO ROTATIONALLY ALIGN WITH CORRECT VERTICAL RACK
`
`THE PICKING MECHANISM IS ADVANCED SUBSTANTIALLY HORIZONTALLY
`TO RETRIEVE THE STORAGE CONTAINER FROM STORAGE TRAY
`
`THE PICKING MECHANISM IS VERTICALLY RAISED A NOMINAL HEIGHT AND
`RETRACTED HORIZONTALLY TO ENGAGE AND WITHDRAW THE
`STORAGE CONTAINER
`
`701
`
`702
`
`703
`
`704
`
`705
`
`I
`7 36
`
`707
`
`708
`
`TO 709
`FIG. 78
`
`FIG. 7A
`
`Hamilton Ex. 1002
`Page 12
`
`

`

`U.S. Patent
`
`Jun. 24, 2003
`
`Sheet 12 0f 26
`
`US 6,581,395 B2
`
`FROM 708
`FIG. 7A
`i
`
`INTERCHANGE MECHANISM IS ROTATED TO ROTATIONALLY
`ALIGN WITH INTERIOR DOOR OF CHAMBER
`
`‘j- 700
`
`709
`
`EXTERIOR DOOR AND INTERIOR DOOR ARE IN CLOSED POSITION WHILE
`A|R PURGING SYSTEM COOLS AND DEHUMIDIFIES AIR IN CHAMBER
`
`7IO
`
`INTERIOR DOOR OPENS, THE TRANSPORT TRAY EXTENDS AS THE PICKING
`MECHANISM ADVANCES INTO CHAMBER TO DISENGAGE THE STORAGE
`CONTAINER IN THE CHAMBER, PICKING MECHANISM WITHDRAWS
`
`711
`
`INTERIOR DOOR CLOSES, AND THE READER DEVICE READS THE
`BARCODE ID OF THE STORAGE CONTAINER TO CONFIRM THAT IT
`MATCHES THE ID THAT WAS ENTERED IN STEP E1
`
`EXTERIOR DOOR OPENS, ALLOWING ACCESS TO THE
`STORAGE CONTAINER
`
`712
`
`713
`
`FIG. 7B
`
`Hamilton Ex. 1002
`Page 13
`
`

`

`U.S. Patent
`
`Jun. 24, 2003
`
`Sheet 13 0f 26
`
`US 6,581,395 B2
`
`23
`
`N O
`
`\
`
`\
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`33
`
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`31
`
`FIG. 8
`
`Hamilton Ex. 1002
`Page 14
`
`

`

`U.S. Patent
`
`Jun. 24, 2003
`
`Sheet 14 0f 26
`
`US 6,581,395 B2
`
`FIG. 10A
`
`FIG. 10B
`
`Hamilton Ex. 1002
`Page 15
`
`

`

`U.S. Patent
`
`Jun. 24, 2003
`
`Sheet 15 0f 26
`
`US 6,581,395 B2
`
`/
`
`I
`
`45
`
`46
`
`(QQQQQG
`
`\Liii
`
`Hamilton Ex. 1002
`Page 16
`
`

`

`U.S. Patent
`
`Jun. 24, 2003
`
`Sheet 16 0f 26
`
`US 6,581,395 B2
`
`7 4
`
`43
`
`53
`
`4 5
`
`FIG. 11B
`
`Hamilton Ex. 1002
`Page 17
`
`

`

`U.S. Patent
`
`Jun. 24, 2003
`
`Sheet 17 0f 26
`
`US 6,581,395 B2
`
`1280
`
`CONTROL
`SYSTEM
`
`COMPUTER
`SYSTEM
`
`LABORATORY
`INFORMATION
`MANAGEMENT
`SYSTEMS
`
`I
`
`ACTUATORS
`
`1284
`
`POSITION
`SENSORS
`
`1285
`
`IDENTIFICATION
`SENSORS
`
`1286
`
`FIG. 12
`
`Hamilton Ex. 1002
`Page 18
`
`

`

`US. Patent
`
`4
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`Hamilton Ex. 1002
`
`Page 19
`
`Hamilton Ex. 1002
`Page 19
`
`
`
`
`
`
`

