Packaging and devices to access screw-top containers in automated systems

Abstract

The present invention relates to a system for access and retrieval of screw-top containers. In one embodiment, the system includes a tray with a plurality of apertures, the tray adapted to receive containers having a cap and a body such that each cap of each container pressed into the tray rests above a respective aperture in the tray and each body is suspended below the tray. The system also includes a rotary tool having a cavity extending from an opening at one end, the cavity defined by an interior surface that includes engagement features. The engagement features on the interior surface of the rotary tool are adapted to engage onto at least a portion of the body of the container surface defined by complementary engagement features when the rotary tool is inserted over the body of the container from below the tray.

Claims

1. A system to access and retrieve screw-top containers, the system comprising: a tray including a plurality of apertures extending therethrough, at least one of the apertures having a container therein, each container having a cap and body such that each cap of each container placed into the tray rests above a respective aperture in the tray and each body is suspended below the tray; a rotary tool comprising a cavity extending from an opening at one end of the rotary tool, the cavity defined by an interior surface wherein the interior surface comprises engagement features, the rotary tool further comprising a socket member having a length between a first end and a second end, a first cavity in the socket member having a first cross-section extending longitudinally from the first end toward the second end and a second cavity in the socket member having a second cross-section extending longitudinally from the second end toward the first end, an inner surface defining a circumference of the second cavity wherein the engagement features are located on the inner surface proximate the second end, wherein the first and second cavity abut one another to define a single passage through the socket member or are separated from one another; and the rotary tool further comprising a handle portion and an engagement portion, the engagement portion having a cross-sectional shape adapted to fit within the first cavity in the socket member; wherein the engagement features on the interior surface of the socket member and on a surface of the body of the container are longitudinally oriented splines.

2. The system of claim 1, wherein the socket member is cylindrical in shape and includes two recessed portions along its length, each recessed portion including anti-rotation features.

3. The system of claim 2 further comprising a socket holder, the socket holder including an upper and lower flange extending from a central portion in a transverse direction, each flange including an edge with recesses adapted to secure the recessed portions of the socket member within.

4. The system of claim 1, wherein the tray and the cap of each container are monolithic.

5. The system of claim 1, wherein a shape of a surface of the tray proximal to each aperture is adapted to guide the body of the container into the cap above the surface of the tray.

6. The system of claim 1, wherein an outer circumferential surface of the cap of each container includes knurling that provides resistance to rotation when positioned in the tray, wherein the tray has tubular extensions sized to interact with the cap of each container surrounding the respective aperture, and wherein an interior surface of each tubular extension includes knurling.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 illustrates a first embodiment including a tray holding a plurality of tubes, and a rotary tool and a tube is also shown as it appears outside of the tray.

(2) FIG. 2 illustrates a container holder for placement of the tube of the first embodiment illustrated in FIG. 1.

(3) FIG. 3 illustrates a second embodiment including a tray holding a plurality of tubes and a socket member with rotary tool inserted over one of the tubes. The socket member is illustrated in phantom.

(4) FIG. 4 illustrates three of the individual socket members illustrated in FIG. 3 placed in a socket holder. Two of the socket members shown include a decapped tube disposed therein while the third socket member is empty.

DETAILED DESCRIPTION

(5) The systems and methods described herein relate to trays and devices such as rotary tools that can be used together to remove bodies of containers from their respective caps so that the caps remain in the tray once the body is removed.

(6) As used herein, “upward” means a side of a tray exposed to top surfaces of container caps.

(7) As used herein, “sample” means a quantity of material from a biological, environmental, medical, or patient source in which detection or measurement of target cells, particles, beads, and/or analytes is sought. The term “sample” encompasses biological samples, e.g., a quantity of blood, a microbiological culture, or the like; environmental samples, e.g., a soil or water sample; medical samples or specimens, e.g., a quantity of blood or tissue; or the like. Preferably, a sample is a human blood sample. The terms “sample” and “specimen” are used interchangeably.

(8) As used herein, “container” means any suitable vessel for receiving samples or specimens, as well as reagents for testing or preserving such samples or specimens. Such samples, specimens, and reagents can be in liquid or dry form. Containers or vessels can also be referred to as tubes, cuvettes, test wells, etc. The present invention is not limited to any type of container or any type of contents. In fact, in certain embodiments of the apparatus described herein the container used in conjunction with the apparatus can be empty.

