Ulllted States Patent [19]
`Boje et al.
`
`US006068437A
`[11] Patent Number:
`[45] Date of Patent:
`
`6,068,437
`May 30, 2000
`
`[54] AUTOMATED LABORATORY SPECIMEN
`ORGANIZER AND STORAGE UNIT
`
`5,941,366
`6,010,016
`
`8/1999 Quinlan et al. .................... .. 198/4651
`1/2000 Siegal .................................... .. 211/126
`
`[75] Inventors: John F. Boje, Omaha; Samuel R. I
`1313373’ gliliefvgli’bFodney S‘ Markm’
`’
`'
`[73] Assignee: Lab-Interlink, Omaha, Nebr.
`
`tEExjgz/igigzrlgli
`Attorney, Agent, or Firm—Koley Jessen PC. A Limited
`Liability Organization; Mark D. Frederiksen
`[57]
`ABSTRACT
`
`[21] APPL NO: 09/198,636
`_
`[22] F1169:
`NOV- 24, 1998
`[51] Int C17
`B65G U127 B656 U137
`'
`'
`’
`BOlL 9/06’
`_
`_
`[52] US. Cl. ................................ .. 4ll4g/gia3léig2é1l9g8éjl36ét57l3,
`_
`'
`’
`'
`Fleld of Search ....................... ..
`414/331'03’ 331'04’ 751'1’ 198/4651’ 3462’
`3473
`
`""""""""""""" "
`
`56
`[
`]
`
`Ct d
`R f
`e erences l e
`U_S_ PATENT DOCUMENTS
`_
`8/1993 KmpPscheer et a1‘ """" " 41463105 X
`5’233’844
`5/1995 Markin et al. ...................... .. 422/65
`5,417,922
`6/1996 Markin et al.
`198/349
`5,529,166
`5,589,137 12/1996 Markin et al.
`422/104
`5,735,387
`4/1998 Polaniec et al. ................... .. 198/6901
`
`A'laboratory organizer unit includes~an enclosed housing
`With a storage area containing a plurality of racks for storing
`specimen containers, the racks movable throughout the
`storage area to permit access to all of the racks from an
`opening in the upper end of the storage area. A robotic
`transfer apparatus is operable to insert and retrieve specimen
`Containers from Selected racks in the Storage area and move
`them betWeen the storage area and a buffer area on the
`housing, as Well as between the bu?‘er area and a Conveyor
`located adjacent the housing. The conveyor is of a type
`Which transports specimen carriers having a specimen con
`tainer therein, and the buffer area includes a rack for
`intermediate storage of specimen containers. The buffer area
`thereby permits the transfer apparatus to retrieve and load
`specimen containers on specimen carriers on the conveyor,
`While aWaiting an appropriate rack to move into position in
`the stem 6 area
`g
`'
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`17 Claims, 5 Drawing Sheets
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`32b 34
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`32a
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`Daifuku Exhibit 1015, Page 1 of 9
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`U.S. Patent
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`May 30, 2000
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`Sheet 1 0f 5
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`Daifuku Exhibit 1015, Page 2 of 9
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`U.S. Patent
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`May 30, 2000
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`Sheet 2 0f 5
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`6,068,437
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`Daifuku Exhibit 1015, Page 3 of 9
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`U.S. Patent
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`May 30, 2000
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`Sheet 3 0f 5
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`6,068,437
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`Daifuku Exhibit 1015, Page 4 of 9
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`U.S. Patent
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`May 30, 2000
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`Sheet 4 0f 5
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`FIG, 4
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`Daifuku Exhibit 1015, Page 5 of 9
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`U.S. Patent
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`May 30, 2000
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`Sheet 5 0f 5
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`6,068,437
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`Daifuku Exhibit 1015, Page 6 of 9
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`

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`1
`AUTOMATED LABORATORY SPECIMEN
`ORGANIZER AND STORAGE UNIT
`
`TECHNICAL FIELD
`
`The present invention relates generally to storage units for
`clinical laboratory containers, and more particularly to an
`improved laboratory organizer for storing, organiZing and
`manipulating laboratory containers.
`
`BACKGROUND OF THE INVENTION
`Clinical laboratory testing has changed and improved
`remarkably over the past several years. Initially, tests or
`assays Were performed manually, and generally utiliZed
`large quantities of serum, blood or other materials and/or
`body ?uids. As mechanical technology developed in the
`industrial Work place, similar technology Was introduced
`into the clinical laboratory. With the introduction of neW
`technology, methodologies Were also improved in an effort
`to improve the quality of the results produced by the
`individual instruments, and to minimiZe the amount of
`specimen required to perform each test.