`

`U.S. Patent
`
`Jun. 24, 2003
`
`Sheet 19 0f 26
`
`US 6,581,395 B2
`
`1428
`
`1428
`
`1437
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`HIIIII
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`
`FIG. 14A
`
`/ \
`
`Hamilton Ex. 1002
`Page 20
`
`

`

`US. Patent
`
`Jun. 24, 2003
`
`Sheet20 0f26
`
`US 6,581,395 132
`
`1428
`
`1440
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`
`1 444
`
` VVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVV
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`7/47/1,”///’////’/’///////’/
`
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`
`FH3.‘h4B
`
`Hamilton Ex. 1002
`
`Page 21
`
`Hamilton Ex. 1002
`Page 21
`
`
`
`
`

`

`US. Patent
`
`Jun. 24, 2003
`
`Sheet 21 0f 26
`
`US 6,581,395 B2
`
`1502
`
`FIG. 15A
`
`1520
`
`1502
`
`FIG. 158
`
`Hamilton Ex. 1002
`
`Page 22
`
`Hamilton Ex. 1002
`Page 22
`
`

`

`US. Patent
`
`Jun. 24, 2003
`
`Sheet 22 0f 26
`
`US 6,581,395 B2
`
`1501
`
`1580
`
`1580“\ \
`
`FIG. 15C
`
`1501
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`1 580
`
`1580 ‘\
`
`1560
`
` 1502
`
`FIG. 15D
`
`Hamilton Ex. 1002
`
`Page 23
`
`Hamilton Ex. 1002
`Page 23
`
`

`

`US. Patent
`
`Jun. 24, 2003
`
`Sheet23 0f26
`
`US 6,581,395 132
`
`
`
`FIG. 16A
`
`Hamilton Ex. 1002
`
`Page 24
`
`Hamilton Ex. 1002
`Page 24
`
`

`

`US. Patent
`
`Jun. 24, 2003
`
`Sheet24 0f26
`
`US 6,581,395 132
`
`
`
`FK3.16B
`
`Hamilton Ex. 1002
`
`Page 25
`
`Hamilton Ex. 1002
`Page 25
`
`

`

`US. Patent
`
`Jun. 24, 2003
`
`Sheet 25 0f 26
`
`US 6,581,395 B2
`
`
`
`FIG. 17A
`
`Hamilton Ex. 1002
`
`Page 26
`
`Hamilton Ex. 1002
`Page 26
`
`

`

`US. Patent
`
`Jun. 24, 2003
`
`Sheet 26 0f 26
`
`US 6,581,395 B2
`
`
`
`FIG. 178
`
`Hamilton Ex. 1002
`
`Page 27
`
`Hamilton Ex. 1002
`Page 27
`
`

