(12) United States Patent
`Felder et al.
`
`111111
`
`1111111111111111111111111111111111111111111111111111111111111
`US0069417 62B2
`
`(10) Patent No.:
`(45) Date of Patent:
`
`US 6,941,762 B2
`Sep.13,2005
`
`(54) AUTOMATED STORAGE AND RETRIEVAL
`APPARATUS FOR FREEZERS AND
`RELATED METHOD THEREOF
`
`(75)
`
`Inventors: Robin A. Felder, Charlottesville, VA
`(US); B. Sean Graves, Charlottesville,
`VA (US); James P. Gunderson,
`Charlottesville, VA (US)
`
`(73) Assignee: University of Virginia Patent
`Foundation, Charlottesville, VA (US)
`
`( *) Notice:
`
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 0 days.
`
`(21) Appl. No.: 10/773,327
`
`(22) Filed:
`
`Feb. 6,2004
`
`(65)
`
`Prior Publication Data
`
`US 2004/0154322 A1 Aug. 12, 2004
`
`Related U.S. Application Data
`
`(63) Continuation of application No. 10/429,490, filed on May 5,
`2003, now Pat. No. 6,688,123, which is a continuation of
`application No. 10/263,910, filed on Oct. 3, 2002, now Pat.
`No. 6,581,395, which is a continuation of application No.
`09/935,488, filed on Aug. 23,2001, now Pat. No. 6,467,287.
`(60) Provisional application No. 60/299,597, filed on Jun. 20,
`2001, and provisional application No. 60/227,166, filed on
`Aug. 23, 2000.
`Int. Cl? ................................................ F25D 13/06
`(51)
`(52) U.S. Cl. .............................................. 62/63; 62/378
`(58) Field of Search .. ... ... .. ... ... ... ... .. ... . 62/98, 177, 178,
`62/336, 337, 378, 381, 382
`
`(56)
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`3,163,994 A * 1!1965 Haumann et a!. ............. 62/218
`3,638,717 A * 2/1972 Harbour eta!. ............. 165/263
`3,782,133 A * 1!1974 Desperier et a!. ............. 62/381
`
`4,485,641 A * 12/1984 Angelier eta!. ............. 62/51.1
`4,870,829 A * 10/1989 Oullette et a!. .............. 62/51.1
`5,125,240 A * 6/1992 Knippscheer eta!. ......... 62/266
`5,233,844 A * 8/1993 Knippscheer eta!. ......... 62/440
`5,305,615 A * 4/1994 McFadden eta!. ........... 62/378
`5,319,939 A * 6/1994 McFadden eta!. ............ 62/63
`6,230,514 B1 * 5/2001 Schulak eta!. ............... 62/434
`6,453,687 B2 * 9/2002 Sharood et a!. ............... 62/127
`6,464,672 B1 * 10/2002 Buckley ..................... 604/304
`6,536,859 B1 * 3/2003 Bathe ......................... 312/305
`
`FOREIGN PATENT DOCUMENTS
`08327215 A * 12/1996
`02001059668 A * 3/2001
`
`JP
`JP
`
`* cited by examiner
`
`Primary Examiner-William E. Tapolcai
`Assistant Examiner---Mohammad M. Ali
`(74) Attorney, Agent, or Firm-Robert 1. Decker
`
`(57)
`
`ABSTRACT
`
`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
`regarding critical samples. The system-a significant tech(cid:173)
`nological breakthrough in laboratory automation-is the
`first 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 dehumidified 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 accumulation of frost. Microplates are sys(cid:173)
`tematically 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 to one of the stationary addresses.
`
`48 Claims, 26 Drawing Sheets
`
`10
`
`20
`
`42
`
`66
`
`Hamilton Ex. 1004
`Page 1
`
`

`

`U.S. Patent
`
`Sep.13,2005
`
`Sheet 1 of 26
`
`US 6,941,762 B2
`
`27
`
`26
`
`43
`
`CONTROL
`SYSTEM
`80
`
`FIG.1
`
`Hamilton Ex. 1004
`Page 2
`
`

`

`U.S. Patent
`
`Sep.13,2005
`
`Sheet 2 of 26
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`US 6,941,762 B2
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`Hamilton Ex. 1004
`Page 3
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`

`

`U.S. Patent
`
`Sep. 13,2005
`
`Sheet 3 of 26
`
`US 6,941,762 B2
`
`11
`
`FIG. 2B
`
`Hamilton Ex. 1004
`Page 4
`
`