(9) In one aspect the present invention relates to a system adapted to remove a body of a container from a respective cap suspended by a tray and transport the container for pipetting or another use at different location. One embodiment of the first aspect is illustrated in FIG. 1. At a minimum, the system includes a rotary tool 20 and a tray 30 for storing a plurality of tubes 10.

(10) Tubes 10 as shown in FIG. 1 include a body 12 and a cap 16. The cap of each tube is attached to the body via a screw thread 14. That is, each of an interior surface of the cap (not shown) and a corresponding exterior surface of the body includes a screw thread. A surface on the body of each tube further includes splines 13 oriented in a longitudinal direction. In a variant, the surface can include another feature in place of splines that provides an anti-rotation function when interlocked with a container having the same feature. One example of a tube is a reagent tube by Axygen.

(11) Rotary tool 20 is cylindrical in shape and is sized to accommodate the size of tubes to be retrieved. For example, a length of the rotary tool can be adapted to any anticipated use with particular instrumentation or tube/container sizes. The rotary tool includes an opening at one end so that a portion of the length has a ring-shaped cross section with a substantially constant thickness. The thickness of the rotary tool is limited to allow it to fit between tubes in an array of tubes in a tray, as applicable. Further, on an interior surface 21 defining the outer bounds of a cavity extending from the opening of tool 20 are longitudinally oriented splines 22 designed to engage with capped tubes 10 suspended in tray 30. These are shown in FIG. 1 near the opening of tool 20 but can be placed further into the cavity of the tool as desired depending on the features of a tube sought to be retrieved. In a variant, the splines can be protrusions or other features known in the art that interlock with a tube having the same feature. In other variants, the splines can be located on a bottom surface of tube 10 and a bottom surface within the cavity of tool 20. When these surfaces make contact, the engagement ensures that each element moves in unison as the rotary tool is activated.

(12) Splines 22 couple with matching splines 13 on the surface of body 12 of each tube 10. When tool 20 is placed over tube 10 and the splines are longitudinally aligned, the shape of the respective splined surfaces produce an interlocking feature restricting rotational movement of the body of the tube relative to the tool. Thus, once the respective components are interlocked or otherwise engaged, any rotation of the tool produces a corresponding rotation of the body of the tube.

(13) In FIG. 1, tray 30 holds a plurality of tubes 10 in suspension. The tray is substantially rectangular in shape and includes upward facing flanges 31 around a perimeter. A top surface 32 includes apertures (not shown) for the placement of tubes therethrough. Typically, and as shown, these apertures are positioned in an array to provide for uniform spacing and a rectilinear arrangement of stored tubes. Surrounding the location of each aperture is a tubular extension 34 extending upward from top surface 32 of the tray. Tubular extension 34 has a constant thickness around its circumference sufficient to ensure structural integrity while tubes are stored, but is thin enough that the top surface of the tray is exposed and no tubular extensions are in contact with one another. An inner diameter of the tubular extension is large enough for body 12 of tube 10 to pass therethrough and for cap 16 of the tube to fit within. Tubular extension 34, and also the tray, are made of a deformable material such as molded plastic that allows tubular extension 34 to stretch upon placement of the tube into the tray. The inner diameter of the tubular extension is larger than a diameter of the corresponding aperture in the tray to ensure there is sufficient structure to support a cap while a tube is stored in the tray. In one variant, the tray can include lead-in features around the apertures in the tray that guide body 12 of the tube into the apertures of the tray as they are returned into the tray for storage after use.

(14) Each tube 10 is suspended in tray 30 so that the cap rests on top surface 32 of the tray within tube extension 34 and body 12 of the tube secured to cap 16 is suspended and exposed underneath a bottom surface of the tray (not shown). Tubes 10 are supported by and suspended from the tray so that a length of each tube 10 is perpendicular to top surface 32 of the tray. As described above, each tube 10 includes splines 13 for engagement with rotary tool 20. When the capped tube is stored on the tray so that its cap rests on the top surface 32 of the tray, the splines of each tube 10 are accessible from underneath tray 30 as there is no obstruction of the tubes from directly below the tray. Therefore, the rotary tool can be positioned directly under the tube should retrieval of the tube body be desired.