`

`US 6,581,395 B2
`
`1
`AUTOMATED STORAGE AND RETRIEVAL
`APPARATUS FOR FREEZERS AND
`RELATED METHOD THEREOF
`
`This application is a continuation of application Ser. No.
`09/935,488, filed Aug. 23, 2001, now U.S. Pat. No. 6,467,
`285 the entire disclosure of which is incorporated by refer(cid:173)
`ence herein. This application claims priority from U.S.
`Provisional Application Serial No. 60/227,166, filed on Aug.
`23, 2000, entitled "Automated Storage and Retrieval Appa- 10
`ratus for Freezers and Related Method Thereof," and Ser.
`No. 60/299,597, filed on Jun. 20, 2001, entitled "Automated
`Storage and Retrieval Apparatus for Freezers and Related
`Method Thereof," the entire disclosures of which are hereby
`incorporated by reference herein.
`
`15
`
`2
`cause more rapid degradation of samples. Keeping the
`freezer door open also allows frost to build up in the freezer
`compartment. With repeated openings of the door, the frost
`eventually can freeze containers to the bottom of the freezer
`5 compartment or to each other. As a result, the door must be
`kept open longer in order to break containers out of the frost,
`which only exacerbates the problem.
`The increasing need for high quality bio-repositories in
`hospitals, research institutions, and pharmaceutical clinical
`research laboratories provides a market for automated ultra(cid:173)
`cold storage devices that will improve sample quality, orga-
`nize storage, provide rapid access to all specimens, and
`maintain electronic records of all specimens stored within
`the container.
`U.S. Pat. No. 5,921,102 to Vago, herein incorporated by
`reference, utilizes a storage apparatus particularly with auto(cid:173)
`matic insertion and retrieval. Drawbacks of the Vago
`approach, but not limited thereto, are that it fails to provide
`the climate control associated with the freezer and the
`various interchanging devices, and other features and
`aspects.
`There is therefore a need in the art for an automated cold
`storage apparatus, and related method thereof, that can
`25 provide, among other things a more organized storage and
`retrieval apparatus, less accumulation of moisture and frost
`within the cold storage compartment, less temperature fluc(cid:173)
`tuation from sample withdrawal, and rapid random access to
`all specimens.
`
`FIELD OF INVENTION
`
`This invention relates to an automated storage and
`retrieval apparatus for ultra low temperature freezers, and
`more particularly an apparatus that improves the overall 20
`quality of the climate associated with storing items therein.
`
`BACKGROUND OF INVENTION
`
`Advancements in biotechnology and medical science
`require the analysis of ever-increasing numbers of various
`biological samples. Many biological samples must be stored
`at below-freezing temperatures in order to preserve them for
`future reference, analysis, or use. For example, DNA, RNA,
`cells and protein samples, as well as the reagents necessary 30
`for conducting various analyses of these samples, must be
`stored at ultra-cold temperatures to prevent degradation that
`would interfere with reliable analyses of the biological
`products.
`Storage below -80° C. is generally required for successful 35
`preservation of biomolecules, cells, and tissue (morphology
`and viability) for extended periods of time. However, shelf
`life and the ability to recover living cells are dramatically
`improved at about -196° C. (-196° C. being the boiling
`point of liquid nitrogen). The National Institute of Standards 40
`and Technology has suggested that the term cryogenics be
`applied to all temperatures below -150° C. ( -238° F. or 123°
`above absolute zero on the Kelvin scale). Some scientists