`

`U.S. Patent
`
`Sep.13,2005
`
`Sheet 4 of 26
`
`US 6,941,762 B2
`
`10
`
`CLIMATE
`CONTROL SYSTEM
`
`66
`
`62
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`FIG.3
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`FIG. 4A
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`FIG.4B
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`67
`
`Hamilton Ex. 1004
`Page 5
`
`

`

`U.S. Patent
`
`Sep.13,2005
`
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`Page 6
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`U.S. Patent
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`Sep.13,2005
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`Hamilton Ex. 1004
`Page 7
`
`

`

`U.S. Patent
`
`Sep.13,2005
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`Sheet 7 of 26
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`Hamilton Ex. 1004
`Page 8
`
`

`

`U.S. Patent
`
`Sep.13,2005
`
`Sheet 8 of 26
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`US 6,941,762 B2
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`Hamilton Ex. 1004
`Page 9
`
`

`

`U.S. Patent
`
`Sep.13,2005
`
`Sheet 9 of 26
`
`US 6,941,762 B2
`
`EXTERIOR DOOR OPENS AND TRANSPORT TRAY
`EXITS, AND STORAGE CONTAINER IS PLACED IN CHAMBER
`
`...f 600
`
`v-
`
`601
`
`J
`AND STORAGE CONTAINER'S BARCODE IS SCANNED BY READER v 602
`
`EXTERIOR DOOR CLOSES, TRANSPORT TRAY RETURNS TO CHAMBER
`
`DEVICE, AND STORAGE LOCATION IS ASSIGNED
`
`~
`EXTERIOR DOOR AND INTERIOR DOOR ARE IN CLOSED POSITION WHILE ~ 603
`AIR PURGING SYSTEM COOLS AND DEHUMIDIFIES AIR IN CHAMBER
`
`J
`
`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
`
`604
`~
`
`~
`THE STORAGE CAROUSEL IS ROTATED TO ROTATIONALLY ALIGN
`CORRECT VERTICAL RACK WITH THE FUTURE POSITION OF THE
`INTERCHANGE MECHANISM
`
`~ 605
`
`~
`INTERCHANGE MECHANISM IS ACTUATED VERTICALLY BY A VERTICAL
`TRANSPORTER TO VERTICALLY ALIGN WITH CORRECT HEIGHT OF
`TARGETED STORAGE TRAY
`
`v 606
`
`~
`A ROTARY TRANSPORTER ROTATES THE INTERCHANGE MECHANISM
`TO ROTATIONALLY ALIGN WITH CORRECT VERTICAL RACK
`
`v- 607
`
`+
`T0608
`FIG. 6B
`
`FIG. 6A
`
`Hamilton Ex. 1004
`Page 10
`
`

`

`U.S. Patent
`
`Sep.13,2005
`
`Sheet 10 of 26
`
`US 6,941,762 B2
`
`~600
`
`FROM 607
`FIG. 6A
`
`~
`
`PICKING MECHANISM IS ADVANCED SUBSTANTIALLY HORIZONTALLY TO
`PLACE THE STORAGE CONTAINER ON STORAGE TRAY
`
`~ 608
`
`j
`PICKING MECHANISM IS VERTICALLY LOWERED A NOMINAL HEIGHT AND
`RETRACTED SUBSTANTIALLY HORIZONTALLY TO DISENGAGE THE
`STORAGE CONTAINER
`~
`PROCESSOR RECORDS RELEVANT STORAGE CONTAINER INFORMATION
`IN DATABASE
`
`~
`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
`
`v- 609
`
`_.,.-- 610
`
`_,-- 611
`
`FIG.6B
`
`Hamilton Ex. 1004
`Page 11
`
`

`

`U.S. Patent
`
`Sep.13,2005
`
`Sheet 11 of 26
`
`US 6,941,762 B2
`
`STORAGE CONTAINER ID FOR DESIRED OR TARGETED
`CONTAINER IS ENTERED ELECTRONICALLY
`
`~ 700
`
`v 701
`
`~
`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
`
`t_
`THE PICKING MECHANISM IS VERTICALLY RAISED A NOMINAL HEIGHT AND
`RETRACTED HORIZONTALLY TO ENGAGE AND WITHDRAW THE
`STORAGE CONTAINER
`
`v- 702
`
`~ 703
`
`v 704
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`v- 705
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`v- 709
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`v 707
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`~
`T0709
`FIG. 78
`
`FIG. ?A
`
`Hamilton Ex. 1004
`Page 12
`
`