(15) In a variant, the system also includes a container holder 40 as illustrated in FIG. 2. The container holder shown is of a rectangular shape with a top surface 42 having six apertures 44 extending therethrough. Of course, alternatives can include container holders defined by other shapes and less or greater than six apertures. The apertures are sized to fit the cross sectional area of tubes 10 and include screw threads 46 on an interior surface defining a circumference of each aperture. Screw thread 46 allows screw thread 14 of body 10 of a retrieved tube to be secured to container holder 40. The container holder is an aluminum plate. Alternatively, other materials known to those of ordinary skill in the art can be used.

(16) In one embodiment, the tray is injection molded with apertures sized to fit Axygen brand O-ring caps used in conjunction with Axygen ST-150 tubes. The tray is further sized to fit three six-tube sets of tubes at 18 mm spacing.

(17) In another embodiment, the caps of the tubes include anti-rotation knurling on an outer circumferential surface 17 (FIG. 1 illustrates location of outer circumferential surface as shown in an embodiment described above). An inner surface of the tubular extensions surrounding each aperture in the tray also include anti-rotation knurling, so that that cap resists rotation when the rotary tool is rotated to remove the body from the cap.

(18) In another embodiment, the tray can include extensions surrounding each aperture with perimeters that are polygonal or otherwise non-circular in shape in place of the tubular extensions. The dimensions of the extension in such embodiments is sufficient to support any forces from the cap inside the extension as the body of the tube is rotated for removal. In other embodiments, the flange on the outside perimeter of the tray is at an acute or oblique angle or has a non-linear cross section along its length. In other embodiments, the tray and the caps can be monolithic. In others, the tray can also include a handle member for carrying the tray. In further embodiments, the tray can include an available surface for identification of contents in the tubes stored in the apertures of the tray.

(19) In other embodiments, the rotary tool can have a non-cylindrical shape and/or a non-cylindrical cavity to accommodate a shape of the container used. In another embodiment, the interior surface of the rotary tool can include engagement features other than splines such as other protrusions as referenced above or recesses. Similarly, protrusions other than splines or other engagement features can be included on the surface of the body of each tube.

(20) In another embodiment of the first aspect, the system includes a socket member 150, a socket rotary tool 160 and a tray 130. The socket member as shown in FIG. 3 has a substantially cylindrical shape. The diameter of the socket member is the same at each end 151 and in a central portion, but also includes two recessed cylindrical portions 152 separating the end portions from the central portion. Within the recessed portions are anti-rotation features 158, visible in FIG. 4. The socket member also includes openings extending from each longitudinal end. At one end is an opening with a hexagonal cross-sectional shape 154 extending into the socket member 150 in a longitudinal direction over a first length and defining a first cavity, as shown in FIG. 3. In a variant, the cross section of the opening over the first length can be any polygonal shape. From another end is a circular cross-sectional shaped opening 156 extending into the socket member in a longitudinal direction over a second length and defining a second cavity. On an interior surface of the circular section opening, defining the outer bounds of the cavity circumference, are longitudinal splines 157 as shown in FIG. 4. The first cavity corresponds with socket rotary tool 160, described in greater detail below, and the second cavity corresponds with tube 110. Further, longitudinal splines 157 correspond with splines 113 (FIGS. 3 and 4). In the depicted embodiment, hexagonal opening 154 and circular opening 156 do not overlap or make contact. However, it is contemplated that the cavities can abut one another to define a single passage through the socket member. The socket member is made of stainless steel. In a variant, the material of the socket member can be any known to those of skill in the art.

(21) Socket rotary tool 160 includes a handle portion 162 and an engagement portion 164. As shown in FIG. 3, the engagement portion is a structural member with a hexagonal section sized to fit into the first cavity through hexagonal opening 154. This type of engagement portion is sometimes referred to as a hex drive shaft. At one end, the engagement portion includes a tapered tip. Handle portion 162 is substantially cylindrical in shape but includes a flat portion towards an outer end for gripping purposes. At an inner end of the handle portion is a flat surface beveled at the edges from which engagement portion 164 extends. Of course, contours of the handle portion and interface with the engagement portion can be modified based on knowledge of one of ordinary skill in the art.