`More recently, instruments have been developed to
`increase the efficiency of testing procedures by reducing
`turnaround time and decreasing the volumes necessary to
`perform various assays. Present directions in laboratory
`testing focus on cost containment procedures and instru
`mentation. Robotic engineering has evolved to such a degree
`that various types of robots and conveyance systems have
`been effectively applied in the clinical laboratory setting,
`permitting the substantial automation of the laboratory.
`With the advent of laboratory automation systems, a
`variety of accessories and associated equipment must also be
`developed. In this regard, the insertion and retrieval of
`specimens on to a conveyor track of a laboratory automation
`system have been sloW and ineffective. In addition, prior art
`laboratory automation systems suffered from difficulties in
`organiZing specimen containers, manipulation of the speci
`men containers as Well as short term and long term storage
`of the specimen containers.
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`SUMMARY OF THE INVENTION
`
`It is therefore a general object of the present invention to
`provide an improved laboratory organiZation unit for effec
`tive storage of specimen containers from a laboratory auto
`mation system.
`Another object is to provide a laboratory organiZer unit
`Which permits quick and efficient insertion and retrieval of
`specimen containers from a conveyor track.
`Still another object of the present invention is to provide
`an organiZer unit Which permits ef?cient short term and long
`term storage of specimen containers, While permitting effec
`tive organiZation and sorting of the containers in the storage
`unit.
`These and other objects Will be apparent to those skilled
`in the art.
`The laboratory organiZer unit of the present invention
`includes an enclosed housing With a storage area containing
`a plurality of racks for storing specimen containers, the racks
`movable throughout the storage area to permit access to all
`of the racks from an opening in the upper end of the storage
`area. A robotic transfer apparatus is operable to insert and
`retrieve specimen containers from selected racks in the
`storage area and move them betWeen the storage area and a
`buffer area on the housing, as Well as betWeen the buffer area
`and a conveyor located adjacent the housing. The conveyor
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`is of a type Which transports specimen carriers having a
`specimen container therein, and the buffer area includes a
`rack for intermediate storage of specimen containers. The
`buffer area thereby permits the transfer apparatus to retrieve
`and load specimen containers on specimen carriers on the
`conveyor, While aWaiting an appropriate rack to move into
`position in the storage area.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`FIG. 1 is a perspective vieW of the laboratory organiZa
`tional unit of the present invention;
`FIG. 2 is a side elevational vieW taken from the right side
`of the organiZer unit, With portions broken aWay to shoW the
`interior thereof;
`FIG. 3 is an enlarged partial sectional vieW through the
`organiZer unit;
`FIG. 4 is an enlarged pictorial vieW of one specimen
`container rack Within the organiZer unit; and
`FIG. 5 is a side elevational vieW of a second embodiment
`of the laboratory organiZer unit.
`
`DESCRIPTION OF THE PREFERRED
`EMBODIMENT
`
`Referring noW to the draWings, in Which similar or
`corresponding parts are identi?ed With the same reference
`numeral, and more particularly to FIG. 1, the laboratory
`organiZer unit (LOU) of the present invention is designated
`generally at 10 and includes an enclosed housing 12 pref
`erably supported on a plurality of Wheels 14. Housing 12
`includes forWard and rearWard ends 16 and 18, upper and
`loWer ends 20 and 22, and opposing side Walls 24 and 26.
`The loWer portion of the interior of housing 12 de?nes a
`storage area 28, shoWn in FIG. 2, Which is accessible from
`a specimen rack input/output (I/O) station 30, located in the
`upper portion of the forWard end of housing 12, as Well as
`by a robotic input/output unit (IOU) 32 eXtending rear
`Wardly from a forWard area 32b adjacent to the user station
`30 in the upper end of the housing 12. The IOU 32 includes
`a robotic arm 34 Which is operable over the top of storage
`area 28, as Well as over a conveyor track 36 (Which is not
`part of the LOU) extending outside the housing 12 of the
`LOU 10, beneath a rearWard area 32a of IOU 32. Conveyor
`track 36 supports and conveys a plurality of individual
`specimen carriers 38, each specimen carrier 38 supporting a
`test tube 40 or other container thereon. Conveyor track 36
`eXtends betWeen various testing Work stations and the LOU,
`to permit automated entry, testing, and storage of various
`specimens. While conveyor track 36 is shoWn located par
`allel to the rearWard end 18 of LOU housing 12, the track
`may be located parallel either side Wall 24 or side Wall 26,
`so long as the IOU 32 eXtends over the top of the conveyor
`track 36.
`As shoWn in FIG. 2, the rearWard end 18 of housing 12 is
`stepped doWnWardly as it eXtends rearWardly to form a
`horiZontal upper step 42 and a horiZontal loWer step 44.
`Conveyor track 36 eXtends over the loWer step 44, as shoWn
`in FIGS. 1 and 2, With the upper edge of the conveyor track
`at substantially the same height as upper step 42. This
`permits the use of a specimen tube rack 46 on upper step 42
`to receive and retain a plurality of test tubes 40 as a buffer
`betWeen the conveyor track 36 and the storage area 28. An
`automated gate 48 is provided proximal to conveyor 36 to
`selectively stop a specimen carrier 38 under IOU 32 to
`permit the insertion or removal of a test tube 40 by robotic
`arm 34.
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`Daifuku Exhibit 1015, Page 7 of 9
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`3
`Rack 46 on upper step 42 serves as a buffer 50 to permit
`rapid insertion and retrieval of test tubes 40 from rack 46 to
`and from specimen carriers 38 as they travel on conveyor
`track 36. Storage area 28 of LOU 10 serves to store and
`archive large quantities of test tubes 40 and operates at a
`much sloWer speed. In this Way, buffer 50 permits the
`conveyor track 36 to maintain its high rate of speed for
`transport of specimen carriers 38, While permitting the sloW
`speed of the operation of storage and retrieval of test tubes
`from the storage area 28.
`As shoWn in FIG. 2, a plurality of trays 52 are operably
`supported and moved betWeen a pair of serpentine chains 54
`(only one being shoWn in FIG. 2) engage around a plurality
`of cogs 56. The upper end of storage area 28 is open into the
`IOU 32, to permit robotic arm 34 to insert and retrieve test
`tubes from trays 52 as the trays are positioned along the
`upper end of storage area 28.
`Referring noW to FIG. 4, one storage tray 52 is shoWn in
`greater detail. Tray 52 includes opposing upright ends 58
`and 60, each end 58 and 60 having a projection 62 adjacent
`the upper end thereof for removable connection to the
`serpentine chains 54. As shoWn in FIG. 4, this connection
`could take the form of a projecting pin 64 on chain 54, With
`a receiver slot 66 formed in the projection. Thus, each tray
`52 is suspended from a pair of opposing pins 64 betWeen
`serpentine chains 54, to maintain the tray 52 in an upright
`position as it is moved through the serpentine pattern Within
`the storage area 28, shoWn in FIG. 3. Each tray 52 includes
`forWard and rearWard vertical Walls 68 and 70, as Well as a
`bottom 72, to support a conventional specimen rack 46
`therein. A cut-out 74 in forWard Wall 68 is provided gener
`ally centrally therein to reveal the bar code 76 imprinted on
`a label on the particular specimen rack 46. In this Way, a bar
`code reader 78 can identify and locate a particular specimen
`rack 46 on a tray 52.
`Referring noW to FIG. 3, it can been seen that chains 54
`and cogs 56 are arranged Within storage area 28 to form a
`substantially horiZontal ?ight 80 of chains 54 along the
`upper end of storage area 28. This permits access by robotic
`arm 34 from IOU 32 into the trays 52 Which are supported
`along upper ?ight 80 in the open upper end of storage area
`28.
`The U0 station 30 in the forWard upper end of housing 12
`includes an access door 82 of the siZe to permit a specimen
`rack 46 to be inserted or retrieved from a tray 52 positioned
`under the access door 82. Bar code reader 78 is preferably
`mounted in housing 12 to read the bar code on the specimen
`rack 46 upon the insertion of the rack 46 into a tray 52
`through access door 82.
`Referring once again to FIG. 1, I/O station 30 also
`includes a keyboard 84 and monitor 86 to permit the input
`of information regarding a specimen rack, as Well as opera
`tions of the LOU.
`Referring noW to FIG. 5, a second embodiment of the
`LOU is designated generally at 110 and is shoWn With a
`conveyor track 136 positioned along one side Wall 126 of the
`housing 112, rather than adjacent the rearWard end as in the
`?rst embodiment. The second embodiment of the LOU 110
`includes a secondary storage unit 188 in operable commu
`nication With the storage area 128 of housing 112. This
`secondary storage unit 188 includes the same serpentine
`chains 154 and trays 152 as the main housing 112 and the
`preferred embodiment of the invention. Secondary storage
`unit 188 also permits the possibility of providing refriger
`ated storage if so desired.