`

`U.S. Patent
`
`Sep.13,2005
`
`Sheet 12 of 26
`
`US 6,941,762 B2
`
`FROM 708
`FIG. ?A
`
`~
`
`INTERCHANGE MECHANISM IS ROTATED TO ROTATIONALLY
`ALIGN WITH INTERIOR DOOR OF CHAMBER
`
`+
`EXTERIOR DOOR AND INTERIOR DOOR ARE IN CLOSED POSITION WHILE
`AIR PURGING SYSTEM COOLS AND DEHUMIDIFIES AIR IN CHAMBER
`
`_.,/" 700
`
`v 709
`
`v 710
`
`+
`INTERIOR DOOR OPENS, THE TRANSPORT TRAY EXTENDS AS THE PICKING v 711
`
`MECHANISM ADVANCES INTO CHAMBER TO DISENGAGE THE STORAGE
`CONTAINER IN THE CHAMBER, PICKING MECHANISM WITHDRAWS
`
`+
`
`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 701 -
`j
`EXTERIOR DOOR OPENS, ALLOWING ACCESS TO THE
`STORAGE CONTAINER
`
`v 712
`
`v
`
`713
`
`FIG. 78
`
`Hamilton Ex. 1004
`Page 13
`
`

`

`U.S. Patent
`
`Sep.13,2005
`
`Sheet 13 of 26
`
`US 6,941,762 B2
`
`23
`
`20
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`31
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`
`Hamilton Ex. 1004
`Page 14
`
`

`

`U.S. Patent
`
`Sep.13,2005
`
`Sheet 14 of 26
`
`US 6,941,762 B2
`
`·~23
`
`28
`
`33
`
`FIG. 9
`
`FIG. 10A
`
`FIG. 108
`
`28
`
`36
`
`36
`
`Hamilton Ex. 1004
`Page 15
`
`

`

`U.S. Patent
`
`Sep.13,2005
`
`Sheet 15 of 26
`
`US 6,941,762 B2
`
`FIG. 11A
`
`Hamilton Ex. 1004
`Page 16
`
`

`

`U.S. Patent
`
`Sep.13,2005
`
`Sheet 16 of 26
`
`US 6,941,762 B2
`
`49
`
`43
`
`FIG. 11 B
`
`Hamilton Ex. 1004
`Page 17
`
`

`

`U.S. Patent
`
`Sep.13,2005
`
`Sheet 17 of 26
`
`US 6,941,762 B2
`
`1280l
`
`12 81 \
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`1282\
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`LABORATORY
`INFORMATION
`_ COMPUTER
`CONTROL
`SYSTEM .,._-----11~ SYSTEM -----~ MANAGEMENT
`SYSTEMS
`
`r-----~~ MOTORS
`
`----1283
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`ACTUATORS v- 1284
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`_--- 1285
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`POSITION
`S ENS 0 R S 1----""'"
`
`IDENTIFICATION !----_ 1286
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`
`FIG. 12
`
`Hamilton Ex. 1004
`Page 18
`
`

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`Hamilton Ex. 1004
`Page 19
`
`

`

`U.S. Patent
`
`Sep.13,2005
`
`Sheet 19 of 26
`
`US 6,941,762 B2
`
`1440
`
`1437
`
`FIG. 14A
`
`Hamilton Ex. 1004
`Page 20
`
`

`

`U.S. Patent
`
`Sep.13,2005
`
`Sheet 20 of 26
`
`US 6,941,762 B2
`
`1440
`
`1444
`
`1420
`
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`
`Hamilton Ex. 1004
`Page 21
`
`

`

`U.S. Patent
`
`Sep.13,2005
`
`Sheet 21 of 26
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`US 6,941,762 B2
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`1501
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`
`Hamilton Ex. 1004
`Page 22
`
`

`

`U.S. Patent
`
`Sep.13,2005
`
`Sheet 22 of 26
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`US 6,941,762 B2
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`1501
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`Hamilton Ex. 1004
`Page 23
`
`

`

`U.S. Patent
`
`Sep. 13, 2005
`
`Sheet 23 of 26
`
`US 6,941,762 B2
`
`94
`
`65
`
`FIG. 16A
`
`Hamilton Ex. 1004
`Page 24
`
`

`

`U.S. Patent
`
`Sep. 13,2005
`
`Sheet 24 of 26
`
`US 6,941,762 B2
`
`91
`
`65
`
`FIG. 168
`
`Hamilton Ex. 1004
`Page 25
`
`

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`US. Patent
`
`Sep. 13, 2005
`
`Sheet 25 0f 26
`
`US 6,941,762 B2
`
`
`
`FIG. 17A
`
`Hamilton Ex. 1004
`
`Page 26
`
`Hamilton Ex. 1004
`Page 26
`
`