(22) As in FIG. 1, FIG. 3 also shows tray 130 holding a plurality of tubes in suspension. The tray and structure for holding tubes is the same as described in the embodiment above. Circular opening 156 of socket member 150 is shaped to slide and otherwise fit over a body 112 of each tube 110 as in the above embodiments.

(23) In a variant, the system shown in FIG. 3 can also include a socket holder 170, as shown in FIG. 4. The socket holder is a storage instrument that can hold socket members 150. This can be for various purposes, including pipetting. Because each tube body can be held within a socket member, the storage of socket members also allows for the storage of decapped tubes, as shown. Socket holder 170 includes an upper flange 172 and a lower flange 174, both extending from a central portion 171. Each flange includes an outer edge with recessed or otherwise jagged portions 173 along its length. Recesses 173 are shaped to accommodate recessed cylindrical portions 152 of the socket member. A neck in recessed edge 173, combined with anti-rotation features 158, allows socket members to be secured to the socket holder when pressed into flanges 172, 174. When stored in the socket holder, each end portion 151 of the socket member rests entirely outside flanges 172, 174. When in place in the socket holder, the socket member is restrained from any rotational movement and any movement along its longitudinal axis. The socket holder is made of a stainless steel sheet. Alternatively, it can be made of any material known to those of skill in the art.

(24) In another embodiment, each of the first cavity and the second cavity can have any cross-sectional shape and together can define any combination of cross-sectional shapes. For example, the first cavity can have an octagonal cross-section and the second cavity can have an elliptical cross section. As with the rotary tool and tubes described above, it is contemplated that the socket member can include any type of engagement feature on its interior surface. Similarly, the engagement portion of the socket rotary tool can be any shape corresponding to the first cavity of the socket member.

(25) In any one of the above embodiments, the tray and the container holder or socket holder can be housed within an instrument. In some embodiments, the tray can be housed within an instrument while the container holder or socket holder are not, and vice versa.

(26) In any one of the above embodiments, the rotary tool or socket member can be connected to an automated device to mechanically control the movement of the rotary tool or socket member. For example, a three axis robotic arm attached to the rotary tool can be controlled to transport the rotary tool below a tube, slide it over a body of the tube and then cause the tool to rotate to remove the body from a cap of the tube.

(27) In other embodiments, the socket member and/or socket rotary tool can have a non-cylindrical shape. The socket member can further include a non-cylindrical cavity extending from a non-circular opening over the second length to accommodate a shape of the container used.

(28) Advantages of the system include that fewer elements are needed to access a reagent or sample from storage than with known systems. For example, no motor is needed in the embodiments described herein and there is no cap-grabbing mechanism needed. Moreover, the space required for the tray, rotary tool or socket member and containers is minimal, particularly compared with known systems. The system is also simple. A container body can be retrieved with a cap removed through one removal step using a rotary tool. No additional mechanisms or elements are required to address cap removal specifically.

(29) With regard to the socket member embodiment specifically, one advantage is that the circular opening in the socket member is located high above a surface of the top flange of the socket holder when held in place by the socket holder. This reduces the risk of contamination.

(30) In another aspect, the invention relates to a method of decapping containers by removing the body of a container from a tray holding a capped container in suspension. The body of the container is then placed in another location for pipetting or another use. The entire process is performed using tools as described herein.

(31) In one embodiment, one or more capped tubes are obtained. The tubes are pressed into open apertures on top surface 32 of tray 30, body 12 side first, until a top surface of cap 16 is flush with a top surface of tubular extension 34 and locked in place with an anti-rotation feature as described above. In this position, the inserted tube is suspended from the tray, as shown in FIG. 1. Rotary tool 20 is then obtained and longitudinally aligned with a tube that a user intends to decap (“desired tube”). The rotary tool is then slid over the desired tube until splines 13 of the desired tube are no longer visible.

(32) With rotary tool 20 in place over the desired tube (e.g., 10 in FIG. 1), the user rotates the rotary tool in a counterclockwise direction until body 12 of tube 10 is removed from cap 16. All that is needed to hold the body of tube 12 upright is rotary tool 20 itself. The rotary tool holding the body of the tube is then transferred to another location as desired.