`Whereas the invention has been shoWn and described in
`connection With the preferred embodiments thereof, many
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`modi?cations, substitutions and additions may be made
`Which are Within the intended broad scope of the appended
`claims.
`We claim:
`1. A laboratory organiZer unit for inserting and retrieving
`specimen containers from a conveyor system, comprising:
`a housing having upper and loWer ends, forWard and
`rearWard ends, and opposing sides;
`a storage area Within the housing, including a rack for
`receiving and storing a plurality of vertically oriented
`specimen containers;
`a buffer area on the housing, including a rack for receiving
`and storing a plurality of vertically oriented specimen
`containers;
`a conveyor site for receiving a conveyor track in a
`predetermined position relative to the housing; and
`a transfer apparatus for selectively moving a specimen
`container betWeen the storage area and buffer area and
`betWeen the buffer area and the conveyor site.
`2. The laboratory organiZer unit of claim 1, Wherein said
`organiZer unit is electronically connected to a central pro
`cessor for processing data relative to specimen containers
`being used by the organiZer unit, and further comprising a
`user station on the housing, including a data input apparatus
`for inputting data to the central processor relative to racks
`inserted in the storage area.
`3. The organiZer unit of claim 2, Wherein said transfer
`apparatus includes a robotic arm electronically connected to
`the central processor and operable to move vertically and
`horiZontally to transfer specimen containers among the
`storage area, buffer area, and conveyor site.
`4. The organizer unit of claim 3, Wherein said storage unit
`includes a plurality of separate racks, each rack having
`means for receiving and retaining a plurality of specimen
`containers in upright positions.
`5. The organiZer unit of claim 4, Wherein each storage area
`rack is supported on a tray, each tray being operably
`mounted on a continuous loop chain for selective movement
`Within the storage area.
`6. The organiZer unit of claim 5, Wherein said storage area
`is enclosed Within said housing, including opposing forWard
`and rearWard ends, a bottom, opposing sides, and an open
`upper end permitting access to specimen containers in at
`least one of said racks.
`7. The organiZer unit of claim 6, Wherein said continuous
`loop chain has a portion formed in a serpentine pattern, such
`that the trays are moved through a central portion of the
`storage area in addition to movement along the ends and
`sides of the storage area.
`8. The organiZer unit of claim 7, Wherein each rack
`includes an identi?cation code therein, and further compris
`ing a reader mounted on the housing and connected to the
`central processor, for reading each identi?cation code as the
`racks move Within the storage area.
`9. The organiZer unit of claim 8, Wherein the user station
`includes an operable access door in the housing permitting
`selective access to the storage area and at least one tray
`Within the storage area.
`10. The organiZer unit of claim 1, Wherein said storage
`unit includes a plurality of separate racks, each rack having
`means for receiving and retaining a plurality of specimen
`containers in upright positions.
`11. The organiZer unit of claim 10, Wherein each storage
`area rack is supported on a tray, each tray being operably
`mounted on a continuous loop chain for selective movement
`Within the storage area.
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`Daifuku Exhibit 1015, Page 8 of 9
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`12. The organizer unit of claim 11, wherein said storage
`area is enclosed Within said housing, including opposing
`forWard and rearWard ends, a bottom, opposing sides, and an
`open upper end permitting access to specimen containers in
`at least one of said racks.
`13. The organiZer unit of claim 12, Wherein said continu
`ous loop chain has a portion formed in a serpentine pattern,
`such that the trays are moved through a central portion of the
`storage area in addition to movement along the ends and
`sides of the storage area.
`14. The organiZer unit of claim 13, Wherein each rack
`includes an identi?cation code therein, and further compris
`ing a reader mounted on the housing and connected to the
`central processor, for reading each identi?cation code as the
`racks move Within the storage area.
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`15. The organiZer unit of claim 14, Wherein said continu
`ous loop chain has a portion formed in a serpentine pattern,
`such that the trays are moved through a central portion of the
`storage area in addition to movement along the ends and
`sides of the storage area.
`16. The organiZer unit of claim 11, Wherein each rack
`includes an identi?cation code therein, and further compris
`ing a reader mounted on the housing and connected to the
`central processor, for reading each identi?cation code as the
`racks move Within the storage area.
`17. The organiZer unit of claim 11, Wherein the user
`station includes an operable access door in the housing
`permitting selective access to the storage area and at least
`one tray Within the storage area.
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`*
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`Daifuku Exhibit 1015, Page 9 of 9