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`US. Patent
`
`Sep. 13, 2005
`
`Sheet 26 0f 26
`
`US 6,941,762 B2
`
`
`
`FIG. 178
`
`Hamilton Ex. 1004
`
`Page 27
`
`Hamilton Ex. 1004
`Page 27
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`

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`US 6,941,762 B2
`
`1
`AUTOMATED STORAGE AND RETRIEVAL
`APPARATUS FOR FREEZERS AND
`RELATED METHOD THEREOF
`
`RELATED APPLICATIONS
`
`This application is a continuation of application Ser. No.
`10/429,490, filed May 5, 2003, issued Feb. 10,2004, as U.S.
`Pat. No. 6,688,123, the entire disclosure of which is hereby
`incorporated by reference herein, which is a continuation of
`application Ser. No. 10/263,910, filed Oct. 3, 2002, issued
`Jun. 24, 2003, as U.S. Pat. No. 6,581,395, the entire disclo(cid:173)
`sure of which is hereby incorporated by reference herein,
`which is a continuation of application Ser. No. 09/935,488,
`filed Aug. 23, 2001, issued Oct. 22, 2002, as U.S. Pat. No.
`6,467,285, the entire disclosure of which is hereby incor(cid:173)
`porated by reference herein, which claims benefit under 35
`U.S.C. Section 119(e) from U.S. Provisional Application
`Ser. No. 60/227,166, filed on Aug. 23, 2000, entitled "Auto(cid:173)
`mated Storage and Retrieval Apparatus for Freezers and
`Related Method Thereof," and 60/299,597, filed on Jun. 20,
`2001, entitled "Automated Storage and Retrieval Apparatus
`for Freezers and Related Method Thereof," the entire dis(cid:173)
`closures of which are hereby incorporated by reference
`herein.
`
`FIELD OF INVENTION
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`20
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`25
`
`This invention relates to an automated storage and
`retrieval apparatus for ultra low temperature freezers, and
`more particularly an apparatus that improves the overall 30
`quality of the climate associated with storing items therein.
`
`BACKGROUND OF INVENTION
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`2
`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
`problematic because it requires keeping the freezer door
`s 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.
`Once the freezer is closed and the temperature decreases, the
`10 samples refreeze. This repeated freezing and thawing can
`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
`15 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(cid:173)
`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
`35 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.
`
`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 40
`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
`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
`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
`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
`-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 65
`of each other to maximize use of the available space. Even
`if the containers are of standard sizes, and therefore easily
`
`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
`45 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-
`so 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-
`ss 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
`60 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.
`
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`US 6,941,762 B2
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`5
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`3
`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-
`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-
`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
`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
`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, 25
`and interchange a container between the interchange mecha(cid:173)
`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 30
`container from the exterior as container is exchanged
`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 35
`interchange a container between the interchange mechanism
`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- 40
`tures. The apparatus comprising: a freezer means for freez(cid:173)
`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- 45
`ling the climate of the chamber means; and an interchange
`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 50
`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 55
`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 60
`comprising: a freezer means for freezing 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 controlling the climate of 65
`the chamber means; and an interchange means. The inter(cid:173)
`change means for: interchanging a container between the
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`10
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`4
`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:
`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,
`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
`15 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
`20 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
`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
`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.
`
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`US 6,941,762 B2
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`5
`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
`vertical supports of the carousel.
`FIGS. llA and llB are schematic perspective views of
`the interchange mechanism and related components.
`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- 15
`plary computer system associated with an embodiment of
`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(cid:173)
`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/ 25
`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/ 30
`interior views of the housing of the climate control chamber
`with related components in both the closed and open
`position, respectively.
`
`10
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`6
`60 prevents ambient, humid air from entering the interior of
`freezer compartment 10 during storage container insertion
`and retrieval. The Chamber 60 has an interior door 61 to
`allow communication between freezer compartment 10 and
`5 chamber 60, and an exterior door 62 to allow communica(cid:173)
`tion between the exterior environment (or adjacent area) and
`chamber 60. The chamber 60 has a climate control system 66
`that provides an air purging capability to cool and dehu(cid:173)
`midify the air in the chamber 60 before interior door 61 is
`opened. A scanning reader device 65, preferably a barcode
`reader, is situated in the chamber 60 to identify storage
`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
`20 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
`35 airlock by adiabatic expansion to about -10° C. to about 0°
`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°
`40 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
`45 is contemplated to operate at conditions colder than ultra
`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
`50 approximately -78° C. Thus, the ultra low freezer-set point
`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
`55 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