Patent Description:
Chemical analysis and processing is often carried out in sample tubes that may be capped and stored in arrays in racks of, for example, <NUM> to <NUM> tubes each. Historically, capping and decapping of tubes was accomplished individually by hand, but more recently, automated systems for capping and decapping entire arrays, or rows within an array, have been introduced. Yet another option is use of hand-held devices that cap and decap an entire row of an array. <CIT> discloses a hand-held capper and decapper device in accordance with the preamble of claim <NUM>.

The manual process of decapping sample tubes, pipetting a sample from or to the tubes, and recapping the sample tubes is a very repetitive process. As such, there is a danger of repetitive strain injury. The disclosed hand-held capper/decapper device is intended to simplify capper/decapper operations and to minimize repetitive strain.

A hand-held capper/decapper device may comprise a housing configured to be held by hand against an array of threaded receptacles such as sample tubes. An array of cap drivers is supported by the housing, and the drivers are configured to engage and retain threaded caps. A motorized rotary drive drives the cap drivers in forward and reverse rotary directions to cap and decap the caps on and from the threaded receptacles. Ejector pins supported by the housing extend through the cap drivers. Motorized linear drive translates the ejector pins through the cap drivers to eject caps from the cap drivers. A motor controller controls the motorized rotary drive and the motorized linear drive in response to a control button on the housing. The controller is configured to control and alternate between a decap function and a cap function with each press of the control button. In the decap function, the motorized rotary drive drives the cap drivers in a reverse rotary direction to decap the threaded receptacles. In the cap function, the motorized rotary drive drives the cap drivers in a forward rotary direction to cap the threaded receptacles, and then the motorized linear drive translates the ejector pins through the cap drivers, to eject the caps from the cap drivers, and retracts the ejector pins. Thus, the device allows for single button operation.

The hand-held device may further include an eject button on the housing. The motor controller responds to press of the eject button to cause the motorized linear drive to drive the ejector pins through the cap drivers and to then retract the ejector pins. The controller then enters a state to perform the decap function with next press of the control button.

In the decap function, the motorized rotary drive may rotate in a forward direction to engage the cap drivers to the caps prior to driving the cap drivers in the reverse rotary direction.

The cap drivers may be supported in a cartridge that is removably attached to the housing. The cap drivers engage the ejector pins in order to be rotated by the motorized rotary drive through the ejector pins. The ejector pins may be driven in a single fixed stroke length, and the cap drivers in the cartridge may be of lengths that complement depths of cap recesses to control depth of stroke length within the caps. The cartridge may be retained on the housing by magnets.

The cap drivers may float vertically against compression springs. The motorized linear drive may be of fixed stroke length and the drive may engage one set of ejector pins prior to another set of ejector pins. The motorized rotary drive may comprise individual rotary motors, each coupled to an ejector pin, to drive the cap drivers through the ejector pins, and the motorized linear drive may comprise a common linear motor that translates all ejector pins.

In a method of using the device, cap drivers on a hand-held device are positioned against threaded receptacles. With a single button on the hand-held device, motorized rotary drive of the cap drivers and motorized linear drive of ejector pins is controlled by the motor controller. The controller alternates between decap and cap functions, and controls each function, with each press of the control button.

<FIG> illustrates a hand-held capper/decapper having eight cap drivers <NUM> extending from one end of a housing <NUM> and a handle <NUM> at the opposite end of the housing. Other numbers of cap drivers may be provided but eight is best suited to most applications. Control of the capper/decapper operation can be performed with a single control (action) button <NUM>, but an additional eject button <NUM> may also be included. The capping (C) or decapping (D) state of the device can be determined from LED indicators <NUM> and <NUM>, respectively, at the top end of the device <NUM> (<FIG>). Also shown are a battery level indicator <NUM> and a charging port <NUM>. Ejector pins <NUM> extend through the drivers <NUM> for ejecting caps or capped tubes from the device.

In operation, as illustrated in <FIG>, the cap drivers with ejector pins are aligned with a row of caps <NUM> having threaded portions <NUM> to be threaded into complementary threads of sample tubes or other receptacles. The caps may be in a rack of caps ready for use or they may be on capped sample tubes prior to a decapping operation. In either case, the hand-held device is aligned with the caps and set against the caps. <FIG> shows a hand-held device <NUM> being aligned with a row of caps <NUM> on a rack <NUM>.

<FIG> is an enlarged view of the end of the housing <NUM> with cap drivers <NUM> being aligned with a row of caps <NUM> on the rack <NUM>.

In <FIG>, a device <NUM> is set against a row of caps <NUM> with the cap drivers <NUM> pressed against the caps. To engage the caps, the control button <NUM> is pressed and released to initiate the decap process. The device <NUM> then automatically rotates the cap drivers briefly in a clockwise direction to align the cap driver features <NUM> with spaces between features in the cap recesses, allowing the cap drivers to be pressed by spring force into the recesses with light friction fit. Thereafter, in a common sequence for both picking up caps from a rack and decapping, the cap drivers are rotated in a counterclockwise direction. That counterclockwise rotation may not be required when removing the caps from a rack of caps if the rack is not threaded, but it is performed to simplify programming of the device as discussed below.

In <FIG>, the caps <NUM> are shown retained by the cap drivers <NUM> at the end of the housing <NUM>. A panel of the housing is removed to show the interior of the device to be discussed below. As shown, the row of ports <NUM> of the rack <NUM> are left empty.

<FIG> shows the device <NUM> being aligned with a row of uncapped sample tubes <NUM> in a rack <NUM> in preparation for capping the tubes with the row of caps <NUM>.

<FIG> is a flowchart of programmed operation of the electronic controller, which is likely a microprocessor, within the device <NUM>. The device need only perform two primary functions: decapping and capping (including recapping) sample containers. Two secondary functions, picking up caps from a rack and ejecting caps such as into a waste bin, can be performed by decapping and capping functions, respectively. All four operations can be performed by pressing the single control button <NUM> once for each of successive operations. With single button control, the eject function is performed using the recap function, which itself includes an eject of the capped tube. However, a second button <NUM> may be provided solely for eject where it is preferred that the cap drivers not be rotated during the eject function.

After the device is powered on at <NUM>, the LED (D) at the end of the device <NUM> is lit. When the action button <NUM> is first pressed and released at <NUM>, the device enters the decap function <NUM>. Individual cap driver motors are rotated clockwise to align the features <NUM> with spaces between features in cap recesses so that the cap drivers <NUM> may press into the cap recesses under spring force to be described below. Because of different orientations of the caps, the cap drivers will be pressed into respective caps at different times. The cap driver motors then rotate counterclockwise to decap the tubes or to remove the caps from the cap tray. The LED (C) is turned on and the LED (D) is turned off at the end of the decap function to indicate that the device is prepared for a capping (recap) function.

The device can be set in the recap function after decap because only one of two functions will occur with the caps retained on the cap drivers: either recap to place the caps back on the sample tubes or eject to dispose of the caps. As noted above, because the recap function <NUM> includes an eject step after the caps are threaded onto the sample tubes, the recap function can serve the eject function, albeit with an unnecessary rotary drive of the cap drivers. Alternatively, while the device is in the C mode ready for capping, the eject button can be pressed, and ejection at <NUM> is followed by return to the D mode.

In capping (recapping) tubes, the caps already retained on the cap drivers are pressed against the sample tubes. The action button <NUM> is pressed at <NUM> and released. In the recap function <NUM>, each cap driver motor is turned clockwise to free the features <NUM> and allow the cap drivers <NUM> to be set into the cap recesses, and to then thread the caps onto the tubes. Because the threads on the caps and the sample tubes may be in different orientations, the caps will likely be completely threaded onto the sample tubes at different times. To account for those different times, the individual motors that drive the cap drivers stall out when a proper capping torque is reached.

The caps are friction fit to the cap drivers. To remove the device from the caps on the capped sample tubes without requiring the user to apply a pulling force, the ejector pins are extended to push the individual cap drivers off of the caps and thus off of the capped tubes. The ejector pins are then retracted for the next decapping operation, and the LED (C) is turned off as the LED (D) is turned on to complete the recap function.

With the cap drivers now free of any caps, the next operation will require that a cap be picked up, either from a cap tray or from a row of capped sample tubes. As noted, the decap function is used for removing caps from a cap tray, so the device is properly placed in the decap mode (D), prepared for the decap function when the action button is again pressed.

When the eject button <NUM> is pressed at <NUM>, the device would likely have just completed the decap function and have caps retained on the cap drivers, but it may be pressed after power on, after the decap function, after the recap function, or even after a prior eject function. After following the decap function, caps retained on the device are ejected. After the other functions, the device harmlessly proceeds through the eject function <NUM>. In the eject function <NUM>, the ejector pins are extended under motor control to push caps off of the cap drivers. In this motorized ejection, the user need not provide any force other than pressing and releasing the eject button. After the motorized ejection, the ejector pins are retracted, the LED (C) is turned off and the LED (D) is turned on to indicate that the device is free of caps and ready for the decap function.

With a motorized rotation of the cap drivers and motorized linear drive of the ejector pins, simple one button operation with little physical input by the user is possible. The optional eject button allows for the eject function without rotation of the cap drivers, thus saving power and time.

<FIG> is a flow chart of device operation where an eject button is not included. The decap function <NUM> and recap function <NUM> are identical to those of <FIG>. The eject function is eliminated. As previously noted, that function can instead be performed by the recap function <NUM>.

The internal structure and operation of the device <NUM> will now be described.

To allow for ready use with different styles of caps, the eight cap drivers <NUM> are supported in a cap driver cartridge <NUM> of <FIG> and are replaceable within that cartridge. The cap drivers <NUM> include splines <NUM> at their upper ends and the cap drives are rotated by drive hubs <NUM> (<FIG>) that protrude from the housing <NUM> and that fit between the splines. To mate the cartridge <NUM> to the housing <NUM>, the cartridge is moved toward the housing <NUM> over the ejector pins <NUM>. The ejector pins pass through center holes that extend the lengths of the drivers <NUM> within the cartridge <NUM>.

<FIG> shows a side panel removed from the housing <NUM> to show the drive hubs <NUM> that fit into the splines <NUM> of the cap drivers <NUM>. The ejector pins <NUM> extend through and are able to translate through the hubs. When the cartridge <NUM> is fully displaced upward against the base of the housing <NUM>, it is retained there by magnets <NUM> attracting retention plates <NUM> at either end of the cartridge. Thus, the cartridge <NUM> can be easily removed from the housing <NUM> by simply pulling it away with sufficient force to overcome the strength of the magnets, and a new cartridge with a different style of caps drives can be readily installed. The cap drivers in the cartridge may also be replaced as described below to allow a cartridge to be adapted to different cap styles.

In <FIG>, the cartridge <NUM> is retained by the magnets against the base of the housing <NUM>. In this position, the ejector pins <NUM> extend completely through the cap drivers <NUM> and the cap driver splines <NUM> are positioned to either side of respective drive hubs <NUM>.

<FIG> illustrates a motorized rotary drive to drive hub <NUM> that drives an individual cap driver <NUM>. As illustrated in <FIG>, the drive hub <NUM> is set within a pair of splines <NUM> of the cap driver. Not shown in <FIG> was the cap driver drive shaft <NUM> that extends through the cartridge <NUM>. <FIG> is an exploded view of the motorized rotary drive down to the hub <NUM>. In each drive, the ejector pin <NUM> is rotated by an individual DC motor with gearhead <NUM> through a drivetrain that enables the ejector pin to, in turn, rotate the hub <NUM>. Axial movement of the ejector pin <NUM> through the cap driver is also provided for, and the motorized linear drive of the ejector pin is described below.

A feature (not shown) within a center hole in a torque spline <NUM> keys onto a flat <NUM> on a drive axle <NUM> of the DC motor <NUM>. The torque spline in turn is keyed to a feature (not shown) within the center hole of the ejector hub <NUM>. The splines <NUM> on either side of groove <NUM> allow ejector hub <NUM> to be rotated while also allowing the hub <NUM> to be moved axially along the splines <NUM>. At its upper end, the ejector pin hub <NUM> has a circumferential groove <NUM> that defines a flange <NUM>, features to be explained with respect to linear drive in <FIG>, <FIG>, <FIG>. Splines <NUM> of the ejector pin hub <NUM> mate with splines <NUM> fixed to the drive hub <NUM> to cause the drive hub <NUM> to be rotated by the ejector hub <NUM> while permitting axial translation of the ejector pin through the drive hub. In the assembly of <FIG>, the ejector pin extends through the drive hub <NUM>, and the spline <NUM> compresses the compression spring <NUM> against the ejector pin hub <NUM>. The spring <NUM> applies pressure through the drive hub <NUM> to the cap driver <NUM> to press it into a cap as described below.

<FIG> illustrates the lower ends of two of the drivetrains of <FIG> retained in the cartridge <NUM> and pressed against caps <NUM>. The cap driver drive shafts <NUM> extend through ports <NUM> in the cartridge <NUM>. They are free to move up and down in the cartridge ports, restricted only by the flange <NUM> at the lower end and the C-clip <NUM> set in a groove <NUM> at the upper end.

When the handheld device is set against a row of caps <NUM>, the cap drivers <NUM> may initially rest on the caps as shown at the left due to interference between the rotational features <NUM> of the cap driver and features <NUM> of the cap recess <NUM>. In that state, the cap driver presses upwardly against the drive hub <NUM> which floats upward against the spring <NUM>. As the cap driver <NUM> is rotated such that the features allow it to be pressed into the recess of the cap, the force applied by compression spring <NUM> presses downwardly against the cap driver to overcome friction, and the cap driver moves into the top recess of the cap as illustrated to the right of <FIG>. Thus, the floating cap drivers acting against compression springs <NUM> allow individual cap drivers to be seated in the cap recesses independently, as the rotational features allow, with no force applied by the user. <FIG> shows the eight cap drivers being set into cap recesses at different stages of insertion.

<FIG> shows the motorized linear drive that drives the ejector pins downwardly to release caps from the cap drivers <NUM>. Each of the flanges <NUM> of the ejector hubs <NUM> rests on a horizontal drive plate <NUM>. That drive plate is in turn driven vertically by a rotary motor <NUM> through a lead screw <NUM>. The motor <NUM> is fixed to a bracket <NUM>. As the plate <NUM> is driven downward, it contacts the lower surfaces of the grooves <NUM> in the ejector hubs <NUM>, thus driving the ejector pins downward.

The motors <NUM> and associated torque splines <NUM> are mounted to a fixed bracket <NUM>. The translation of each ejector hub <NUM> relative to the torque spline allows for downward translation of the ejector pins <NUM> as the motors <NUM> remain stationary.

A feature of the device is to stagger ejector pin motion to allow caps to be ejected at different times rather than all at once. Adding an incremental delay in cap ejection start time results in less force required to push the caps out. In the disclosed device, the four caps in the central positions of the array of eight caps are first ejected, and the remaining four caps, two at each end, are only ejected after a delay. With only four caps being ejected initially, the required force is reduced, and the generated momentum is used to push the remaining caps out, leading to even less motor force required to initiate motion of the remaining caps. <FIG> illustrates staggered arrangement of the ejector pins during ejection. The four center pins extend further than the two pins on either end throughout the ejection movement.

<FIG> illustrate the mechanism for obtaining the staggered drive. An additional plate <NUM> is positioned below the plate <NUM> at the four center ejector hubs <NUM>. <FIG> shows the system with ejector pins retracted. When the ejector plate <NUM> is moved downward, the additional plate immediately presses the lower surface of the groove <NUM> as in <FIG> to initiate downward movement of the center four ejector pins. As the ejector plate <NUM> is narrower than the groove <NUM> of the ejector hubs, the ejector plate only strikes the lower surface of the grooves <NUM> of those ejector hubs after a short delay <FIG>. Then the end ejector pins are moved down, slightly raised relative to the center pins as shown in <FIG>.

<FIG> also show the controller <NUM> and limit switches <NUM> and <NUM> on a board <NUM>.

<FIG> showed the system of <FIG> in the retracted position (<FIG>) and the extended eject position (<FIG>). In the retracted position of <FIG>, the plate <NUM> is in a raised position with the lead screw <NUM> fully exposed below the plate <NUM>. The plate supports all eight of the ejector hub flanges <NUM> to retain the ejector pins in raised positions, all at the same height.

In <FIG>, the plate <NUM> has been lowered by the lead screw <NUM>, forcing the plate <NUM> against the lower surfaces of the grooves <NUM> of the center ejector pin hubs and the plate <NUM> itself against the lower surfaces of the grooves <NUM> of the end ejector pin hubs, lowering the center four ejector pins a small amount further than the two ejector pins at either end of the array. In <FIG>, the springs <NUM> are compressed, the upper portions of the end grooves <NUM> are exposed, and the grooves <NUM> in the torque splines <NUM> are exposed as the ejector pin has moved downward from the fixed torque spline and motor assembly.

<FIG> shows a cap driver <NUM> seated in the recess of a cap <NUM> with the ejector spring <NUM> in a retracted position. In <FIG>, the ejector spring <NUM> has been fully extended to push the cap <NUM> off of the cap driver <NUM>. Of course, during a capping operation, the cap <NUM> would be threaded into a sample tube, the ejection releasing the cap driver <NUM> from the capped tube.

The cap drivers <NUM> are designed to correspond to specific styles of caps. One aspect of that design is that the lower end of the driver below the flange <NUM> is properly sized and has appropriate features for a press fit within the cap recess and to properly align with features <NUM> in the cap recess. Another aspect of the design is to allow for a fixed length of translation of the ejector pins <NUM> regardless of the depth of recess. To that end, for caps with shallow recesses as illustrated to the left of each of <FIG>, the cap driver 102a has a longer flange 1306a. For a cap with a deeper recess as illustrated in cap 202b, a shorter flange 1306b is provided. <FIG> shows the ejector pins <NUM> retracted within the fully engaged cap drivers. In <FIG>, both pins <NUM> have been extended the same distance, and each has engaged the bottom of the respective cap recess at the same length of travel even though the cap 202a has a much shallower recess than cap 202b.

Claim 1:
A hand-held capper/decapper device comprising:
a housing (<NUM>) configured to be held by hand against an array of threaded receptacles;
an array of cap drivers (<NUM>) supported by the housing and configured to engage and retain threaded caps; and
motorized rotary drive that drives the cap drivers in forward and reverse rotary directions to cap and decap the caps on and from the threaded receptacles; characterized by:
an array of ejector pins (<NUM>) supported by the housing, the ejector pins extending through the cap drivers;
motorized linear drive that drives the ejector pins through the cap drivers to eject caps from the cap drivers; and
a motor controller (<NUM>) that controls the motorized rotary drive and the motorized linear drive in response to a control button (<NUM>) on the housing, the controller configured to control and alternate between a decap function and a cap function with each press of the control button,
in the decap function, the motorized rotary drive driving the cap drivers in a reverse rotary direction to decap the threaded receptacles; and
in the cap function, the motorized rotary drive driving the cap drivers in a forward rotary direction to cap the threaded receptacles, followed by the motorized linear drive driving the ejector pins through the cap drivers to eject the caps from the cap driver and then retracting the ejector pins.