`regard the normal boiling point of oxygen ( -183 o C. or
`-297° F.), as the upper limit. The term ultra low temperature 45
`is probably not officially recognized by any standards body.
`However, it is generally agreed that a freezer refers to a
`storage device that operates from about -5° C. to -20° C.,
`an ultra low operates from about -50° C. to about -90° C.,
`and a cryogenic freezer operates from about -140° C. to 50
`-196° c.
`There are many problems associated with placement and
`retrieval of samples from ordinary laboratory freezer com(cid:173)
`partments. For instance, in an ordinary freezer compartment,
`containers of samples must be stored in front of and on top 55
`of each other to maximize use of the available space. Even
`if the containers are of standard sizes, and therefore easily
`stackable and even if a positional inventory of the samples
`is kept, it is still necessary to shuffle the containers around
`manually in order to retrieve a desired container. This is 60
`problematic because it requires keeping the freezer door
`open for possibly extended periods of time. Keeping the
`freezer door open causes the interior temperature of the
`freezer compartment to rise temporarily, which can cause
`thawing of samples housed near the door of the freezer. 65
`Once the freezer is closed and the temperature decreases, the
`samples refreeze. This repeated freezing and thawing can
`
`SUMMARY OF THE INVENTION
`
`The present invention automated cold storage apparatus,
`and related method thereof, provides a sample process
`management system that is a revolutionary approach to the
`storage and retrieval of critical samples. The system-a
`significant technological breakthrough in laboratory
`automation-is the first ultra low temperature robotic sys(cid:173)
`tem capable of being validated. Samples in containers are
`stored and retrieved robotically through an airlock climate(cid:173)
`control chamber (access means) that is automatically dehu(cid:173)
`midified by a dry gas purge, such as a carbon dioxide or
`nitrogen purge or the like. This purge rapidly reduces
`ambient humidity to a desirable relative humidity (RH), e.g.,
`less than about 15% RH, virtually eliminating the accumu(cid:173)
`lation of frost. Microplates or storage containers, or the like,
`are systematically identified using barcode technology, for
`example. Once through the climate-controlled chamber, the
`containers (i.e., samples) are robotically transferred to the
`rotary mechanism. This mechanism transports the containers
`to a derived nest location upon the storage means, such as a
`carousel or one of the stationary addresses. For illustrative
`purposes only, the carousel and stationary nests may have a
`combined capacity of 1,000 standard microplates. It is
`contemplated that various capacities may be designed.
`The preferred embodiments of the present invention auto(cid:173)
`mated storage and retrieval apparatus, and related method
`thereof, operate at an ultra low temperature of about -50° C.
`to about -90° C. It should be understood that the apparatus
`may operate in a range of -50° C. up to ambient temperature
`or greater. The normal design operating temperature of the
`freezer compartment of the present invention is about -80°
`C. It should be noted that the present invention is contem(cid:173)
`plated to operate at conditions colder than ultra low tem(cid:173)
`peratures in the range of about -140° C. to about -90° C.
`Conveniently, if the freezer fails for whatever reason(cid:173)
`maintenance or scheduled outage-then liquid carbon diox(cid:173)
`ide can be pumped into the system and keep it at approxi-
`
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`

`US 6,581,395 B2
`
`3
`mately -78° C. The ultra low freezer set point
`(approximately 78° C.) of the apparatus can be backed up by
`installing a cylinder of liquid carbon dioxide.
`In one aspect, the present invention features an automated
`storage and retrieval apparatus for storing containers at ultra 5
`low temperatures or other preferred temperatures. The appa(cid:173)
`ratus comprising: a freezer compartment, the freezer com(cid:173)
`partment having a side wall; a storage carousel disposed
`inside the freezer compartment for holding the containers; a
`climate-controlled chamber disposed on the side wall; a 10
`climate system for controlling the climate of the chamber;
`and an interchange mechanism configured. The interchange
`mechanism is configured to:
`interchange a container
`between the interchange mechanism and the climate(cid:173)
`controlled chamber while in a chamber exchange position,
`and interchange a container between the interchange mecha- 15
`nism and the carousel while in a carousel exchange position.
`The chamber also being configured to: isolate the container
`from the interchange mechanism as container is deposited
`from the exterior or placed into the exterior, and isolate the
`container from the exterior as container is exchanged 20
`between the chamber and the interchange mechanism.
`In some embodiments, the carousel can be replaced with
`a stationary storage rack, and additional storage racks may
`be added. The interchange mechanism is configured to
`interchange a container between the interchange mechanism 25
`and the rack(s) while in a rack exchange position(s).
`In a second aspect, the present invention provides an
`automated storage and retrieval apparatus for storing con(cid:173)
`tainers at ultra low temperatures or other preferred tempera(cid:173)
`tures. The apparatus comprising: a freezer means for freez- 30
`ing the containers; a storage means disposed inside the
`freezer means for holding the containers; a chamber means
`for interchanging the containers between the exterior and the
`freezer means; a climate system control means for control(cid:173)
`ling the climate of the chamber means; and an interchange 35
`means. The interchange means for: interchanging a con(cid:173)
`tainer between the interchange means and, the chamber
`means while in a chamber exchange position, and inter(cid:173)
`changing a container between the interchange means and the
`storage means while in a storage exchange position. The
`chamber means for: isolating the container from the inter(cid:173)
`change means as container is deposited from the exterior or
`placed into the exterior, and isolating the container from the
`exterior as container is exchanged between the chamber
`means and said interchange means.
`In a third aspect, the present invention provides a method
`for automatically depositing and storing containers, as well
`as a method for storing and retrieving containers in a freezer
`compartment of an automated apparatus. The apparatus
`comprising: a freezer means for freezing the containers; a 50
`storage means disposed inside the freezer means for holding
`the containers; a chamber means for interchanging the
`containers between the exterior and the freezer means; a
`climate system control means for controlling the climate of
`the chamber means; and an interchange means. The inter- 55
`change means for: interchanging a container between the
`interchange means and the chamber means while in a
`chamber exchange position, and interchanging a container
`between the interchange means and the storage means while
`in a storage exchange position. The chamber means for: 60
`isolating the container from the interchange means as con(cid:173)
`tainer is deposited from the exterior or placed into the
`exterior, and isolating the container from the exterior as
`container is exchanged between the chamber means and said
`interchange means.
`An advantage of the present invention automated storage
`and retrieval apparatus for ultra low temperature freezers,
`
`4
`and related method thereof, is that the apparatus can operate
`in a stand-alone mode or can be integrated into a completely
`automated laboratory. It is scalable to meet the needs of
`small laboratories as well as large institutions that will
`require long-term storage of large numbers of samples.
`Another advantage of the present invention is that the
`apparatus can be designed as a slide-in unit for existing
`ultra-cold freezers, which will keep the majority of the
`hardware in the door so as to be insulated from the freezer
`compartment, minimizing both the number of low(cid:173)
`temperature hardware components and the actual alteration
`to the freezer itself. A reduced number of moving compo(cid:173)
`nents is continuously exposed to the design temperature of
`about -80° C., reducing the cost of production.
`Further advantages of the present invention are attributed
`to the improved sample quality, lowered operating costs, and
`reduced maintenance of the automated storage and retrieval
`apparatus.
`Finally, an advantage of the present invention is that it
`provides ultra-low temperature automation or lower and
`user-friendly information technology in a proven reliable
`manner.
`These and other objects, along with advantages and
`features of the invention disclosed herein, will be made more
`apparent from the description, drawings and claims that
`follow.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`The foregoing and other objects, features and advantages
`of the present invention, as well as the invention itself, will
`be more fully understood from the following description of
`preferred embodiments, when read together with the accom(cid:173)
`panying drawings, in which:
`FIG. 1 shows a schematic plan view of the automated
`storage and retrieval apparatus.
`FIG. 2A shows a schematic perspective view of the
`automated storage and retrieval apparatus.
`FIG. 2B shows a perspective partial view of the door or
`40 wall of a compartment and/or housing.
`FIG. 3 shows a schematic cross-sectional view of the
`climate controlled chamber with the exterior door in open
`and closed positions.
`FIGS. 4A and 4B show a schematic frontal view and plan
`45 view, respectively, of the related translation mechanisms of
`the climate controlled chamber.
`FIGS. 5A-5D show a schematic representation of select
`positions of the rotational alignment of the interchange
`mechanism.
`FIGS. 6A and 6B comprise a flow chart illustrating the
`operation for depositing and storing a storage container or
`the like in the automated storage and retrieval apparatus.
`FIGS. 7A and 7B comprise a flow chart illustrating the
`operation for retrieving the targeted or desired storage
`container or the like in the automated storage and retrieval
`apparatus.
`FIG. 8 shows a schematic perspective view of the storage
`carousel of the automated storage and retrieval apparatus.
`FIG. 9 shows a perspective view of an individual vertical
`rack from the carousel of FIG. 8, comprised of a plurality of
`storage trays,
`FIGS. lOA and lOB show a schematic perspective view of
`the storage trays and their related cooperation with the
`65 vertical supports of the carousel.
`FIGS. llA and llB are schematic perspective views of
`the interchange mechanism and related components.
`
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`Page 29
`
`

`

`US 6,581,395 B2
`
`5
`FIG. 12 shows a schematic block diagram of the general
`features of the control system of the automated storage and
`retrieval apparatus.
`FIG. 13 shows a schematic block diagram of an exem(cid:173)
`plary computer system associated with an embodiment of 5
`the automated storage and retrieval apparatus.
`FIGS. 14A and 14B show schematic perspective views of
`an alternative embodiment of the automated storage and
`retrieval apparatus.
`FIGS. 15A-15D show schematic plan views of an alter- 10
`native embodiment of the automated storage and retrieval
`apparatus providing expanded network system of cooperat(cid:173)
`ing freezer apparatuses.
`FIGS. 16A and 16B show schematic perspective front/ 15
`exterior views of the housing of the climate control chamber
`with related components in both the closed and open
`position, respectively.
`FIGS. 17 A and 17B show schematic perspective back/
`interior views of the housing of the climate control chamber 20
`with related components in both the closed and open
`position, respectively.
`
`30
`
`6
`containers as they are inserted into and retrieved from
`chamber 60. Information relative to the storage containers is
`transmitted from reader device 65 to central and/or remote
`processor.
`Still referring to FIGS. 3 and 4A-4B, the storage con(cid:173)
`tainers 3 are carried by a transport tray 63 that is slidably
`mounted on two channels 67, 68. The transport tray 63 can
`transport the container 3 to the exterior as the exterior door
`62 is open, as indicated by the dashed lines. Alternatively,
`the transport tray 63 can transport the container 3 to the
`interior of the freezer compartment 10 as the interior door 61
`is open, as indicated by the dotted lines. In one embodiment,
`the interior door 61 may slide open and close on a track (not
`shown). A climate control system 66 is in communication
`with the chamber 60 that dehumidifies and cools the cham(cid:173)
`ber 60 while the container is isolated therein, i.e., both
`exterior and interior doors are closed. The climate control
`system 66 includes a dry gas or dry air purge (i.e., nitrogen,
`carbon dioxide, or the like), that rapidly reduces ambient
`humidity to any desired level, e.g., less than about 25%
`relative humidity (RH) and as low as about 1% RH. In fact,
`any compressed gas from which moisture has been removed
`will reduce the humidity in the airlock, and will cool the
`airlock by adiabatic expansion to about -10° C. to about 0°
`25 C., or as desired.
`A preferred embodiments of the present invention auto(cid:173)
`mated storage and retrieval apparatus, and related method
`thereof, operate at an ultra low temperature from about -50°
`C. to about -90° C. It should be understood that the
`apparatus may operate in a range of -50° C. up to ambient
`temperature or greater. The normal design operating tem(cid:173)
`perature of the freezer compartment of the present invention
`is about -80° C. It should be noted that the present invention
`is contemplated to operate at conditions colder than ultra
`35 low temperatures in the range of about -140° C. to about
`-90° C. Conveniently, if the freezer fails for whatever
`reason-maintenance or scheduled outage-then liquid car(cid:173)
`bon dioxide can be pumped into the system and keep it at
`approximately -78° C. Thus, the ultra low freezer-set point
`40 of the apparatus can be backed up by installing a cylinder of
`liquid carbon dioxide.
`One skilled in the art would appreciate that various types
`and substitutes for interior and exterior chamber doors can
`45 be used. Moreover, a single door can be utilized which can
`rotate between interior and exterior sides.
`Additional details pertaining to the climate controlled
`chamber 60 will be provided, as best shown in the perspec(cid:173)
`tive views of FIGS. 16A-16B and FIGS. 17A-17B. The
`50 front/exterior view and the back/interior view of climate
`controlled chamber 60 are shown in FIGS. 16A-16B and
`FIGS. 17 A-17B, respectively. Referring to front/exterior
`view of FIG. 16A, the chamber 60 includes a chamber
`housing 91 having its exterior door 62 in a closed position
`55 with a deep well micro-plate 92 placed thereon the transport
`tray 63. It should be appreciated that a shallow well micro(cid:173)
`plate may be used, as well as any other size, type, or number
`of containers, which can be accommodated for storage and
`interchange. Also shown is a tray-motor and gear box
`60 housing 93, reading device 65, and air purge port 94. FIG.
`16B shows the chamber 60 having its exterior door 62 in an
`open position.
`Referring to the back/interior view of FIGS. 17A-17B,
`there is shown the chamber 60 including an interior door-
`65 motor gear and motor housing 95 and lead screw 96, and
`having its interior door 61 in a closed position. FIG. 17B
`shows the chamber 60 having its interior door 61 in an open
`
`DETAILED DESCRIPTION OF 1HE
`INVENTION
`Turning now to the drawings, the present invention is
`schematically shown in the plan view of FIG. 1 and per(cid:173)
`spective view of FIG. 2A, which includes an automated
`storage and retrieval apparatus 1 having one or more storage
`carousels 20 disposed in a freezer compartment 10, with one
`or more optional stationary racks 26, 27, an interchange
`mechanism 40, and a climate controlled chamber 60 that is
`generally disposed on a wallll of the freezer compartment
`10 or associated housing 2. A central control system 80 is
`coupled to the storage carousel 20, interchange mechanism
`40, and climate controlled chamber 60 for controlling their
`operations. Generally, the control system 80 controls the
`operation of the apparatus so that the containers can be
`loaded from the exterior into the climate-controlled chamber
`60 for retrieval by the interchange mechanism 40 for inser(cid:173)
`tion onto the carousel 20 in the freezer compartment 10.
`Stored containers subsequently can be retrieved from the
`carousel 20 by the interchange mechanism 40 and available
`to be taken away to the exterior through the climate con(cid:173)
`trolled chamber 60.
`FIG. 2B shows a perspective partial view of the wallll
`of the compartment and/or door of the housing. Mounted on
`the wall 11 are the climate-controlled chamber 60 and a
`touch screen interface 82. As will be discussed later, it is
`envisioned that