(33) In a variant, the user can transfer tool 20 holding the tube to container holder 40 for storage or pipetting. The user positions rotary tool 20 directly below an aperture 44 in the container holder and moves the tool upward until a top surface of the body of the tube contacts edges of the aperture in the container holder. The user then rotates the tool in a clockwise direction and screw threads 14 of the tube interact with screw threads 46 on the surface of the insertion aperture. The tool is rotated until the body of the tube is secured to container holder 40 and at least a portion of the body is exposed above container holder surface 42, as shown in FIG. 2. Once secured, a user can access the contents of each tube as desired. For example, pipetting can be done with the tubes secured to the container holder.

(34) In another embodiment, socket member 150 and socket rotary tool 160 are used to retrieve body 12 of tube 10. First, the tubes are pressed through apertures 134 in a surface 132 of the tray and suspended therefrom as described above. Then, socket rotary tool 160 is engaged to socket member 150 by inserting the hexagonal drive shaft of engagement portion 164 into hexagonal opening 154 of the socket. The combined socket member and tool are then slid over body 112 of the tube sought to be decapped and retrieved. As in the above embodiment, socket member 150 is slid over body 112 until splines 113 on the surface of the tube match splines 156 within the circular opening of the socket member. Socket rotary tool 160 is then rotated counterclockwise until body 112 of the tube is removed from cap 116.

(35) As in the previous embodiment, the tube can be transported as desired. In a variant, socket member 150 holding the tube can be placed into socket holder 170 for pipetting or temporary storage as shown in FIG. 3. Recesses 173 on the outer edge of the flanges of the socket holder provide means for the socket member to be clipped in. This is achieved by placing recessed portions 152 of the socket member into recesses 173 on the edge of the flanges. In particular, anti-rotation features 58 on recessed portions 152 of the socket member, when clipped into flange recesses 173, form an interlocking connection with recesses 173. This connection ensures that the socket member does not rotate and that it does not move relative to a longitudinal axis of the socket member. To achieve this connection, the user presses the socket in, and lowers the socket to obtain engagement with the anti-rotation features. To leave the socket in place, the user continues to lower the socket rotary tool until it disengages from the socket member.

(36) In any one of the above embodiments, the automated device can be used to control the movement of either the rotary tool or the socket member. In particular, the automated device can control the rotary tool or the socket member to remove the body of the tube from the tray and then transfer it to another location. The automated device can also perform the same steps in reverse and place the body of the tube back into the cap in the tray.

(37) In any one of the above embodiments, the tubes placed into the tray can be filled with a reagent or sample prior to placement. In still further embodiments, any given tray can store tubes that hold different reagents or samples. In a variant, when more than one reagent or sample type is stored on a tray, tubes holding common reagents or samples can be retrieved together so that each type of reagent or sample can be analyzed separately and the risk of contamination is reduced.

(38) In any one of the above embodiments, color coding can be used for the tubes to aid in identifying types and quantities of reagents or samples taken from the tray.

(39) In other embodiments, if the reagents or samples in the plurality of tubes can cause contamination if mixed or spilled, then each tube may be transferred to a location other than a container holder for pipetting so that each individual tube can be analyzed separately. Alternatively, a socket member can retrieve a tube body as described above and transfer the retrieved tube body to a socket holder via the socket member, thus minimizing the risk of contamination.

(40) In any one of the above embodiments, the tubes filled with reagents or samples can be kept in cold temperature storage. Generally, cold temperature storage improves shelf life of reagents or samples disposed within the tubes.

(41) The above methods can be performed with any embodiment of the systems contemplated herein.

(42) Advantages of the method described include that fewer steps are required to retrieve an opened body of a container from a tray to transport it to another location for pipetting or another use. For example, one step that is no longer required is the removal of a cap prior to removal of the body of the container. This advantage of not having to perform this step is magnified by the fact that known methods also required a recapping step to place the container into storage after use. With the methods herein, both of these steps are no longer necessary.

(43) Other advantages include that the risk of error is lower with the methods described herein because fewer steps are required than those previously understood to be necessary. For similar reasons, the risk of contamination is also reduced. In some embodiments, the use of cold temperature storage increases the volume of reagent or sample that can be stored in one container, thus lowering cost.

(44) Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims.