US20050135972A1 - Method and apparatus for modifying pressure within a fluid dispenser - Google Patents

Abstract

A method and apparatus for an automated biological reaction system is provided. In the processing of a biological reaction system, there is a need for consistently placing an amount of fluid on a slide. In order to accomplish this, several methods are used including a consistency pulse and a volume adjust means. Moreover, in order to reliably operate an automated biological reaction system, the dispenser must be reliable, easy to assemble and accurate. Among other things, in order to accomplish this, the dispense chamber is substantially in line with the reservoir chamber, the reservoir chamber piston is removed, and the flow of fluid through the dispenser is simplified. Further, in order to operate the automated biological reaction system more reliably, the system is designed in modular pieces with higher functions performed by a host device and the execution of the staining operations performed by remote devices. Also, to reliably catalog data which is used by the automated biological reaction system, data is loaded to a memory device, which in turn is used by the operator to update the operator's databases. The generation of the sequence of steps for the automated biological reaction device based on data loaded by the operator, including checks to determine the ability to complete the run, is provided.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS
• This application is a continuation-in-part of co-pending U.S. patent application Ser. No. 10/060,602, filed Jan. 30, 2002. The application is also a continuation-in-part of co-pending U.S. patent application Ser. No. 09/896,649, filed on Jun. 29, 2001, which is a continuation of U.S. patent application Ser. No. 09/483,218 filed on Jan. 14, 2000, now U.S. Pat. No. 6,416,713, which is a divisional of U.S. patent application Ser. No. 08/995,052 filed on Dec. 19, 1997, now U.S. Pat. No. 6,045,759, which is a continuation-in-part of U.S. patent application Ser. No. 08/909,335 filed on Aug. 11, 1997, now U.S. Pat. No. 6,093,574. This application incorporates by reference all of the U.S. patent applications listed above in their entirety. This application also incorporates by reference U.S. Pat. Nos. 6,416,713, 6,045,759 and 6,093,574 in their entirety.
NOTICE REGARDING COPYRIGHT
• A portion of the disclosure of this patent document contains matter subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent disclosure document as it appears in the Patent and Trademark Office files and records but otherwise retains all copyrights whatsoever.
BACKGROUND OF THE INVENTION
• A. Field of the Invention
• This invention relates to biological reaction systems, and more particularly relates to a method and apparatus for an automated biological reaction system.
• B. Description of Related Art
• Immunostaining and in situ DNA analysis are useful tools in histological diagnosis and the study of tissue morphology. Immunostaining relies on the specific binding affinity of antibodies with epitopes in tissue samples, and the increasing availability of antibodies which bind specifically with unique epitopes present only in certain types of diseased cellular tissue. Immunostaining requires a series of treatment steps conducted on a tissue section mounted on a glass slide to highlight by selective staining certain morphological indicators of disease states. Typical steps include pretreatment of the tissue section to reduce non-specific binding, antibody treatment and incubation, enzyme labeled secondary antibody treatment and incubation, substrate reaction with the enzyme to produce a fluorophore or chromophore highlighting areas of the tissue section having epitopes binding with the antibody, counterstaining, and the like. Each of these steps is separated by multiple rinse steps to remove unreacted residual reagent from the prior step. Incubations are conducted at elevated temperatures, usually around 40° C., and the tissue must be continuously protected from dehydration. In situ DNA analysis relies upon the specific binding affinity of probes with unique nucleotide sequences in cell or tissue samples and similarly involves a series of process steps, with a variety of reagents and process temperature requirements.
• Automated biological reaction systems include the biological reaction apparatus and the dispensers for the reagents and other fluids used in the biological reaction apparatus. As disclosed in U.S. Pat. No. 5,595,707, inventors Copeland et al., entitled Automated Biological Reaction Apparatus, assigned to Ventana Medical Systems, Inc. which is incorporated herein by reference, the biological reaction apparatus may be computer controlled. However, the computer control is limited in that it is dedicated to and resident on the biological reaction apparatus. Moreover, the memory, which is used in conjunction with the computer control, contains data relating to the reagents including serial number, product code (reagent type), package size (250 test), and the like.
• One of the requirements in a biological reaction system is consistency in testing. In particular, the biological reaction system should apply a predetermined amount of fluid upon the slide in order to consistently test each slide in the automated biological reaction apparatus. Therefore, an important focus of a biological reaction system is to consistently and efficiently apply a predetermined amount of fluid on the slide.
• Further, as disclosed in U.S. Pat. No. 5,232,664 entitled Liquid Dispenser by inventors Krawzak et al. and assigned to Ventana Medical Systems, Inc., which is incorporated herein by reference, reagents must be dispensed on the slide in precise amounts using a fluid dispenser. The fluid dispenser, which is used in conjunction with the biological reaction apparatus, should be easy to manufacture, reliable and compact in size.
SUMMARY OF THE INVENTION
• In accordance with a first aspect of the invention, a fluid dispenser for an automated biological reaction system is provided. The fluid dispenser has a reservoir chamber, a dispense chamber which is substantially in line with the reservoir chamber, and a means for transferring fluid between the dispense chamber and the reservoir chamber based on pressure differential between the dispense chamber and the reservoir chamber.
• In accordance with a second aspect of the invention, a fluid dispenser for an automated biological reaction system is provided. The fluid dispenser has a barrel which has a reservoir chamber and an upper portion, a cap connected to the upper portion of the barrel, a valve adjacent to the reservoir chamber, and a coupler having a dispense chamber and the coupler being coaxial with the barrel.
• In accordance with a third aspect of the invention, a fluid dispenser for an automated biological reaction system is provided. The fluid dispenser has a barrel which has a reservoir chamber and an upper portion, a cap connected to the reservoir chamber, a valve adjacent to the reservoir chamber, a coupler having a dispense chamber, and a vent adjacent to the cap. The vent includes a first means to maintain constant pressure in the reservoir chamber, a second means to maintain constant pressure in the reservoir chamber, and a space, the space being between the first and second means to maintain constant pressure in the reservoir chamber.
• In accordance with a fourth aspect of the invention, a fluid dispenser for an automated biological reaction system is provided. The fluid dispenser has a barrel which has a reservoir chamber and a piston at a lower portion of the barrel, a cap connected to the reservoir chamber, a valve adjacent to the reservoir chamber, and a coupler. The coupler has a dispense chamber whereby the piston moves in the dispense chamber.
• In accordance with a fifth aspect of the invention, a method of assembly of a fluid dispenser for an automated biological reaction system is provided. The method includes the step of inserting a valve and a valve insert into the lower portion of a barrel. The method also includes the step of welding the cap to the upper portion of the barrel. The method further includes the step of placing the ball in the check valve ball seat. Further, the method includes the step of snapping the check valve ball seat into the coupler. In addition, the method includes the step of snapping the coupler and barrel together.
• In accordance with a sixth aspect of the invention, a method of filling and priming a fluid dispenser for an automated biological reaction system is provided. The method includes the step of providing the fluid dispenser with a cap, a barrel having a reservoir chamber, the barrel being adjacent to the cap, a dispense chamber adjacent to the reservoir chamber, and a nozzle adjacent to the dispense chamber. The method also includes the step of providing a syringe with a tip and a syringe plunger. The method further includes the step of opening the cap on the fluid dispenser. The method also includes the step of filling the reservoir chamber within the fluid dispenser with fluid. In addition, the method also includes the step of closing the cap on the fluid dispenser. Further, the method also includes the step of placing the tip of the syringe inside the nozzle of the fluid dispenser without requiring the fluid dispenser be turned upside down. And, the method also includes the step of expanding the plunger of the syringe in order to draw fluid from the reservoir chamber and the dispense chamber into the syringe.
• In accordance with a seventh aspect of the invention, an automated biological reaction system is provided. The automated biological reaction system has a slide support carousel, drive means engaging the slide support carousel for moving the slide support carousel, a consistency pulse application station comprising at least one nozzle for directing a stream of fluid onto a slide which is less than 35 degrees from the horizontal, and a volume adjust application station positioned above the slide for applying a predetermined amount of fluid on the slide by dropping the fluid onto the slide.
• In accordance with a eighth aspect of the invention, a method of placing a consistent amount of fluid on a slide in an automated biological reaction apparatus is provided. The automated biological reaction apparatus has at least one rinse station, the rinse station comprising a rinse station nozzle positioned for directing a stream of fluid onto the slide and connected to tubing which is connected to at least one valve. The valve is connected to a bottle containing fluid, wherein the valve controls the flow of fluid from the bottle to the nozzle. The method includes the step of turning on the valve for supplying fluid to the nozzle and directing a stream of fluid onto the slide. The method also includes the step of waiting until the pressure is substantially equal in the tubing. And, the method includes the step of turning off the valve for supplying fluid to the nozzle.
• In accordance with a ninth aspect of the invention, a method of washing a slide in an automated biological reaction apparatus is provided. The method includes the step of providing a rinse station comprising a first rinse station nozzle and a second rinse station nozzle, the first and second rinse station nozzles positioned to direct a stream of fluid onto the slide. The method also includes the step of directing a stream of fluid onto the slide from the first rinse station nozzle with a first momentum for a first predetermined amount of time. In addition, the method includes the step of directing a stream of fluid onto the slide from the second rinse station nozzle for a second predetermined amount of time with a second momentum. And, the method includes the step of directing a stream of fluid onto the slide from the second rinse station nozzle for a third predetermined amount of time with a third momentum, the third momentum being greater than first or second momentum, the third predetermined amount of time being greater than the first or second predetermined amount of time.
• In accordance with a tenth aspect of the invention, an automated biological reaction apparatus is provided. The automated biological reaction apparatus includes a slide support carousel, drive means engaging the slide support carousel for moving the slide support carousel, a reagent delivery system for applying a predetermined quantity of reagent to one of the slides by movement of the slide support carousel in a reagent delivery zone, a heat zone for heating samples on the slide support carousel, and a rinse station. The rinse station comprises a first nozzle, a first valve connected to the first nozzle through tubing, the first valve connected to a bottle containing fluid. The rinse station further comprises a controller, the controller controlling the flow of fluid from the bottle to the first nozzle via the operation of the first valve, the controller opening the first valve until the pressure is substantially equal in the tubing.
• In accordance with a eleventh aspect of the invention, an automated biological reaction system is provided. The automated biological reaction system includes a host device, the host device comprising a processor, a memory device connected to the processor, the memory device including a look-up table which contains steps for staining a slide, the processor creating a sequence of steps from the look-up table. The automated biological reaction system further includes a remote device, the remote device being physically separate from the host device, the remote device being in electrical communication with the host device. The remote device comprises a processor, a memory device connected to the processor, a slide support carousel connected to the processor, drive means engaging the slide support carousel for moving the slide support carousel, the drive means connected to the processor, a reagent delivery system for applying a predetermined quantity of reagent to one of the slides by movement of the slide support carousel in a reagent delivery zone, the reagent delivery system connected to the processor, a heat zone for heating samples on the slide support carousel, the heat zone connected to the processor, and a rinse station for rinsing slides on the slide support carousel, the rinse station connected to the processor, the remote device receiving the sequence of steps from the host device, the remote device executing, through the processor, the sequence of steps in the processor to control the slide support carousel, the reagent delivery system, the heat zone and the rinse station.
• In accordance with a twelfth aspect of the invention, a method for generating a run program in an automated biological reaction system is provide. The method includes the step of providing a host device and a remote device, the remote device being physically separate from the host device, the remote device being in communication with the host device. The method also includes the step of reading by the remote device of a barcode on a slide in a carousel on the remote device. The method further includes the step of reading by the remote device of a barcode on a dispenser in the remote device. In addition, the method includes the step of sending of the slide barcode and dispenser barcode from the remote device to the host device. Also, the method includes the step of generating of a sequence of steps for a run based on the slide barcode and dispenser barcode. Moreover, the method includes the step of determining by the host device whether the remote device is capable of executing the sequence of steps. And, the method includes the step of sending by the host device of the sequence of steps to the remote device.
• In accordance with a thirteen aspect of the invention, a memory management system for an automated biological reaction apparatus is provided. The memory management system includes a memory device, the memory device including a table containing data for a dispenser used in the automated biological reaction apparatus. The memory management system also including a means to transfer the data in the memory device to a host device. The host device comprises a processor, a host memory device connected to the processor. The host memory device includes a look-up table. The processor is connected, via the means to transfer the data in the memory device to a host device, to the memory device, and the processor updates the look-up table in the host memory device based on comparisons to the table in the memory device.
• In accordance with a fourteenth aspect of the invention, a method for updating dispenser information in an automated biological reaction system is provided. The method includes the steps of providing a host device and a memory device, the host device comprising a processor, a host memory device connected to the processor, the host memory device including a look-up table, the memory device including barcode and expiration date information for the dispenser used in the automated biological reaction apparatus. The method also includes the step of reading by the host device of the barcode and expiration date information in the memory device. In addition, the method includes the step of updating the look-up table in the host device based on the barcode and expiration date information in the memory device. And, the method includes the step of writing in the memory device that the barcode and expiration date information has previously been read.
• In accordance with a fifteenth aspect of the invention, a method for programming a memory device for an automated biological reaction system is provided. The method includes the step of selecting a form which includes information on numbers and types of dispensers in a kit for the automated biological reaction system. The method also includes the step of scanning in barcodes for a set of dispensers. Moreover, the method includes the step of determining the type of dispenser for each of the dispensers scanned in. Further, the method includes the step of comparing whether the numbers types of dispensers scanned in correspond to the numbers and types of dispenser in the kit form. And, the method includes the step of programming the memory device if the numbers types of dispensers scanned in equal the numbers and types of dispenser in the kit form.
• In accordance with a sixteenth aspect of the invention, a fluid dispenser for an automated biological reaction system is provided. The fluid dispenser has a barrel, the barrel having a reservoir chamber and an upper portion. The fluid dispenser also has a cap connected to the upper portion of the barrel. The fluid dispenser also has a cup check valve, the cup check valve having a first end and a second end, the cup check valve adjacent to the reservoir chamber at the first end, the cup check valve having a cup piece at the second end. The fluid dispenser further has a dispense chamber adjacent to the second end of the cup check valve.
• In accordance with a seventeenth aspect of the invention, a valve is provided. The valve passes fluid from one side of the valve to the other side based on a pressure differential between the one side and the other side, whereby the valve is placed in a housing. The valve includes an attachment, the attachment piece being attached to the housing, a connecting piece being connected to the attachment piece, and a cup piece. The cup piece is connected to the connecting piece. The cup piece abuts against the housing when the pressure on the one side of the valve is equal to the pressure on the other side of the valve. The cup piece does not abut against the housing when the pressure on the one side of the valve is unequal to the pressure on the other side of the valve.
• In accordance with a eighteenth aspect of the invention, a method of equilibrating pressure within a fluid dispenser is provided. The method includes the step of providing a fluid dispenser with a barrel having a cap. The cap includes a surface with at least one hole and a valve having a biasing member and a hole sealer. The biasing member includes at least two positions. The also includes the step of placing the biasing member in one of the two positions by applying a force to the valve wherein in a first position of the biasing member, the hole sealer seals the hole and wherein in a second position, the hole sealer does not seal the hole.
• In accordance with a nineteenth aspect of the invention, a method of mechanically operating a valve for a fluid dispenser is provided. The valve of the fluid dispenser includes a head and a bulge. The method includes the step of abutting the bulge against a hole in the fluid dispenser to create a seal. The method also includes the step of applying a mechanical force to move the head so that the bulge does not abut the hole. Further, the method includes the step of reducing the mechanical force so that the bulge abuts the hole.
• In accordance with a twentieth aspect of the invention, a method for passing liquid through a housing based on a pressure differential is provided. The method includes the step of providing a valve having an attachment piece, a connecting piece being connected to the attachment piece, and a cup piece, the cup piece being connected to the connecting piece. The method also including the step of abutting the cup piece against the housing when the pressure on the one side of the valve is equal to the pressure on the other side of the valve. And, the method includes the step of flexing the cup piece inward so that the cup piece is not abutting against the housing when the pressure on the one side of the valve is unequal to the pressure on the other side of the valve.
• In accordance with a twenty-first aspect of the invention, a fluid dispenser for an automated biological reaction system is provided. The fluid dispenser has a barrel having a reservoir chamber and a piston, the piston being adjacent to the reservoir chamber. The fluid dispenser also has an extension piece connected to the piston. And, the fluid dispenser has a coupler, wherein the coupler has a dispense chamber. The dispense chamber is adjacent to the reservoir chamber. Further, the extension piece moves inside the coupler.
• Accordingly, a primary object of the invention is to provide an automated biological reaction system which is modular in design.
• Another object of the invention is to provide an automated biological reaction system which provides for a means of automatically downloading data relating to the reagents including serial numbers, reagent types, lot numbers, expiration dates, dispenser type, and the like in an efficient and reliable manner.
• Another object of the invention is to provide an automated biological reaction system which consistently and efficiently applies a predetermined amount of buffer upon the slide to which a precise volume of reagent can be added upon the slide.
• A further object of the invention is to provide a fluid dispenser, which is used in conjunction with the biological reaction apparatus, which is reliable.
• Yet a further object of the invention is to provide a fluid dispenser, which is used with a wider array of chemistries in conjunction with the biological reaction apparatus, which is easy to manufacture.
• Still another object of the invention is to provide a fluid dispenser, which is used in conjunction with the biological reaction apparatus, which is compact in size.
• Still yet another object of the invention is to provide a fluid dispenser which is easy to prime.
• These and other objects, features, and advantages of the present invention are discussed or apparent in the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
• A presently preferred embodiment of the present invention is described herein with reference to the drawings wherein:
• FIG. 1 is a left front, isometric view of the automated biological reaction system according to a first embodiment of this invention;
• FIG. 2 is an exploded right front isometric view of the system shown inFIG. 1;
• FIG. 3 is a partial exploded left front isometric view of the system shown inFIG. 1;
• FIG. 4 is a partial exploded right rear isometric view of the apparatus shown inFIG. 1;
• FIG. 5A is a block diagram of the modularity of the host and remote devices of the automated biological reaction system;
• FIG. 5B is a format of the addressing for the host devices and remote devices described inFIG. 5A;
• FIG. 5C is a communication transmission protocol between the host device and remote devices described inFIG. 5A;
• FIG. 6A is an expanded block diagram of the remote device inFIG. 5A;
• FIG. 6B is a circuit board connection diagram for the microcontroller;
• FIG. 7A is a block diagram of the dual rinse and volume adjust components of the remote device inFIG. 6A;
• FIG. 7B is a perspective view of the dual rinse top and dual rinse bottom, volume adjust/coverslip, airknife/barcode blowoff and vortex mixers;
• FIG. 8A is a side isometric view of one embodiment of the dual rinse top nozzle and dual rinse bottom nozzle as shown inFIG. 7A;
• FIG. 8B is a side view of the angle of the dual rinse top nozzle as shown inFIG. 8A;
• FIG. 8C is a side view of the angle of the dual rinse bottom nozzle as shown inFIG. 8A;
• FIG. 8D is a side view of one embodiment of the volume adjust as shown inFIG. 7A;
• FIGS. 9A, 9B, and9C are flow charts of the dual rinse, the consistency pulse and the volume adjust steps;
• FIGS. 10 and 11 illustrate the mounting of a fluid dispenser on a reagent tray and the manner in which a reagent tray is engaged with a drive carousel;
• FIG. 12A is an elevational cutaway view of a prefilled fluid dispenser in the extended position;
• FIG. 12B is an elevational cutaway view of a user fillable fluid dispenser in the extended position;
• FIG. 12C is an elevational cutaway view of a prefilled fluid dispenser in the compressed position;
• FIG. 13A is a cutaway view of the ball chamber and nozzle;
• FIGS. 13B and 13C are front and side cutaway views of the lower portion of the barrel with an extension section;
• FIG. 14A is an exploded view of an elevational cutaway of a prefilled fluid dispenser;
• FIG. 14B is an exploded view of an elevational cutaway of a user fillable fluid dispenser;
• FIG. 15A is a side view of a prefilled fluid dispenser;
• FIG. 15B is a side view of a customer fillable fluid dispenser with flip top;
• FIG. 15C is an exploded view of a prefilled fluid dispenser with an evaporation ring adjacent the cap;
• FIG. 16A is a cutaway view of the cap and vent of a prefilled fluid dispenser according to one embodiment;
• FIG. 16B is an underside view of the cap and vent ofFIG. 16A;
• FIG. 16C is a cutaway view of the cap and vent of a prefilled fluid dispenser with a bi-directional duckbill valve;
• FIG. 16D is a cutaway view of the cap and vent of a prefilled fluid dispenser with a uni-directional duckbill valve;
• FIG. 16E is a cutaway view of the cap and vent of a prefilled fluid dispenser according to another embodiment;
• FIG. 16F is a perspective view of a valve arranged to operate in accordance with an exemplary embodiment of the present invention;
• FIG. 16G is a perspective view of a cap of a fluid dispenser arranged to operate in accordance with an exemplary embodiment of the present invention;
• FIG. 16H is a perspective view of a valve ofFIG. 16F inserted into the cap ofFIG. 16G;
• FIG. 16I is a perspective view of a vent as shown inFIG. 16H arranged to operate in accordance with an exemplary embodiment of the present invention;
• FIG. 16J is a side view of the cap ofFIG. 16H inserted into a fluid dispenser arranged to operate in accordance with an exemplary embodiment of the present invention;
• FIG. 16K is a side view of one method of operating the valve ofFIG. 16F arranged to operate in accordance with an exemplary embodiment of the present invention;
• FIG. 17A is a cutaway view of the lower portion of the barrel, duckbill check valve, duckbill check valve insert, quad seal, ball, ball check valve insert and coupler of a fluid dispenser;
• FIG. 17B is a cutaway view of the lower portion of the barrel, duckbill check valve, duckbill check valve insert of a fluid dispenser;
• FIG. 17C is a cutaway view of the quad seal of a fluid dispenser;
• FIG. 18A is an alternative embodiment of a cutaway view of the lower portion of the fluid dispenser;
• FIG. 18B is an alternative embodiment of a cutaway view of the lower portion of the fluid dispenser;
• FIG. 19A is a cutaway view of a syringe with a restrictor for use in the nozzle of the coupler;
• FIG. 19B is an exploded view of a syringe with a restrictor and an O-ring for use in the nozzle of the coupler;
• FIG. 20 is an alternative embodiment of a cutaway view of the lower portion of the fluid dispenser with a cup check valve;
• FIG. 21A is a side view of the cup check valve;
• FIG. 21B is a bottom view of the cup check valve;
• FIG. 21C is a top view of the cup check valve;
• FIG. 21D is a view of the cup check valve at cross-section A-A inFIG. 21C;
• FIG. 21E is a view of the cup check valve at cross-section B-B inFIG. 21C;
• FIG. 22 is a block diagram of the manufacturer's system for programming an external memory device;
• FIGS. 23A and B are flow charts for updating the forms on the manufacturer's reagent database;
• FIGS. 24A and B are flow charts for updating the master lot on the manufacturers reagent database and for inputting data into a memory device;
• FIG. 25 is a flow chart for downloading data from a memory device to the host system;
• FIGS. 26A and B are flow charts for updating the memory devices of the user through information downloaded from an external memory device;
• FIG. 27 is a flow chart for determining if the kit/dispensers for use by the operator is the correct number and correct complement;
• FIGS. 28A-28G are flow charts of a preparation for a run using the dispense table; and
• FIG. 29 is a flow chart of the testing run for the remote device.
DETAILED DESCRIPTION OF THE PREFERRED AND ALTERNATIVE EMBODIMENTS OF THE INVENTION
• The automated immunostaining system of this invention performs all steps of immunohistochemical irrespective of complexity or their order, at the time and temperature, and in the environment needed. Specially prepared slides containing a bar code identifier and a mounted tissue section are placed in special supports on a carousel, subjected to a preprogrammed sequence of reactions, and are removed from the carousel, ready for examination. For purposes of clarity of the following description of the apparatus of this invention and not by way of limitation, the apparatus will be described in terms of immunohistochemical processes.
• FIG. 1 is front right isometric view of the automated biological reaction system with ahost device32 and oneremote device166. Theremote device166 includes astaining module167,bulk fluid module230 and thehost device32 includes ahost computer33, amonitor34, akeyboard35 and amouse37.FIG. 2 is a front right isometric view of the staining module which is part of the automated biological reaction system. Liquid and air supply tubing and electrical wiring connecting the respective components are conventional, well known in the art, and are omitted from the drawings for purposes of clarity.
• The apparatus has anupper section2,intermediate section4 andlower section6. In theupper section2,reagent tray10 which supports thereagent fluid dispensers12 is mounted for rotation about itscentral axis7 onreagent carousel8. Thereagent carousel8 and slidecarousel24 are circular in the preferred embodiment, but can be any shape which allows integration with other components in the system.Reagent fluid dispensers12, described herein with respect toFIGS. 10-21, required for the immunohistochemical reactions to be conducted during slide treatment cycle, are supported by thereagent tray10 and mounted in reagent fluid dispenser receptors11. These receptors11 are configured to receivereagent fluid dispensers12. The receptors11 are preferably equally spaced in a circular pattern axially concentric with thecarousel axis7. The number of receptors11 provided should be sufficient to accommodate the number of differentreagent fluid dispensers12 required for a cycle or series of cycles. Twenty-five fluid dispenser receptors11 are shown, but the number can be smaller or greater, and the diameter of thereagent tray10 can be increased to accept a larger number ofreagent fluid dispensers12. Thereagent carousel8 is rotated by thestepper motor14drive belt16 to a position placing a selectedreagent fluid dispenser12 in the reagent deliver position under the air cylinder reagent delivery actuator over a slide to be treated with reagent.
• Theintermediate section4 comprises a vortex mixing plate to which the4 of the6 mix blocks are attached, the remaining two mix blocks being mounted on the lower section. Thelower section6 comprisessupport plate22 upon which theslide carousel24 is rotatably mounted. Theslide carousel24 supports slide supports26. Heated air is supplied to the apparatus via a resistive heating element and a blower. The heated air recirculates within the apparatus as shown inFIG. 3. Thesupport plate22 also supports aremote device microcontroller36 on the automated biological reaction apparatus,power supply24 and fluid andpneumatic valves62. The remote device microcontroller printedcircuit board36, as described subsequently, is generally a processor and can be replaced by a standard computer. The remote device microcontroller printedcircuit board36 interfaces, via an RS-485 line, with ahost device32, as described subsequently inFIGS. 5A-5C. Thelower section6 includes support plate40 upon which are supported accessories such aspower supply42 andbuffer heater44.
• In thelower section6, thestepper motor48 rotates theslide carousel24, engagingdrive belt25 engaging the drive sprocket of theslide carousel24. The annular waste liquid sump surrounds the shroud and is supported on the bottom ofplate22. The waste reagent and rinse fluids are collected in the sump and passed to a drain through an outlet tube in the sump bottom (not shown).
• Rinse and Liquid Coverslip™ (which is light oil substance used to prevent evaporation of the aqueous solutions on the slide) spray blocks60 are supplied with fluid through conventional solenoid valves62 (see alsoFIG. 6A,248F-J). Bufferheater temperature sensor66, mounted onbuffer heater44, controls the heat energy supplied to thebuffer heater44. Slidetemperature monitoring sensor68, mounted onsupport plate22, controls the temperature of the air in the apparatus by controlling energy supplied toannular heater elements27.Power supply42 provides power to thestepper motors14,48 and control systems.FIG. 4 is a left front isometric view of the bulkfluid module system230 which is included in the automatedbiological reaction system150. Thebulk fluid module230 includes anair compressor232, a pressure relief valve (prv)238, coolingtubing231, a water condenser andfilter234, anair pressure regulator236, a bottle containingwash buffer246, and a bottle containingLiquid Coverslip™244. Theair compressor232 provides compressed air which is regulated by the pressure relief valve (prv)238 to25 psi. The air passes from thecompressor232 through the cooling tubing and enters the condenser andfilter234. From the condenser andfilter234, the air passes to thepressure regulator236. Thepressure regulator236 regulates the pressure to13 psi. The air, maintained at13 psi, is supplied to thewash buffer bottle246 and the LiquidCoverslip™ bottle244 and the staining module167 (seeFIG. 2). Water condensing out of the compressed air passes out of the condenser and filter through the pressure relief valve and exits the bulk module. Wash buffer and Liquid Coverslip™ are supplied to the staining module.
• Referring toFIG. 5A, there is shown a block diagram of the automatedbiological reaction system150. The automatedbiological reaction system150 is segmented into ahost device32, which includes a typical personal computer, and at least oneremote device166, which includes the automated biological reaction device inFIGS. 2 and 6A. In the preferred embodiment, there are up to eightremote devices166 which communicate with thehost device32. Eachremote device166 on the network has a unique address so that eachremote device166 may be identified and individually controlled by thehost device32. As described subsequently inFIG. 5B, the automatedbiological reaction system150 can support up to eightremote devices166 due to the 3 bits (values 0-7) dedicated to the addressing of theremote devices166. A rotary switch is provided on theremote device166 to allow for the identification and the changing of the 3 bit address for eachremote device166. All host messages include this address in them, as described subsequently inFIG. 5B. However, the number ofremote devices166 can be smaller or larger than eight, depending on the capacity requirements or practical limitations of the laboratory in terms of space. Moreover, theremote devices166 may be immunohistochemistry staining modules, another type of instrument that performs a different type of staining, or another type of medical testing device.
• Communication between thehost device32 and theremote devices166 is accomplished using a serial RS-485 link, which serves as a network, that supports one host and up to 32 remotes at one time. In the preferred embodiment, addressing of theremote devices166 allows up to 8 remote devices to communicate with the host at one time. The RS-485 link has at least two pairs of lines for communication, one pair for transmitting and one pair for receiving. Theremote devices166 which are connected to the network “hear” the host messages but do not “hear” other remote messages. In the preferred embodiment, all communications begin with a host message, followed a short time later by a response by aremote device166 if present. If thehost device32 sends a message and there is noremote device166 to respond to it, thehost device32 times out. In this manner, the communication provides a simple, collision-free link between thehost device32 and theremote devices166. In an alternative embodiment, theremote devices166, in addition to communicating with thehost device32, address each other. For example, theremote devices166 address each other using the unique3 bit address, sending information about staining runs, which are described subsequently.
• As shown inFIG. 5A, thehost device32 is a typical personal computer with aprocessor152 which includes acomparator154 for comparing values in the processor. Theprocessor152 is also in communication with memory devices156, including non-volatile memory devices such as aROM158, volatile memory devices such as aRAM160, and ahard disk162. Any of the memory devices may contain databases or look-up tables; however, in the preferred embodiment, thehard disk162 contains the databases or look-up tables164. Theremote device166 includes a processor, such as amicrocontroller36 wherein themicrocontroller36 has acomparator170 for comparing values in themicrocontroller36. In an alternative embodiment, themicrocontroller36 in theremote device166 is replaced by a personal computer. Themicrocontroller36 is manufactured by Dallas Semiconductor, model number DS2251T 128K Soft microcontroller module. Themicrocontroller36 has two lines (serial to PC, serial to next inst) to facilitate communication between the host and the remote devices. As shown inFIG. 5A, thehost device32, through theprocessor152, is connected to the serial to PC pin of themicrocontroller36 of remote device1 (166). The serial to next inst line of themicrocontroller36 of remote device1 (166) is connected to the serial to PC pin of remote device2 (166). The connections follow similarly through remote device N (166). In the preferred embodiment, there are up to8 remote devices on the network. In order to terminate the network with the correct impedance in order to avoid any pulse reflections on the network, the serial to next instrument line is connected to aterminator171. Theterminator171 can thereby match the impedance of the network. In the event that one of the remote devices on the network must be removed from the network, the serial to PC line and the serial to next remote device line need only be connected to each other for theremote device166 to be removed from the network. Thereby, the network does not “see” thatremote device166 and is effectively removed from the network.
• Referring toFIG. 5B, there is shown a format of the addressing for the host andremote devices166 described inFIG. 5A. Both thehost device32 and theremote devices166 have the same format and are distinguishable from one another only by the messages in their fields. Both the host device command and the remote device response for a given message transaction contains the same message. The first character is the start of message character. The 8^thbit is always set to 1, the lower 3 bits contain the address of the remote and bits3-6 are unused. Thehost device32 addresses theremote device166 in this manner. The addressed remote responds in kind with its own address here.
• The message length is 2 characters in length. This number indicates the number of characters in the entire message. This includes the start of message character and the message checksum character. This is the actual number of characters transmitted as seen through the host/remote serial ports. The message ID is one character in length. It tags a message with a number (0-255) that identifies it from other messages. The message ID provides identification for message acknowledges from the remote and provides safe message retry processing in the remote. The message ID is implemented by incrementing a number until it reaches 255, and thereafter returning to 0. Each successful message transmission causes the message ID to increment by 1. Retransmitted messages from the host, due to unsuccessful acknowledgments from the remote, are repeated with the same message ID as the original message. The message command is 1 character in length. For host messages, the message command indicates to the remote the type of command the message command data pertains to. For remote messages, this field is used to tell thehost device32 how the request was received. The message command data is of variable length. It contains additional message data, depending on the particular host command. The size of the message command data is dictated by the message length, described previously. After removing the other fields from around this field, the remainder is the message information. Since message commands may not require message command data, this field may not always be used. The message checksum is I character in length. It contains the computed checksum of all characters in the message, starting with the start of message character and including all message characters up to, but not including, this checksum field. No message is processed if the message checksum does not match the actual computed checksum of the received message.
• Referring toFIG. 5C, there is shown a communication transmission protocol between thehost device32 andremote devices166 described inFIG. 5A. Messages are downloaded from thehost device32 to theremote devices166. The host device initiates a message to send to a remote device (172). The host device allocates memory to hold amessage176 and loads the message intomemory178. Thehost device32 then places the message at the top or at the bottom of the queue180,182, depending on the priority of the message. Since the queue is first-in-first-out, the messages at the bottom of the queue go out first. Therefore, if a message must be sent out immediately, it is placed at the bottom of the queue180. Otherwise, if it is a routine status message, the message is placed at the top of the queue182. Thereafter, the messages are sent to the message queues for each of the up to eightremote devices184,186,188,190,192,194,196,198.
• Ordinarily, when a message is sent from thehost device32 to aremote device166, messages are sent periodically through the use of a timer. When thehost device32 determines that a message needs to be sent rapidly174, the timer is turned off200 and all of the messages from the specific queue as indicated by the host are sent202. If thehost device32 determines that the message does not need to be rapidly sent, the message is sent in the predetermined sequence based on the timer by sending it in thepredetermined sequence206. The host uses thetab position204, which indicates which remote to send the message to.
• Referring toFIG. 6A, there is shown an expanded block diagram of theremote device166. As discussed previously, theremote device166 includes amicrocontroller36. Themicrocontroller36 has a user switch and LEDs line which connects to the status PCB (printed circuit board)294. Thestatus PCB294 is the interface to the user for theremote device166 and includes three LEDs (light emitting diodes) for power determination, error notification and notification of a run in progress. Thestatus PCB294 also includes aswitch295, such as a push-button switch, which is used for testing of various functions. When the push-button switch295 is depressed, themicrocontroller36 executes the last set of instructions (described later as macro 0) that was entered in themicrocontroller36.Macro 0, as described subsequently, is a list of instructions which are used to execute a staining run in theremote device166. For testing purposes, operators may wish to review the last staining run. In order to do this without requiring the operator to download the program from thehost device32 to the remote device166 (which may be in a different location), the operator may depress the push-button switch295. In this manner, the operator may repeatedly execute the last run at the touch of a button.
• Themicrocontroller36 also has a slide fan out connection which is used to control theblower fan4. Theblower fan4 recirculates air to heat the slides on theslide carousel24 of the5remote device166 by forcing air over theheater302 and then over the slides. The slide temp in connection onmicrocontroller36 is connected to the slidetemperature monitoring sensor68 which senses the temperature of the air. The slidetemperature monitoring sensor68 is positioned in the path of the heated air and thereby sends information to themicrocontroller36 when to turn theslide heater302 on and off. The slide heater out connection is connected to the10slide heater302 which, as discussed previously, heats the air in order to elevate the temperature of the slides. As discussed subsequently, thehost device32 downloads to theremote device166 both the sequence of steps in a run program, and the sensor monitoring and control logic called the run rules. One of the environmental parameters is the upper and lower limit of the air temperature of the slides (used for heating the slides). If, during a run, the environmental15 temperature is below the lower limit, as indicated by slidetemperature monitoring sensor68, theslide heater302 is turned on. Likewise, if the environmental temperature is above the upper limit, as indicated by slidetemperature monitoring sensor68, theslide heater302 is turned off.
• Thepower supply24 supplies both 24 VDC and 5 VDC to the applicable 24 VDC and 5 VDC connections. The 24Volt power supply24 is used to power themotors14,48 which move the20slide carousel24 and thereagent carousel8, and thevalves248A-J, which are described subsequently. The 120 VAC input is sent through a power switch310, a fuse308 and a filter306 to the AC In connection of thepower supply24. The 120 VAC input is also used to power theslide heater302,buffer heater44 andcompressor232 of the bulk fluid module, which are described subsequently. The serial to PC line and the serial to next remote device line are described with reference toFIG. 5A. The tub overflow in line receives input from aconductivity sensor255 which senses the level of the waste in thetub254. When theconductivity sensor255 senses that the waste line is above a predetermined level, theconductivity sensor255 notifies themicrocontroller36, which in turn sends a status message to thehost device32. The operator is first given an opportunity to clear the waste from thetub254. If thetub254 is still above the predetermined level, the run is stopped.
• Thebuffer heater44 is used to heat the wash buffer before it is placed on the slides since it has been determined that better results are achieved by heating the wash buffer to the temperature of the tissue on the slide. Thebuffer heater44 consists of acast aluminum block250 with aspiral tubing251 inside the block. When the wash buffer flows through thetubing251 through theblock250, the temperature of the wash buffer will be the temperature of thealuminum block250 upon exit from thetubing251. In order to control the temperature of the block, a bufferheater temperature sensor66 is used which is physically placed on thealuminum block250. Themicrocontroller36 receives the buffer temperature sensor input via the buffer temp line and can thereby control the temperature of thebuffer heater44 by turning on and off thebuffer heater44 via the buffer heater line on thePCB microcontroller36.
• Thefluid valves248A-J for the Liquid Coverslip™ and the wash buffer are controlled by the fluid valve connections. There is a separate pair of wires (power and ground) for eachvalve248A-J shown inFIG. 6A which are omitted for ease of display. Eachvalve248A-J is a relay which is activated by themicrocontroller36. The volume adjust266, dual rinse top263, and two dual rinse bottom264 devices will be described subsequently inFIGS. 7-9. Further, there is a slide dooroptical sensor258 which is input to the slide door switch in line connection and which is used to determine if thefront door256 of theremote device166 is open. Thissensor258 is used for safety reasons so that, if the front door is open and remains open for five minutes, theslide carousel24 does not move. Moreover, there is a second optical sensor, the upper leveloptical sensor262, which is used to determine if the upper chassis on theremote device166 has been opened.
• Further, as shown inFIG. 6A, the dispensecylinder282 uses the dispense cylinder extend and the dispense cylinder retract so that the dispense plunger extends and retracts the fluid dispensers. Using air via the system air line, the dispensecylinder282 is pushed out by using the dispense cylinder extend line. Themicrocontroller36 controls theair valves248A,248B so that the relay corresponding to the dispense cylinder extend line is activated. In this manner, the dispensecylinder282 pushes the fluid dispenser down, as described subsequently inFIGS. 12A-12C, thereby dispensing reagent. In order to retract the dispensecylinder282, the dispense cylinder retract valve248B is activated using the system air line so that the fluid dispenser is pushed to retraction. Additionally, an extension spring is used to help speed the retraction process, as described subsequently. An optical sensor is used to determine if the dispense is extended, and thereby activated. When the dispensecylinder282 is extended, the optical sensor is tripped validating that the dispense operation has occurred.Motors14,48 move theslide carousel24 and thereagent carousel8, and are connected to the slide motor out connection and the reagent motor out connection, respectively. Themotors14,48 are typically stepper motors.
• Sensors274,286 are placed in proximity to theslide carousel24 and thereagent carousel8 in order to determine the “home” position of each. In the case of theslide carousel24, the slidecarousel home sensor274 is inductive-type and senses a piece of metal placed underneath the slide designated as the “home” position. When the “home” position is found, thesensor274 sends a signal to the slide home in line of themicrocontroller36. In the case of thereagent tray10, thesensor286 also is an inductive-type of sensor. Thereagent tray10 has a large flat metal ring around the entire tray except for the home position. In this manner, when thesensor286 senses an absence of metal, this is determined to be the home position thereby indicating to themicrocontroller36, via the reagent home in connection, that the home position is found. Thesensor286 senses thereagent tray10, rather than thereagent carousel8, since the user may remove thereagent tray10. Additionally, since thesensor286 looks for the absence of metal for the home position, the absence of thereagent tray10 may be tested by looking for the absence of metal in two consecutive positions.
• System pressure is determined via the system air line which directly feeds into atransducer290. Thetransducer290 generates an analog voltage which is proportional to the pressure. The output of thetransducer290 is then sent to an analog to digital converter (ADC)292 whose output is sent to themicrocontroller36 via the system pressure in connection. Contrary to previous pressure switches which only indicated whether the pressure was below a minimum value, thetransducer290 andADC292 combination indicates to themicrocontroller36 the exact pressure. Therefore, themicrocontroller36 can determine both whether the pressure is too low and too high. In either instance, themicrocontroller36 sends an error message and shuts down the run.
• As shown inFIG. 6A, thebulk fluid module230 includes thecompressor232 which pressurizes the air to up to 90 psi. The compressed air is sent to afilter234 in order to filter out water and other contaminants. Pressure is regulated in a two-step fashion. First, the pressure is regulated at the compressor to approximately 25 psi (±1 psi) via a spring diaphram (prv)238. Theprv238 is manufactured by Norgren in Littleton, Colo., part number NIP-702 with a plastic bonnet. Second, the pressure is fine-tuned to 13 psi using anair pressure regulator236. Thepressure regulator236 is very accurate in terms of precise pressure regulation over long periods of time. In this manner, thecompressor232 need not overwork itself since theprv238 maintains the pressure at the output of the compressor to 25 psi by opening and letting out excess pressure when the pressure exceeds 25 psi. Water and particulates, which are filtered out of the air via thefilter234, are sent to a waste receptacle. The compressed air pressurizes the Liquid Coverslip™ and washbuffer bottles244,246 so that when thevalves248F-J are opened corresponding to the Liquid Coverslip™, volume adjust, dual rinse top, dual rinse bottom lines, the pressure is already on the line and the fluid may flow. In addition, the compressed air is used for the dispense cylinder extend line, the dispense cylinder retract line, the mirror air cylinder line, the vortex mixers line, and the bar code blowoff/airknife line.Filters240 are used at the outputs of the Liquid Coverslip™ and washbuffer bottles244,246 in order to remove particulates which may get caught in thevalves248.
• The mirror air cylinder line is used to turn themirror cylinder278 so that thebar code reader276 either reads bar codes on the slides of theslide carousel24 or bar codes on the fluid dispensers on thereagent carousel8. The output from thebar code reader276 is input to themicrocontroller36 via the bar code serial I/O connection. In between the valve248C for the mirror air cylinder line and the mirror cylinder is aflow restrictor268. The flow restrictor268 slows the flow of air in the line while still maintaining the 13 psi pressure on the line. In this manner, this moves the mirror slower than would otherwise be done without therestrictor268.
• Thevortex mixers271 likewise operate off of the 13 psi system air line to mix the contents on the slide. Thevortex mixers271 may be used in a single stream or in a dual stream mode. In particular, a single stream of air or a dual stream of air may be used to mix the contents on the slide. Further,restrictors268 are used in the vortex mixers lines in order to reduce the flow of air. In this manner, when thevortex mixers271 are used to mix the contents on the slide, the fluid does not blow off the slide and the mixers do not dry any particular spot on the slide.
• The bar code blowoff/airknife267 is used to blow air on the portion of the slide which contains the bar code. In this manner, the bar code is easier to read. Further, fluid can be kept on the slide better due to surface tension if fluid near the edge of the slide is removed.
• Referring toFIG. 6B, there is shown a circuit board connection diagram for the microcontroller. The sensors and motors for theremote device166 plug into this board which in turn is in communication with the microcontroller.
• Referring toFIG. 7A, there is shown a block diagram of the dual rinse and volume adjustcomponents263,264,266 of theremote device166 inFIG. 6A. A run is generally executed in a series of steps including the following: reagent is applied to the slide, Liquid Coverslip™ is applied to the slide, the reagent reacts with the tissue on the slide, a different reagent is applied to the slide, Liquid Coverslip™ is applied to the slide, the different reagent reacts with the slide, etc. After the reagent reacts with the slide, but before the next reagent is applied to the slide, the excess reagent which did not react with the sample should be removed from the slide. Otherwise, there is the possibility of having non-specific staining, or background staining, on the slide. This non-specific staining may interfere with the visual analysis of the slide at the end of the run. In order to minimize the non-specific staining, the residual reagent from the previous step is washed from the sample using a wash buffer. Washing may be achieved using a dual rinse device which executes a dual rinse step using a dual rinsetop valve248H and a dual rinse bottom valve248I, as shown inFIG. 7A. Themicrocontroller36 controls the valves so that the wash buffer pulses the slide with the dual rinsetop valve248H and one of the dual rinsebottom valves2481 or248J consecutively. In particular, during the dual rinse step, themicrocontroller36 turns on the dual rinsetop valve248H, then one of the dual rinsebottom valves248I or248J, and so on. As described subsequently, there are two dual rinsebottom valves248I or248J in order to achieve the consistency pulse.
• Referring toFIG. 7B, there is shown a perspective view of the dual rinse top and dual rinse bottom, volume adjust/coverslip, airknife/barcode blowoff and vortex mixers. The configuration is in the form of a boomerang whereby the boomerang follows the curved portion of theslide carousel24.
• Referring toFIG. 8A, there is shown a side isometric view of one embodiment of thewash block312 which employs the dual rinsetop nozzle263 and dual rinsebottom nozzle264 as shown inFIG. 7A. Thewash block312 comprises a lower set ofnozzle outlet openings316 corresponding to the dual rinsebottom nozzle264 and an upper set ofnozzle outlet openings314 corresponding to the dual rinsetop nozzle263. In the preferred embodiment, the dual rinsebottom nozzle264 and dual rinsetop nozzle263 each comprise a plurality of openings. In an alternate embodiment, the dual rinsebottom nozzle264 and dual rinsetop nozzle263 each comprise a single opening. During the dual rinse step, theseopenings314,316 direct streams of pulsed rinsed fluid towards one or the other of thelongitudinal edges322 of theslide318. The streams of the pulsed rinsing fluid, from each of the lower and upper sets ofnozzle outlet openings314,316 preferably impact theslide318 at the rinsefluid impact zone320 which is upstream on theslide318 from the tissue sample (not shown) positioned thereon. Positioning of thewash block312 is important due to the fragile nature of the tissue sample positioned on the slide. By directing streams of pulsed rinsing fluid at theimpact zone320 of the slide, the rinse fluid is provided with laminar flow by the time the rinse fluid reaches the tissue sample. As a result, undue damage to the fragile tissue sample is prevented.
• The upper set ofnozzle outlet openings314 is constructed so that the associated streams of rinse fluid are off-set at an angle from the longitudinal center line of the slide so that the pulsed streams of rinse fluid are directed toward one of the longitudinal edges of theslide318. The lower set ofnozzle openings316 is constructed so that the associated streams of rinsing fluid are also off-set at an angle from the longitudinal center line of the slide so that the pulsed streams of rinse fluid are directed toward the other one of the longitudinal edges of theslide318. As a result of this arrangement, pulsed streams of rinse fluid are alternatively and repeatedly directed to one and then the other of the longitudinal edges of the slide.
• As shown inFIG. 7A, separate plumbing and valving are provided for each of the lower and upper sets ofnozzle outlet openings314,316 of the dual rinse top nozzle and dual rinsebottom nozzle263,264 to permit independent operation thereof. In operation of the dual rinse step, thewash block312 directs streams of pulsed rinsing fluid, for example from the lower set ofnozzle openings316 toward a single longitudinal edge of the slide and after completion then directs streams of pulsed rinse fluid, for example from the upper set ofnozzle openings314, to the other longitudinal edge of the slide. This procedure is repeated, via control of thevalves248H-J using themicrocontroller36, and has the effect of rinsing the previous layer of rinse fluid and chemicals off of the slide. The wash block nozzle axis of each of the dual rinse top nozzle and dual rinsebottom nozzle263,264 forms an angle with the horizontal of between15 and35 degrees, preferably substantially35 degrees for the dual rinsetop nozzle263 and substantially25 degrees for the dual rinsebottom nozzle264, as described inFIGS. 8B and 8C. Moreover, the angle of the slide is substantially horizontal (0.5 degrees to 1.25 degrees) so that the wash buffer both washes the excess reagents off of the slide and also flows off of the slide.
• After cleaning the excess reagent off of the slide, a precise amount of wash buffer should be applied to the slide. Ordinarily, 270 μL is the optimal amount of buffer which should be placed on the slide for the next step. In executing the dual rinse step, there is residual wash buffer on the slide; however, the amount of wash buffer left on the slide varies considerably. In order to consistently leave a specific amount of fluid on the slide, themicrocontroller36 executes a consistency pulse.
• The consistency pulse consistently leaves an amount of fluid on the slide with variation in amount lower than a shorter pulse, and the consistency pulse cleans the slide of excess reagents. The consistency pulse is a pulse of wash buffer which is executed for a longer period of time than the individual pulses of the dual rinse step. To send wash buffer onto the slide, the tubing containing the wash buffer is pressurized. Because of this pressure and because of the turning on and off of thewash buffer valves248H-J, there is a pressure wave effect generated in the wash buffer tubing (i.e., there are “reflections” with a certain frequency that travel through the tubing based on, among other things, the length and geometry of the tubing). Therefore, one cannot consistently determine where one is on the wave. Because of this wave effect, the amount of pressure that the pulse has varies so that the amount of buffer left on the slide varies as well. In order to minimize the wave effect, the consistency pulse turns the valve on for a period of sufficient time and/or for a sufficient strength in order to let the wave effect minimize within the tubing. This sufficient amount of time amounts to a few periods of the frequency of the reflected wave. Since the reflected wave is a decaying sinusoid, after a few periods, the wave is no longer a factor in the consistency pulse. The consistency pulse is therefore an extended burst of either the dual rinsetop nozzle263 or the dual rinsebottom nozzle264 for a period longer than the dual rinse step. For example, as describe inFIG. 9 in more detail below, the period for a pulse during the dual rinse step is 60 mSec whereas the period for the consistency pulse is 300 mSec.
• Moreover, in order for the consistency pulse to leave a consistent amount of fluid on the slide, the momentum of the consistency pulse should be greater than that during the dual rinse step. In the preferred embodiment, the increase in momentum of the pulse is achieved by increasing the volume of wash buffer flow using two dual rinsebottom valves248I and248J, as shown inFIG. 7, as opposed to using only one dual rinsevalve248I or248J during the dual rinse step. In this manner, the stream of wash buffer with an increased momentum is sent across the slide with the result that the residual volume of buffer left on the slide after the consistency pulse is lower and also has a lower variation. If a pulse of lower momentum is used, more solution is left on the slide due to interaction with the surface tension of the slide. In an alternative embodiment, the increase in volume and subsequent increase in momentum for the consistency pulse may be achieved using a valve which has an opening which is larger than the opening of thevalves248H-J used during the dual rinse step. The consistency pulse therefore has a strong flow out of the nozzle, generating a laminar, not turbulent, flow on the slide. The laminar flow then washes off the slide, consistently leaving an amount of fluid on the slide. Moreover, the consistency pulse is consistent, not only from run to run on an individual machine, but also from machine to machine as well. Therefore, machine may be interchanged without the need for recalibrating the system to determine the amount of buffer left on the slide.
• Further, when both a consistent and a minimal amount of buffer is desired to be left on the slide, the dual rinsebottom nozzle264 should be used rather than the dual rinsetop nozzle263. The angle of the dual rinsebottom nozzle264 is less than the angle for the dual rinsetop nozzle263; therefore, the less steep the angle, the more likely the buffer will flow off of the slide, not interacting with the surface tension of the slide. For example, using a dual rinsetop nozzle263 with a single valve leaves approximately 275±40 μL on the slide whereas using a dual rinsebottom nozzle264 with a dual valve leaves approximately 180±20 μL on the slide.
• With varying the time of the pulse, the angle of the pulse, and the momentum, the consistency pulse may be used in several ways. The first way is for the consistency pulse to leave a minimal amount of wash buffer on the slide with minimal variation from run to run and machine to machine (180±20 μL) for any given instrument. In particular, this variation of ±20 μL is across all machines so that, in the event that one machine must be replaced by a second machine, the variation is small enough so that the amount of fluid left on the slide is within acceptable parameters. Moreover, the variation from run to run within a single machine is approximately ±10 μL; therefore, once the machine is calibrated (and the amount of volume dispensed from the volume adjust, as discussed subsequently, is determined to achieve a total volume of 270 μL), the fluid on the slides for a particular machine does not vary significantly run to run.
• The modification of the consistency pulse is done by using a time longer than the individual dual step pulse, the dual rinsebottom nozzle264, and the twovalves248I and248J; after the consistency pulse step, the required amount of buffer on the slide (as determined by experiment) may be added using the volume adjust266, which is described subsequently, with extreme precision.
• Apart from using the consistency pulse to leave a minimal amount of buffer on the slide, the consistency pulse may be used to leave an amount greater than a minimal amount, while still having a low variation in the amount left on the slide. For example, the operator may adjust the amount of momentum of the pulse, the duration of the pulse, the angle of the outlet nozzle with respect to the slide, and the angle of slide with respect to horizontal. As one example, the outlet of the nozzle may be designed with an angle which is less than the angle of the dual rinse bottom nozzle. In this manner, the operator may tailor the amount left on the slide depending on the amount and variance of the buffer necessary for the experiment.
• After the consistency pulse, if additional buffer is necessary to be placed on the slide to run the experiment, the volume adjust is used, as shown inFIGS. 7A and 7B. Themicrocontroller36 turns on thevalve248G for the volume adjust line to place buffer on the slide. As described previously, the volume adjust line has a restrictor268 which reduces the volume flow of the wash buffer through the line. This is done so that the buffer does not disturb the tissue on the slide since the needle of the volume adjustnozzle388 is directly above the slide and the wash buffer is dropped onto the slide. A precise amount of buffer is able to be placed on the slide. This is based on the amount of pressure in the wash buffer bottle, the amount of time thevalve248G for the volume adjust line is open, and the amount of flow through therestrictor268. Based on these parameters, the amount of volume placed on the slide may be adjusted by changing the dial nozzle which controls the amount of time the valve for the volume adjust line is open. In the alternative, the amount of time the valve is open may be adjusted using a potentiometer.
• In operation, the volume adjust266 is more accurate when it is turned on for more than 60 mSec. Operating the volume adjust266 less than 60 mSec makes the dispensing of the buffer less accurate. This is due to the fact that the turning on and off of the valves, which is controlled by the microcontroller, is interrupt driven. There is a window of accuracy of approximately 10 mSec when turning on/off the valves (e.g., if the volume adjust266 is to be turned on for 50 mSec, the actual time in which the valve for the volume adjust is turned on is between 40 mSec and 50 mSec). Therefore, when designing a system which combines both the consistency pulse with the volume adjust, the consistency pulse should leave a volume of fluid on the slide low enough so that the volume adjust may be turned on for more than 60 mSec (which is determined to be the minimal amount of time in which the accuracy of the volume adjust is acceptable). In order to accomplish this, the consistency pulse is designed to leave a minimal amount of fluid on the slide by using the dual rinsebottom nozzle264 and the twovalves248I and248J. In practice, after the consistency pulse using the dual rinsebottom nozzle264 and the twovalves248I and248J, there is 180±20 μL. By turning on the volume adjust for approximately 100 mSec, the volume on the slide is increased to approximately 270 μL.
• Referring toFIGS. 8B and 8C, there are shown side views of the angles of the dual rinsetop nozzle263 and dual rinsebottom nozzle264, respectively, as shown inFIG. 8A. Note that bothFIGS. 8B and 8C are positioned upside down for ease of reference of the angles of the nozzle openings. The angle, as described previously, is35 degrees from the horizontal for the outlet of the dual rinse top nozzle (263) is25 horizontal for the outlet of the dual rinse bottom nozzle (264). These angles may be varied in order to modify the amount and/or variation of fluid left on the slide after the consistency pulse.
• Referring toFIG. 8D, there is shown a side view of one embodiment of the volume adjust as shown inFIG. 7A. Theneedle388 of the volume adjust is composed of a stainless steel with a 90 degree needle. Fluid therefore goes at a downward angle and drops onto the slide, thereby allowing for greater control of the placement of the fluid. The connector pieces which connect theneedle388 to theacrylic block392 of the volume adjust are also composed of stainless steel. The stainless steel is used since it does not react with the wash buffer. At the back of theacrylic block392 is aconnector394 which connects to the volume adjust line ofFIG. 6A. At the side of the acrylic block is aconnector396 which connects to the Liquid Coverslip™ line ofFIG. 6A.
• Referring toFIG. 9, there is shown a flow chart of the dual rinse, the consistency pulse and the volume adjust steps. For the dual rinse step, one of the dual rinse bottom valves (248I or248J) is first turned on324, themicrocontroller36 waits for 60mSec326, and the dual rinse bottom valve (248I or248J) is turned off328. Themicrocontroller36 then delays for 30mSec330. The dual rinse top valve (248H) is then turned on332, themicrocontroller36 waits for 60mSec334, and the dual rinse top valve (248H) is turned off336. Themicrocontroller36 then delays for 30mSec338. This sequence is repeated twotimes340. Then, themicrocontroller36 waits 1100mSec342. Then, the dual rinse top valve (248H) is turned on344, themicrocontroller36 waits for 60mSec346, and the dual rinse top valve (248H) is turned off348. Themicrocontroller36 then delays for 30mSec350. One of the dual rinse bottom valves (248I or248J) is first turned on352, themicrocontroller36 waits for 60mSec354, and the dual rinse bottom valve (248I or248J) is turned off356. Themicrocontroller36 then delays for 30mSec358. This sequence is repeated fourtimes360. Then the dual rinse top valve (248H) is turned on362, themicrocontroller36 waits for 60mSec364, and the dual rinse top valve (248H) is turned off366. Themicrocontroller36 then waits 1200mSec368.
• In the preferred embodiment, the dual rinse step begins with a bottom-top, bottom-top rinse cycle, and then a top-bottom, top-bottom, top-bottom, top-bottom rinse cycle. In this manner, the slide is cleaned better. This switching of the dual rinse step, starting with one set of nozzles (in the preferred embodiment, the dual rinse bottom valve), and in the next step, starting with the other set of nozzles (in the preferred embodiment, the dual rinse top valve), allows for quicker cleaning of the slide while using less buffer. Depending on the rinsing needs of the slides, the number of pulses (top-bottom or bottom-top) and the amount of buffer sent in the pulses are varied. Rinsing removes excessive reagent in the slide and the tissue, which in turn will reduce the background staining on the slide and aid in analysis of the slide.
• By experimentation, 6.5 to 7.5 mL of buffer should be used in the dual rinse step. More than 7.5 mL in the dual rinse step uses an excessive amount of buffer (i.e., one may run out of buffer during a staining run), and may limit the amount of dual rinse steps performed in one run. Moreover, by experimentation, the dual rinse step should end by using the bottom valve and bottom nozzle. This is so that, the consistency pulse, which also uses the bottom valves, is run more consistently.
• For the consistency pulse step, both the dual rinse bottom valves (248I and248J) are turned on370,372, themicrocontroller36 then delays 300mSec374, and both the dual rinse bottom valves (248I and248J) are turned off376,378. For the volume adjust step, after theslide carousel24 is moved oneposition380, thevalve248G for the volume adjust line is turned on382. Themicrocontroller36 waits, depending on the amount of fluid to be deposited on theslide384. Then, the valve (248G) for the volume adjust line is turned off386. Delays in between the dual rinse step, consistency pulse step, and volume adjust step are inserted in the steps above in order to minimize the possibility of having too many valves on in the system at the same time. If this occurs, this drops the pressure and, in turn, reduces the force of fluid of wash buffer and Liquid Coverslip™.
• FIGS. 10 and 11 illustrate the manner of mounting afluid dispenser400 in a reagent tray which is engaged in thereagent carousel8. Thefoot440 is initially inserted into a circularU-shaped groove442 formed in thereagent tray10. In an alternative embodiment, the foot is inserted into a rectangular shaped groove. Groove444 ofspring member448 engages acircumferential lip446 of thereagent tray10.FIG. 11 shows a cross sectional view of thefluid dispenser400 after it has been mounted on thereagent tray10 showing in particular the manner in which foot440 fits intogroove442 and showing the flexing ofspring member448 to hold thefluid dispenser400 firmly in place. To remove thefluid dispenser400,spring member448 is simply bent inward slightly so that thegroove444 clears thelip446, and thefoot440 is withdrawn fromgroove442.
• Referring toFIG. 12A, there is shown an elevational cutaway view of aprefilled fluid dispenser400 in the extended position.FIG. 12B shows an elevational cutaway view of a userfillable fluid dispenser400 in the extended position. The main difference between the prefilled and customer fillable dispensers is the substitution of aflip cap402 to replace thesnap cap404. Thefluid dispenser400 has areservoir chamber410, which stores the fluid, and a dispensechamber412, whereby thereservoir chamber410 is above the dispensechamber412. Thereservoir chamber410 is substantially in line with the dispense chamber, and in the preferred embodiment, coaxial with the dispensechamber412.
• Previous liquid dispensers had a side by side arrangement whereby the reservoir chamber was to the side of the dispense chamber. In this configuration, the reservoir chamber was smaller and therefore held less fluid. In the present invention the reservoir chamber can be enlarged thereby holding more fluid. For example, in previous dispensers, the reservoir chamber could hold approximately 27.5 mL of fluid whereas, in the present invention, the reservoir chamber can hold approximately 34.0 mL of fluid. Ordinarily, a single dispenser is rated to give 250 shots (i.e., 250 dispenses of fluid). In order to provide the 250 shots in the previous dispensers, different types of couplers, depending on different types of reagents had to be made. This was due, in part, to the limited capacity of the reservoir chamber and to the thickness of the fluids (some fluids dispense different amounts based on the viscosity of the fluid). Because of the increased capacity of the reservoir chamber in the present invention, the dispenser can provide 250 shots, regardless of the viscosity of the fluid, so that different couplers are not necessary.
• Moreover, previous fluid dispensers which included areservoir chamber410 that was to the side of the dispensechamber412 required a connecting or horizontal section which connected thereservoir chamber410 with the dispensechamber412. In addition to potential problems of clogging of the horizontal section, the previous design was more difficult to manufacture. In particular, the side-by-side design required that the molding process of the horizontal or connecting piece be carefully controlled so that all sides of the connecting piece interact correctly with thereservoir chamber410, the dispensechamber412, and theball chamber432 andnozzle430. As described subsequently, theball chamber432 includes aball426 which seats in the upper part of theball chamber432 during a portion of the operation of thefluid dispenser400. In previous designs, the coupler was formed via a T-shaped chamber, i.e. a horizontal chamber abutting two vertical pieces. At the intersection of the pieces, the ball seat area was formed. In manufacturing this coupler, the consistency of the T-shaped piece varied so that the ball seat area was, at times, difficult to manufacture properly. In the present invention, thefluid dispenser400 requires no horizontal connecting portion between thereservoir chamber410 and the dispensechamber412. Thereservoir chamber410 is on top of dispensechamber412 and, in the preferred embodiment, thereservoir chamber410 is coaxial with the dispensechamber412. Since the flow is substantially in one line or vertical, the T-shaped piece is removed. Moreover, the ball seat area is replaced by a check valve ball insert424 which is a separate and smaller molded piece, and therefore can be controlled, from a manufacturing standpoint, better than in previous designs.
• In the preferred embodiment, thereservoir chamber410 shape is as shown inFIGS. 12A and 12B. The reservoir shape may also be funnel-like or any other shape which drains the fluid through the connecting means between thereservoir chamber410 and the dispensechamber412. The connecting means between thereservoir chamber410 to the dispensechamber412 in the preferred embodiment is a valve, such as aduckbill check valve416 which has a means to sense pressure differentials. The duckbill check valve is manufactured by Vernay Laboratories, Inc. in Yellow Springs, Ohio, part number X6597-E. In alternate embodiments, the connecting means is any device which transfers fluid in one direction (from thereservoir chamber410 to the dispense chamber412) and which passes fluid based on a pressure differential. This includes using an umbrella valve or thecup check valve792 as described inFIGS. 20-21.
• Fluid is ejected from the dispensechamber412 by exerting a downward force on the cap, against the force of thecompression spring418. This forces thebarrel408 downward until it reaches thestop420 which prevents thebarrel408 from further downward movement, as shown inFIG. 12C. When thefluid dispenser400 is mounted on areagent tray10, as described inFIGS. 10 and 11, the downward force on thecap404 is applied by the dispense cylinder extend air line, as described inFIG. 6A, or by some other means to push thebarrel408 downward. The downward movement of thebarrel408, including the lower portion of the barrel which acts as a piston, expels fluid from the dispensechamber412.
• As thespring418 expands, thebarrel408 moves upward and theball426 moves upward as well. Referring toFIG. 13A, there is shown a detailed view of theball chamber432 andnozzle430. Thecoupler428 is formed where a hole in the coupler is offset forball chamber432 so that an inner edge ofnozzle430 protrudes into the outlet ofball chamber432.Ball chamber432 contains aball426 which fits loosely against the cylindrical surface ofball chamber432 and is free to move between an uppermost position and a lowermost position. In its uppermost position,ball426 mates with the ballcheck valve insert424, thereby preventing fluid flow in the direction fromnozzle430 to dispensechamber412. At its lowermost position, theball426 is restrained by inner edge ofnozzle430 and prevented from falling intonozzle430. This does not prevent fluid from flowing fromball chamber432 tonozzle430, however.
• Using the above described structure as a basis, the operation and unique characteristics offluid dispenser400 will now be described. At the beginning of a dispense stroke, thefluid dispenser400 is in the positions shown inFIGS. 12A and 12B. When fluid is to be dispensed, a downward force is applied againstcap402. This overcomes the force ofcompression spring418 and forces thebarrel408 downward until it reaches the top of thestop420, thereby dispensing a predetermined volume of liquid equal to approximately 100 μL. This is equal to the liquid volume of the area that thebarrel408 moves down minus the “suck back” (which is the amount of fluid that travels past the ball on the upstroke of thebarrel408 before theball426 shuts off the flow). The fluid flows from dispensechamber412 intoball chamber432. The downward flow throughball chamber432forces ball426 to its lowermost position, abuttingedge434, but this does not prevent flow in this direction and the measured amount of fluid is ejected fromnozzle430.
• When thebarrel408 has reached its lower extreme position, the downward force oncap402 is released, by themicrocontroller36 actuating the valve248B for the dispense cylinder retract air line, as described inFIG. 6A, andcompression spring418 takes over, forcingbarrel408 andcap402 in an upward direction. Fluid begins to be sucked into dispensechamber412, which was described previously as the “suck back.”
• It is here that the interplay of ballcheck valve insert424 andball426 in theball chamber432 is described. Theball426 moves freely withinball chamber432, and therefore provides essentially no resistance to fluid flow fromnozzle430 until it reaches its sealing position at the ballcheck valve insert424. When the dispenser operation is completed, the fluid flow has forcedball426 to its lowermost position, abuttingedge434. As the upward movement of thebarrel408 begins to draw fluid back into dispensechamber412, the upward flow of fluid inball chamber432 pullsball426 upward until it reaches ballcheck valve insert424, where it cuts off any further fluid flow toward dispensechamber412. Untilball426 reaches the ballcheck valve insert424, however, there is virtually no resistance to fluid flow fromnozzle430, and therefore no pressure differential is created across duckbill check valve416 sufficient to cause fluid flow fromreservoir chamber410 to dispensechamber412.
• The volume of fluid which flows from nozzle towards dispense chamber412 (“suck back”) whileball426 is moving from its lowermost to its uppermost position is preselected to be a volume equal to the volume of the hanging drop left at tip at the end of the dispense cycle. Thus, the drip is effectively drawn back intonozzle430 and an internal meniscus forms at tip.
• Whenball426 reaches the ballcheck valve insert424, it shuts off further flow fromnozzle430 into dispensechamber412. This immediately creates a pressure differential acrossduckbill check valve416 and causes fluid to flow fromreservoir chamber410 into dispensechamber412. The suction generated in dispensechamber412 keepsball426 firmly seated against the ballcheck valve insert424 and prevents any further flow fromnozzle430. Whencompression spring418 has forcedbarrel408 upward, as shown inFIGS. 12A and 12B, thefluid dispenser400 is ready for another dispense cycle. When the pressure differential is at equilibrium, theball426, being made of a material slightly more dense than the liquid, falls throughball chamber432 until it make contact again withedge434.
• Referring toFIGS. 13B and 13C, there is shown a front and side cutaway of the lower portion of thefluid dispenser400, respectively, in an alternative embodiment of the invention wherein the ballcheck valve insert424 andball426 are removed. In order to retract a hanging drop from the edge of thenozzle430, thepiston454 on the end of thebarrel408 has anextension piece456 connected to it. In this manner, when thebarrel408 is raised upward, theextension piece456 moves upward as well, thereby retracting any drops on the edge of thenozzle430. In particular,FIG. 13B shows the barrel is in the down position.
• There areholes806 where the extension piece is attached to the bottom of thepiston454. In an alternate embodiment, thepiston454 has asingle hole806. When the piston rides down, the O-ring810 is a tight fit with the extension piece so that the O-ring810 travels with the extension piece. Because the O-ring810 is not flush with the chamfer808 (which is a cone shaped), fluid in the dispense chamber can flow down around the back side of the O-ring810 and out through thenozzle430. A second O-ring814 takes the place of thequad seal422, as shown inFIGS. 14A-14B.
• On the upstroke, the O-ring810 travels with theextension piece454, which is attached to thepiston454, until the O-ring810 seats against thechamfer808. In this manner, theextension piece454 acts as a piston extension. Thechamfer808 is housed inside the O-ring insert812 and is fixed during movement of the piston. The O-ring insert812 is connected to thecoupler428. When the O-ring810 seats in the chamfer808 (closing off any flow), there is a vacuum created in the dispensechamber412, which creates the pressure differential to dispense fluid into the dispensechamber412 through thecheck valve482. Simultaneously with the upstroke, the fluid travels with theextension piece454, and the drop at the end of the tip of the dispenser travels with the fluid due to surface tension. Therefore, the hanging drop is pulled back into thenozzle430. Moreover, with thebarrel408 in the up position, fluid does not travel through theholes806 due to the O-ring810 seating inside thechamfer808. In this embodiment, the ball and ball check valve insert is not necessary.
• Referring toFIGS. 14A and 14B, there are shown exploded views of a cutaway of a prefilled and userfillable fluid dispenser400, respectively. Differences between the prefilled and the user fillable fluid dispensers include: (1) thesnap cap404, as shown inFIGS. 14A and 14B; thebarrel408 being transparent in the user fillable fluid dispenser; and (3) the lack of anevaporation ring405 in the user fillable fluid dispenser. Fluid can be filled into the reservoir through a fill hole and subsequently closed using asnap cap404 in order to close the system. For prefilled fluid dispensers, thesnap cap404 is permanently attached over the fill hole after filling. The fill hole and thesnap cap404 are matched using a luer fitting design in order to be a tight seal, as shown inFIG. 16. The userfillable fluid dispenser400 utilizes a living hinge design and luer slip design between the fill hole and theflip cap402. Thecap406, as previously described, is sonically welded to thebarrel408. Thecap406 also has a vent460, which is described subsequently with respect toFIG. 16. The duckbillcheck valve insert414 holds theduckbill check valve416 in place and creates a seal so that fluid cannot drip either from the dispensechamber412 to thereservoir chamber410 or from thereservoir chamber410 to the dispensechamber412. Further, the duckbillcheck valve insert414 has a protrusion, or a nipple, which holds the duckbill to it for ease of assembly, as shown in more detail inFIG. 17B. Theduckbill check valve416, which serves as a check valve, is snapped to the duckbillcheck valve insert414. Theduckbill check valve416 is a one way valve with a high cracking pressure of between 0.6 to 3.0 psi. This acts to hold the fluid in thereservoir chamber410 since the cracking pressure is greater than the head pressure of fluid in thereservoir chamber410. And, the duckbill passes fluid from thereservoir chamber410 to the dispensechamber412 on the upstroke of thebarrel408 while preventing fluid to pass during the downstroke of thebarrel408. Theduckbill check valve416 and duckbillcheck valve insert414 are seated in the lower portion of thebarrel408 as shown inFIG. 17A.
• Thespring418 is a compression spring which expands and contracts based on the movement of thebarrel408. Thestop420, as described previously, stops the downward stroke of thebarrel408. The stop also holds thequad seal422 in place during movement of thefluid dispenser400 and composed of polypropylene. Thestop420 is held in place based on thecompression spring418 with the force varies based on the movement of thebarrel408. Thestop420 is held in place, in turn, keeps thequad seal422 in place via aledge420A, as shown inFIG. 17C, on thestop420. Thequad seal422 ensures that thefluid dispenser400 is always a closed system thereby keeping thefluid dispenser400 primed. Thequad seal422 is made of Viton™ rubber that is a fluoroelastomer, and is distributed by Lutz Sales, in Hanover Park, Ill., part number QS-008-2799. The ballcheck valve insert424 is a separate part from thecoupler428 and is seated inside thecoupler428, being snapped into place by grooves in the chamber of thecoupler428 and by being seated on aledge428A, as shown inFIG. 17A. The ballcheck valve insert424 has aball seat424A on the inside with which to engage theball426 on the upstroke of thebarrel408. Previous fluid dispensers integrated the coupler with the ball check valve insert for the ball. However, manufacturing of the coupler integrating those functions was difficult due to the fact that 3 pins, at the positions of 12:00, 3:00 and 6:00, had to come together and not distort the ball check valve insert. Therefore, processing is simplified by separating the ballcheck valve insert424 from thecoupler428. Theinner cavity432 of the ballcheck valve insert424, which engages theball426, may then be manufactured more easily. Theball426 is made of borosilicate (which is a type of glass). In an alternative embodiment, aball426 composed of rubber may be used. In certain instances, a rubber ball may seat better in the plastic ballcheck valve insert424, provided there is no chemical interaction of the rubber ball with the reagents.
• Assembly and filling of thefluid dispenser400 is simple based on the invention. Theduckbill check valve416 and duckbillcheck valve insert414 are placed in the lower part of thebarrel408. Thecap406 is welded to the barrel. Theball426 is placed, the ballcheck valve insert424 is snapped and then thequad seal422 is inserted into thecoupler428. Thestop420 and thespring418 are inserted into thecoupler428 and thecoupler428 is snapped on to thebarrel408. Thebarrel408 is filled with reagent and thefluid dispenser400 is primed. Thecap404 is placed on the top of the dispenser and thenozzle cap458 is placed on the output of thenozzle430 on thecoupler428.
• Further, the present invention allows for easier manufacture and filling of the reagents in thefluid dispenser400. Previous fluid dispensers required gluing of many pieces and sonic welding after filling the dispenser, thus requiring a certain level of skill and training. In contrast, the fluid dispenser of the present invention requires snapping in of pieces and only the sonic welding of the vent460 to thecap406 and thecap406 to thebarrel408. Moreover, the filling of the reagents in thefluid dispenser400 is easier in the present invention. In previous fluid dispensers, the fluid dispenser is assembled except for the piston, piston guide, cap and nozzle cap. The reservoir chamber is filled with reagent. The piston and piston guide are then placed in the reservoir chamber and any leftover fluid on top of the piston is evacuated. Finally, the cap is sonically welded or screwed onto the top of thebarrel408. In the present invention, since there is no piston in thereservoir chamber410, there is no need to evacuate the area on top of the piston. Instead, thecap406 is first sonically welded to thebarrel408, and then the reagents are added to thereservoir chamber410. In this manner, there are fewer steps in the filling of the dispenser. Moreover, in the present invention, some of the more manufacturing sensitive parts are smaller, thereby making manufacturing easier. In the preferred embodiment, the material used is polypropylene. Under these conditions, smaller parts have a higher level of dimensional stability. Therefore, smaller components, such as the ball check valve insert424 (which is, in the present invention, a separate component from the coupler428) are able to be processed more consistently.
• Referring toFIGS. 15A and 15B, there are shown side views of aprefilled fluid dispenser400 and customerfillable fluid dispenser400, respectively. Both types of dispensers have barcode labels which are read by thebarcode reader276, as described above. In order to allow the customer to fill thefluid dispenser400 with reagent, thesnap cap404 is replaced by aflip cap402 which varies in two ways from the snap cap: (1) the flip cap has an attachment to the cap; and (2) the flip cap has aprotrusion402A which acts as a thumbpad to prop open theflip cap402. In previous fluid dispensers, the fluid dispenser had to be inverted in order to prime the syringe. The customer was required to first fill up a transfer syringe manually, push on an epindorf syringe and fill up this syringe. Then, the customer pressed this syringe into the coupler and forced fluid from the syringe through the connecting section between the reservoir chamber and the dispense chamber. The customer had to then pump the plunger, at least 6 to 8 times, holding the coupler upside-down, until fluid came out of the nozzle which did not have any bubbles. In the present invention, the customer opens the flip cap, fills thereservoir chamber410, and closes the flip cap. The customer, without turning the fluid dispenser upside down, uses atypical syringe459, as shown inFIG. 19A, to prime thefluid dispenser400. The syringe may be manufactured by B-D Corp., in Franklin Lakes, N.J.,size 20 cc, part number BC301032. Thesyringe459 has a restrictor459A and an O-ring459B. Therestrictor459A has an internal diameter of approximately 5 thousandths of an inch. Thesyringe459 is placed inside thenozzle430 of thecoupler428 and the syringe plunger is expanded to draw fluid from thereservoir chamber410 and the dispensechamber412. To prime thefluid dispenser400 more quickly, thebarrel408 is pushed down, and is released simultaneously when the syringe plunger is expanded. In this manner, there is significantly less waste of reagent. In the previous fluid dispensers, the pumping of the plunger 6-8 times wasted reagent. In thepresent fluid dispenser400, any reagent is sucked into thesyringe459. Because thesyringe459 is clean, its contents may be placed back into thereservoir chamber410 through theflip cap402, without waste of any reagent.
• Referring toFIG. 19B, there is shown an exploded view of the syringe459 (and a syringe label788) with a restrictor459A and an O-ring459B for use in the nozzle of the coupler. The O-ring459B is placed on the side of the restrictor459A that does not have the v-notch in it. Therestrictor459A, with the O-ring459B side down, is placed into a holdingfixture790, as shown inFIG. 19B. Thesyringe459 is then pressed onto the restrictor459A for assembly. Therestrictor459A is made by Airlogic, in Racine, Wis., part number F-2815-050 (color: lime green), with a one inch orifice for the restrictor459A. The O-ring459B is manufactured by Parker Co., in Lexington, Ky., part number 2-003. The restrictor459A fits well in the nozzle of thesyringe459 so that thesyringe459 does not need the O-ring459B to seat against the coupler. Because of potential differences in mold runs for thecoupler428 of thefluid dispenser400, the O-ring459B is used so that therestrictor459A fits tightly against thecoupler428.
• To check for a good prime, the customer may flip the dispenser upside-down, tap the dispenser, dislodging any trapped air then pressing down on the barrel slowly to move the air bubble past the ball seat. The customer may then flip the coupler right-side-up and release the barrel. Good priming occurs with approximately one drop of waste.
• Referring toFIG. 15C, there is shown an exploded view of a prefilled fluid dispenser with anevaporation ring405 adjacent to the cap. The interaction of the vent, theevaporation ring405 and the cap are discussed subsequently with respect to FIGS.16A-E. Thebarcode label784 is placed on the dispenser in order to be read by thebarcode reader276. Thedispenser label786 is also placed on the dispenser.
• Referring toFIG. 16A, there is shown a cutaway view of thecap406 and vent460 of afluid dispenser400. The vent is the component adjacent the top of the cap and includes thevent area464,vent material466, andbacking468. The vent460 is used as a means to allow air to flow both into and out of the reservoir chamber410 (i.e., so that the reservoir chamber can “breathe”). The vent460 allows for a constant pressure in the reservoir chamber and equalizes the pressure in thereservoir chamber410 with the pressure in the atmosphere. There are several ways in which to construct the vent in order to maintain a constant pressure in thereservoir chamber410 and/or equalize the pressure in thereservoir chamber410. In the preferred embodiment, as discussed more fully in subsequent figures, the vent area is approximately70 thousandths of an inch, with avent material466 composed of a hydrophobic material. By experimentation, it was determined that due to size of the opening, fluid in the reservoir chamber was evaporating through the vent area. In order to reduce the evaporation (i.e., have the reservoir chamber “breathe” less), anevaporation ring405, as shown inFIGS. 15C and 16A, was inserted in the air gap formed between thesnap cap404 and thecap406. Thisevaporation ring405 restricts the amount of air flow across the vent area, thereby reducing the amount of evaporation of fluid from the reservoir chamber.
• In an alternative embodiment, the vent area is reduced to approximately 10 thousandths of an inch, thereby reducing the amount of evaporation from thereservoir chamber410. However, processing a fluid dispenser with a reduced vent area is more difficult due to the corresponding reduced area of the vent material. In another alternative embodiment, thevent area464 may be any area. And, the vent material may be composed of a tighter material, thereby reducing the air flow through the vent material and reducing the amount of evaporation through thevent area464. In the preferred embodiment, the vent material is 1 μm in the size of the mesh. Reducing the size of the mesh, such as to 0.25 μm, further reduces the amount of evaporation through thevent area464. In another alternative embodiment, the vent area may be any area and a section of tape is placed across the vent area. The tape contains a pin hole whereby the vent area is effectively reduced thereby reducing the amount of evaporation.
• As shown inFIG. 16A, thecap406 and snap cap404 (orflip cap402 for user fillable fluid dispensers) are luer fitting design so that thecap406 andsnap cap404 portion which engage each other to seal the fill hole is conical. At the lower portion of the conical section of thesnap cap404 is a ring or alip462 that is used to snap thesnap cap404 into place. In this manner, thesnap cap404 is pushed down until it locks into thecap406. Thesnap cap404 has acurved section472 that abuts against a curved section of the cap thereby stopping thesnap cap404 at that point. Thesnap cap404 also engages thecap406 to form anair space474 that is adjacent to the vent area. Thisair space474 forms a ring, so that regardless of the orientation of the snap cap to the cap, a hollow section is adjacent to the vent area464 (which is approximately70 thousandths of an inch or less). Further, the outside diameter of thesnap cap404 is slightly smaller than the inner diameter of thecap406 so that asmall air gap476 is formed adjacent to theair space474 to the outside of the dispenser. Theair space474 serves as a path from the vent460 to the outside atmosphere as well as serving as a buffer between the outside of the dispenser and the vent460. In an alternative embodiment, theair gap476 may be used in conjunction with a notch in the side of the cap, as shown inFIG. 15C. This notch allows more air into theair gap476, in the event that the greater air flow is required. Moreover, the notch may replace theair gap476, so that the sole means of air flow into theair space474 is through the notch.
• The vent460 is a hydrophobic vent which allows air to flow through the vent while keeping fluid trapped inside thereservoir chamber410. The vent is composed of afilter material466 such as a teflon material with a backing to attach the vent to the cap. The vent opening orarea464, as described previously, is approximately70 thousandths of an inch. The pressure inside thereservoir chamber410 is constant, even though the level of reagent may be changing inside thereservoir chamber410 since air is allowed to flow into thereservoir chamber410. Moreover, some reagents produce a by-product of gas (called outgassing). In the event that a reagent outgasses, the hydrophobic vent460 allows gas through the vent460, thereby avoiding any pressure build-up inside thereservoir chamber410. In this manner, previous fluid dispensers that required a piston to exert force on the fluid in thereservoir chamber410 may be removed. The piston in previous designs suffered from several drawbacks. First, certain reagents (such as proteins) may stick to the reservoir chamber, therefore preventing the piston from traveling with the fluid in the reservoir chamber. Additionally, the interaction between the piston and the barrel rely on lubricants. Certain reagents are composed, in part, of detergents and the detergents interfere with the lubrication between the piston and the barrel. Both effects interfere with the performance of the fluid dispenser, thereby giving inconsistent dispensing of fluid. Further, outgassing interacts with the piston either to increase the flow out of thereservoir chamber410 or to create a compressible air gap between the piston and the main section of thereservoir chamber410.
• Also, certain types of reagents interact with thequad seal422, causing thequad seal422 to break down. In order to minimize this interaction, thequad seal422 is coated with fluorine. Fluorine reacts with the outer layer of thequad seal422, thereby discouraging reactions with certain types of reagents.
• In addition, as shown inFIGS. 15C and 16A, inside theair space474 is anevaporation ring405. Theevaporation ring405 is composed of low density polyethylene material manufactured by Whitmark (vendor part number 105060), and is ⅛ inch thick. As discussed previously, the ring acts as a barrier, making it more difficult for air to pass across the vent. In this manner, the ring acts as a restrictor (of air), thereby reducing the amount of evaporation, while still allowing thereservoir chamber410 to breathe. The ring is a closed cell foam, and is inexpensive in nature. The ring may be composed of any material or foam that acts to restrict the air across thevent area464. During manufacture of the fluid dispenser, the ring is inserted in between thecap406 and thesnap cap404. The ring should abut thevent area464, thereby restricting the air flow across thevent area464. Moreover, the ring, being composed of cell foam, compresses to fill up theair section474.
• Referring toFIG. 16A, there areprotrusions470 on the inside upper portion of thecap406 which are used to align the piece of vent material. The vent460 is therefore centered on top of that upper portion of thecap406. Referring toFIG. 16B, there is shown an underside view of the vent460. Included with the vent460 is aplatform468 for the vent460, star-shaped in design, which holds the vent460 flat. When air is passing through the vent460, particularly when outgassing, the vent460 has a tendency to flex which may damage the teflon in the vent. In order to minimize flexing of the vent460, theplatform468 is adjacent to the vent. Therefore, the surface area of the vent may still be relatively large but still have a grid support to stabilize the vent460 during outgassing. Theplatform466 is star-shaped due to ease of molding; however, the shape of the platform may be any design, which supports or stabilizes the vent.
• In an alternative embodiment, as shown inFIG. 16C, the vent may be substituted with abi-directional valve478 or bi-directional duckbill (or two valves or two duckbills) as another means by which to allow air to flow into and out of thereservoir chamber410. Thebi-directional valve478 has abi-directional valve insert480 for placement of thebi-directional valve478. Thebi-directional valve478 also has a hydrophobic layer which allows air to flow through thebi-directional valve478 while keeping fluid trapped inside thereservoir chamber410. In one direction (air flowing into the reservoir chamber410), thebi-directional duckbill478 has a low cracking pressure, in order to equalize the pressure in thereservoir chamber410 when fluid is dispensed. In the second direction (air flowing out of the reservoir chamber410), thebi-directional duckbill478 has a high cracking pressure, in order to alleviate any pressure due to outgassing. Thebi-directional duckbill478 allows air to flow through while keeping fluid trapped inside thereservoir chamber410. Therefore, thebidirectional duckbill478 allows air to flow into and out of thereservoir chamber410 and allows for equalization of the pressure. In practice, abi-directional duckbill478 may have less refinement in terms of control when compared to two uni-directional duckbills.
• If additional refinement is required, thebi-directional duckbill478 may be replaced by two uni-directional duckbills, as shown inFIG. 16D. Moreover, when integrating the two uni-directional duckbills, with another unidirectional duckbill at the bottom of the barrel, the system becomes a three duckbill system. In this configuration, the duckbill that releases to atmosphere has the light cracking pressure, the duckbill that allows air into the reservoir chamber has the light cracking pressure, and theduckbill check valve416 that is down in the barrel has a medium cracking pressure. Theduckbill check valve416 in the barrel should be of a higher cracking pressure than the duckbill releasing air to the atmosphere so that pressure built up in the reservoir should be relieved through the lighter cracking pressure duckbill.
• Pressure differentials caused by outflow of fluid from thereservoir chamber410, as discussed previously, may make the dispensing of fluid difficult. Further, in certain instances, outgassing may not interfere with the operation of thefluid dispenser400. Therefore, the vent460 may be substituted with a uni-directional valve orduckbill482, (made by Vernay in Yellow Springs, Ohio, part number VL-857-101) with aduckbill valve insert484. In the one direction (air flowing into the reservoir chamber410), theunidirectional duckbill482 has a low cracking pressure to alleviate pressure due to outflow of fluid from thereservoir chamber410. In this embodiment, vent material is not required since the air is flowing only into the reservoir chamber.
• In a further embodiment, as shown inFIG. 16E, thevent opening464 may be reduced to approximately 10 thousandths of an inch (from 70 thousandths of an inch as shown inFIG. 16A). Thesnap cap404, for prefilled fluid dispensers, or theflip cap402, for user fillable fluid dispensers, may also be modified to include aseal488 where thesnap cap404 orflip cap402 engages thecap406. Thus, this alternative embodiment does not have agap476 between the snap cap404 (or flip cap402) and thecap406, but instead includes aseal488. In order for the flow of air into or out of thereservoir chamber410, there is anopening486, such as a pin hole or a second vent, placed in the top of the snap cap404 (or flip cap402) which is adjacent to theair region474 formed between thesnap cap404 and thecap406.
• In one embodiment, venting may be accomplished by using a mechanical valve. In one aspect, the mechanical valve comprises at least two pieces: a biasing member and a stem, the biasing member is connected or attached to the stem. In an alternate embodiment, the biasing member and stem form an integral piece. The biasing member and the stem may be comprised of the same material or the biasing member and the stem may be comprised of different materials.
• In one embodiment, the mechanical valve operates such that in one position, a hole in the fluid dispenser is sealed, and in another position, the valve does not seal the hole. In one embodiment, in operation, the biasing member of the valve without external mechanical force biases the stem such that at least a portion of the stem seals the hole in the fluid dispenser. By applying a mechanical force to at least a portion of the biasing member, the stem, which is connected to or integral with the biasing member, moves, thereby unsealing the hole in the fluid dispenser. Subsequently, the biasing member, without external force, biases the stem again such that the stem does not seal the hole. Applying mechanical force to at least a portion of the biasing member moves the stem so that at least a portion of the stem seals the hole in the fluid dispenser. In an alternate embodiment, the biasing member without external mechanical force seals the hole in the fluid dispenser so that by applying a mechanical force, at least a portion of the hole is unsealed.
• Using an elastomeric mechanical valve (and in one embodiment, an umbrella valve), the reservoir of the fluid dispenser may be sealed. However, in the embodiment where an umbrella valve is used, the umbrella valve is not used in the normal manner as known to those skilled in the art. Umbrella valves are normally used as pressure actuated check valves that seal against flow in one direction and are opened by pressure in the other direction. In the normal manner of umbrella valve usage, the outer flange of the umbrella is urged against a flat sealing surface by the spring force of the deflected umbrella. Fluid pressure on top of the umbrella valve only tends to further seal the flange to its mating seat. The valve is opened by pressure under the umbrella pushing it away from its mating surface, allowing fluid to pass between the flange and its mating sealing surface.
• One aspect of the invention makes a mechanical valve out of an umbrella valve, instead of a pressure actuated valve, by using the bulge on the stem, urged against a sharp corner at the end of a hole through which the stem passes as a sealing point. The flange is prevented from sealing by adding slots to its mating surface. The flanged head is used as a disk spring to urge the bulge to seal against it seat, which is opened when the center of the umbrella is deflected downward by the dispenser actuator. The movement of the center of the umbrella downward, or at least a portion of the umbrella downward, pushes the stem and its associated bulge down, uncovering the sealing area, thereby opening the valve and venting the reservoir. An oliophobic vent may be added in series to provide additional safety in preventing liquid from leaking out even if the mechanical vent fails.
• Thus, this provides a method and apparatus to modify the pressure in a fluid dispenser. This further provides a method and apparatus that prevents a vacuum from forming in the reservoir chamber of a fluid dispenser while the liquid contained in the dispenser may be pumped out, and at the same time preventing a pressure buildup in the reservoir due to outgassing during the pumping cycle. Moreover, the method and apparatus can prevent liquid from leaving the reservoir through an insert vent that may be placed underneath the mechanical valve of the fluid dispenser. In addition, the method and apparatus can prevent the vapor of an evaporated reagent from leaving the reservoir chamber. Finally, this may eliminate the need for a circuitous path or the use of foam between the vent and the surroundings as has been used in the past.
• Referring toFIG. 16F, an assembly of avalve1000 is shown arranged to operate in accordance with one embodiment of the present invention. The valve may take a variety of forms such as an umbrella shape, as shown inFIG. 16F, or any other shape consistent with the operations of the mechanical valve. Examples of other forms consistent with the operations of the mechanical valve include, but are not limited to: a spring mechanism, or an elastomeric mechanism. Thevalve1000 may have a stem with two portions, either being an integral piece or a series of pieces. Theupper portion1002 of the stem may connect to thehead1008 of thevalve1000. Thehead1008 may be a flanged head as shown inFIG. 16F. Other forms may include a flat surface, or a non-circular head.
• Theupper portion1002 of the stem may be connected to thelower portion1004 of the stem by abulge1006. Thelower portion1004 of the stem may extend below thebulge1006. Theupper portion1002 of the stem and thelower portion1004 of the stem may not be the same size, shape, or length. In a preferred embodiment, at least a section of theupper portion1002 andlower portion1004 of the stem of thevalve1000 may be cylindrical in shape. Thevalve1000 may be entirely made of an elastomeric material with each component interconnected. In another embodiment, at least one of thebulge1006 or thehead1008 are comprised of an elastomeric material.
• In one embodiment, thehead1008 of thevalve1000 may act as a spring force. Thehead1008 may be capable of being deflected and re-formed for a purpose of applying a force to the stem portion of thevalve1000. Thehead1008 may be comprised of a curved surface. In another embodiment, thehead1008 may have an umbrella shape. The underside of thehead1008 may be comprised of an open space to allow for the deflection of thehead1008. Anannular portion1009 may exist on the underside ofhead1008 at the upper end ofstem1002 that acts as a stop for motion ofhead1008. Thehead1008 may be deflected by pressing down on the top of thehead1008. In a preferred embodiment, thehead1008 may be deflected by pressing down on a center portion of thehead1008. Furthermore, thehead1008 may be deflected by pressing down on the uppermost portion of the head, although those skilled in the art will recognize that thehead1008 may be depressed by applying a force onto any portion of thehead1008. Anouter perimeter portion1010 of the underside of thehead1008 may be substantially flat in order to contact a surface.
• Thebulge1006 of thevalve1000 may be of a spherical shape. Other forms may include an oblong shape or an elliptical shape. In one embodiment, thebulge1006, theupper portion1002 of the stem, and thelower portion1004 of the stem may be one integral piece. In another embodiment, thebulge1006 may be a separate piece of thevalve1000 connected to theupper portion1002 and thelower portion1004 of the stem. In one embodiment, thebulge1006 may have a larger diameter than theupper portion1002 of the stem. In another embodiment, thebulge1006 may have a larger diameter than thelower portion1004 of the stem. At least a section of thelower portion1004 of the stem may have a diameter that decreases in distance from thebulge1006. This may allow for thevalve1000 to be easily placed into holes or small areas since at least a section of thelower portion1004 of the stem may have a conical shape.
• Referring toFIG. 16G, acap2000 of a fluid dispenser is shown arranged to operate in accordance with one embodiment of the present invention. Thecap2000 may be mounted on top or on the side of a fluid dispenser. Thecap2000 may have asealing surface2016 which may seal thecap2000 with the fluid dispenser. The cap may be comprised of a plastic material, or another rigid material. The sealingsurface2016 may have aridge2017 which may fit tightly into the fluid dispenser. Ahole2004 may be present in thecap2000. Thehole2004 may be placed at any position on thecap2000. In the preferred embodiment, thehole2004 is placed in the center of thecap2000. Thebottom corner2010 of thehole2004 should preferably have a small radius (e.g.,0.002 inch), so that thebottom corner2010 is sharp.
• Thecap2000 may have asurface2002 that mates with thehead1008 of thevalve1000. Thesurface2002 may be raised from thehole2004 by a small amount in order to provide an area for thehead1008 of themechanical valve1000 to be deflected into, as discussed above. Thesurface2002 may have cuts, such ascut2008, breaks, or passageways for air through thesurface2002 so that gas and/or vapor may always pass underneath thehead1008 of thevalve1000. The cuts may act as breaks or trenches for air. Moreover, the cuts may be of any shape and any size large enough to allow air to pass through. The cuts may be positioned in order to always allow air to pass through, even whenvalve1000 is inserted into thecap2000. Air may only pass through thehole2004, and subsequently through the breaks or cut2008, when thevalve1000 is depressed or open.
• A smallprotective ridge2006 may surround thesurface2002 and thehead1008 of thevalve1000. Theprotective ridge2006 may be raised from thesurface2002 of thecap2000. Theprotective ridge2006 may provide an outer perimeter for thehead1008 of thevalve1000 to be placed. Theprotective ridge2006 may be raised an amount equal to the thickness of anouter edge1005 of the valve in order to provide a secure housing for placement of thevalve1000. Thecut2008 may pass through theprotective ridge2006 in order to allow for a passageway for air.
• An innercircular wall2012 and an outercircular wall2014 may mate to aninsert vent4000, as will be described later. The innercircular wall2012 and the outercircular wall2014 may extend below thehole2004 of thecap2000. The innercircular wall2012 and the outercircular wall2014 may be thin and may be separated by a distance substantially equal to the thickness of theinsert vent4000 housing. The outercircular wall2012 may extend directly below theprotective ridge2006 of thecap2000. The innercircular wall2012 and the outercircular wall2014 may have a length substantially equal to the length of the stem of themechanical valve1000. The outercircular wall2014 and the innercircular wall2012 may be comprised of the same material as thecap2000 of the fluid dispenser. Alternatively, the outercircular wall2014 and the innercircular wall2012 may be comprised of a different material than thecap2000.
• In one embodiment, thecap2000 may contain afastener member2018 on each side of thecap2000. In a preferred embodiment, twofastener members2018 are placed on thecap2000, but those skilled in the art will recognize that any desired number offastener members2018 may be present. The fastener member(s)2018 may be placed directly across from one another. The fastener member(s)2018 may hold thecap2000 in place on the fluid dispenser. The fastener member(s)2018 may be shaped to allow thecap2000 to slide into the fluid dispenser and click into place, but not slide out. The fastener member(s)2018 may have a smooth surface which allows thecap2000 to slide into the fluid dispenser. The fastener member(s)2018 may lock onto a ridge of the fluid dispenser upon placement of thecap2000 into the fluid dispenser.
• Referring toFIG. 16H, acap2000 with thevalve1000 installed is illustrated arranged to operate in accordance with one embodiment of the present invention. Thebulge1006 on the stem of thevalve1000 may mate with thebottom corner2010 of thehole2004. Thebulge1006 may be urged against thebottom corner2010 of thehole2004 to form a seal to thehole2004 by the spring tension of thehead1008 of thevalve1000. The force from thehead1008 of thevalve1000 may be transmitted to thebulge1006 by theupper portion1002 of the stem. Theupper portion1002 of the stem may pass through thehole2004 in thecap2000. Thehole2004 may be slightly larger than the diameter of the stem, so that vapor or gas may pass through thehole2004 if thebulge1006 is not sealed against thehole2004. Thebulge1006 may be slightly larger than thehole2004, so that thebulge1006 may seal to thebottom corner2010 of thehole2004.
• In one embodiment, upon urging thebulge1006 against thebottom corner2010 of thehole2004, thebulge1006 may form a seal that prevents gas, vapor and/or liquid from exiting a reservoir chamber of the fluid dispenser. Thebulge1006 may be biased by a biasing member, such ashead1008, used to seal thehole2004 of thecap2000. Thebulge1006 may become compressed upon urging thebulge1006 against thebottom corner2010 of thehole2004. This may occur because thebulge1006 may be comprised of an elastomeric material. If the pressure in the reservoir increases so that the pressure is higher than the surrounding atmosphere, the pressure may cause thebulge1006 to seal more tightly than before. As shown inFIG. 16H, an o-ring3000 may be provided to aid in the sealing of thecap2000 to the fluid dispenser. The o-ring3000 may be comprised of an elastomeric material in order to allow for thecap2000 to tightly fit into the fluid dispenser. The o-ring may3000 may become compressed upon inserting thecap2000 into a fluid dispenser.
• As shown inFIG. 16H, aninsert vent4000 may be placed underneath thevalve1000. The housing ofinsert vent4000 may fit between the innercircular wall2012 and the outercircular wall2014. Specifically, the housing of theinsert vent4000 may slide between the innercircular wall2012 and the outercircular wall2014 and fit tightly to disallow air, vapor, or liquid to pass through the vent. Theinsert vent4000 may be any shape, preferably of a circular shape to conform to the shape of thecap2000 for the fluid dispenser. Theinsert vent4000 may be placed underneath thevalve1000 at a distance great enough to allow for an open space between theinsert vent4000 and thevalve1000. Theinsert vent4000 may also contain anoliophobic vent4004 in the center of theinsert vent4000 as an added safety feature.
• Referring toFIG. 16I, aninsert vent4000 is shown in accordance with an embodiment of the present invention. An exemplary insert vent found suitable for use in thecap2000 of the fluid dispenser is one made and sold by W.L. Gore & Associates, and having model number D10, although those skilled in the art will recognize that any insert vent with similar characteristics would also be suitable. Theinsert vent4000 may have anoliophobic vent4004 attached to one end. Theoliophobic vent4004 does not allow liquid to pass through. Theoliophobic vent4004 may connect to aplastic cylinder4002. Theoliophobic vent4004 may be placed on one end of the housing of theinsert vent4000. Theinsert vent4000 may mate to an innercircular wall2012 and an outercircular wall2014 of thecap2000 as shown inFIG. 16H. The innercircular wall2012 and the outercircular wall2014 may allow theinsert vent4000 to fit tightly into thecap2000. Theinsert vent4000 may act as an added safety feature for the venting of the fluid dispenser, or as an added liquid barrier for thecap2000 of the fluid dispenser. Theinsert vent4000 may allow air to pass through in order to modify the pressure in the reservoir chamber of the fluid dispenser, but theinsert vent4000 may not allow liquid to pass through thereby creating a liquid barrier.
• Referring toFIG. 16J, a side view of thevalve1000 inserted into thecap2000 is illustrated arranged to operate in accordance with one embodiment of the present invention. The top5000 of the fluid dispenser is positioned horizontally with reference to the fluid dispenser. In an alternate embodiment, thecap2000 may be positioned vertical with reference to the fluid dispenser. Onecut2008 underneath thevalve1000 is shown atsurface2002 withprotective ridge2006. In a preferred embodiment, four cut are provided for passageways for air to vent the reservoir of the fluid dispenser. The cut may be equally spaced around thesurface2002. Theinsert vent4000 is shown inserted between the innercircular wall2012 and the outercircular wall2014 of thecap2000. Theoliophobic vent4004 is shown placed at one end of theinsert vent4000. Theoliophobic vent4004 may be a thin membrane inserted between the outer and inner housing of theinsert vent4000.
• As shown inFIG. 16J, thevalve1000 may fit into thecap2000 in order to provide for a match with thesurface2002 of thecap2000. Aspace5002 inside the innercircular wall2012 of thecap2000 may be open to allow for air to pass through as shown. Theinsert vent4000 may be placed underneath thevalve1000 at a distance so as not to touch thevalve1000. A space or a small distance may be present between theoliophobic vent4004 of theinsert vent4000 and thevalve1000 to allow for thevalve1000 to be pressed downward. The small distance available between theoliophobic vent4004 and the lower portion of thestem1004 is substantially the amount of distance that thebulge1006 may be displaced in order to allow air to pass underneath themechanical valve1000.
• The fluid in a fluid dispenser may be dispensed by movement of the barrel. An example of a barrel is shown inFIG. 12A. Referring toFIG. 16K, the fluid dispenser may be placed into a machine with aplunger6000, or other means of applying force, to press down upon the barrel of the fluid dispenser. When pushing on the barrel, theplunger6000 may contact thecap2000 of the fluid dispenser. Thus, theplunger6000 of the machine may mechanically open thevalve1000 as shown inFIG. 16K. When theplunger6000 on the machine contacts the fluid dispenser, theplunger6000 may first contact the top of thehead1008 of thevalve1000 which is inserted into thecap2000. Any portion of thehead1008 may be contacted. In one embodiment, theplunger6000 contacts the center of thehead1008 of thevalve1000 exerting a mechanical force on thehead1008. This mechanical force in the direction perpendicular to thehead1008 depresses thehead1008 downward. When thehead1008 of thevalve1000 is pressed down, this displaces the stem and its associatedbulge1006 as shown inFIG. 16K. The top ofhead1008 is displaced downward until flush withprotective ridge2006 whereplunger6000 then contactsprotective ridge2006.
• In one embodiment, thehead1008 of thevalve1000 may be deflected downward because thehead1008 is made of an elastomeric material. Thehead1008 may be deflected downward until theplunger6000 contactsprotective ridge2006. The contact of theannular portion1009 of thehead1008 with thesurface2002 does not prevent air from passing underneath thevalve1000. Since thehead1008 of thevalve1000 may be positioned on top of thesurface2002 of thecap2000, air may be able to pass underneath thevalve1000 through the cuts. The cuts on thesurface2002 allow for passageways for air to pass underneath thevalve1000. Thevalve1000 contacts thesurface2002 upon mechanically opening thevalve1000, but the cut are made in thesurface2002, and thus allow for air to pass underneath thevalve1000.
• Upon deflection of thehead1008, thehead1008 exerts a force onto the stem portion of thevalve1000. Theupper portion1002 of thevalve1000 may transmit the force from thehead1008 onto thebulge1006 which displaces thebulge1006 from thehole2004. Once thebulge1006 is displaced from thehole2004, thevalve1000 will be open as shown inFIG. 16K. Since thehole2004 is of a smaller diameter than the stem of thevalve1000, a space may be present between theupper portion1002 of the stem and the outer area of thehole2004. This may allow for the pressure in the reservoir to equilibrate with that of the surrounding atmosphere by allowing air to pass through thespace6004 between theupper portion1002 of the stem and the outer area of thehole2004, and subsequently pass through the cut.
• The cut on thesurface2002 of thecap2000 allow for a passageway of free communication of air between the outer atmosphere and the inside of the reservoir chamber when thebulge1006 is displaced from thehole2004. Air may pass through the cut underneath thevalve1000 because of a pressure differential between the inside of the reservoir chamber and the outside of the reservoir chamber. The air will move from a region of higher concentration of pressure to a region of a lower concentration of pressure. In one embodiment, the pressure inside the fluid dispenser may be higher than the pressure on the outside of the fluid dispenser. In another embodiment, the pressure inside the fluid dispenser may be lower than the pressure on the outside of the fluid dispenser. Air may pass out of the fluid dispenser until the pressure inside the fluid dispenser is equal to the pressure outside the fluid dispenser.
• The seal of thebulge1006 against thehole2004 may be re-formed to disallow air to pass underneath thevalve1000 upon removing theplunger6000 from the top of thehead1008 of thevalve1000. Once theplunger6000 is removed by the machine, thehead1008 may not be deflected, and thehead1008 may slowly re-form due to the stored potential spring energy of thehead1008 of thevalve1000 and pull theupper potion1002 and thelower portion1004 of the stem of thevalve1000 upward a small distance. When the stem is moved upward, thebulge1006 may move upward as well. Thebulge1006 may then become pressed against thehole2004 of thecap2000 and form a tight seal. A portion of the stem may become compressed upon moving the stem upward. Moreover, thebulge1006 may become compressed as well upon pressing thebulge1006 against thehole2004 to form a tight seal.
• Using theelastomeric valve1000 may seal the reservoir of the fluid dispenser. In one embodiment, a requirement of a valve is for the valve to have a dual-purpose vent. The first purpose is to allow air to pass into the reservoir to prevent a vacuum from forming as liquid is removed. The second purpose of the vent is to allow any internal pressure that might build up inside the reservoir to equilibrate with ambient pressure before the first dispense. Internal pressure is not in itself a substantial problem. However, internal pressure may not be tolerated when the dispenser is actuated, as the pressure would expel too large of a volume of liquid. Thevalve1000 provides a manner of sufficiently venting the fluid dispenser.
• Referring toFIG. 17A, there is shown a cutaway view of the lower portion of thebarrel408,duckbill check valve416, duckbillcheck valve insert414,quad seal422,ball426, ballcheck valve insert424 andcoupler428 of afluid dispenser400. Thebarrel408 hasprotrusions408A, which mate with the coupler in order to, maintain the position of thebarrel408 on the upstroke. Otherwise, if the spring pushes thebarrel408 upward too high, the seal, as provided by thequad seal422, may be broken thereby creating an air path and causing thefluid dispenser400 to lose prime. Thebarrel408 also has aflange408B which mates with thestop420 on the downstroke. Thebarrel408 also has apocket408C, where the duckbillcheck valve insert414 is inserted. This pocket acts as a funnel so that no puddles are formed at the bottom of thebarrel408 at the interaction point with theduckbill check valve416 or duckbillcheck valve insert414, thereby minimizing waste. Thebarrel408 also has at its lower portion apiston454 by which fluid is expelled in thedispenser400. At the lower portion ofFIG. 17A is anozzle cap458 for engagement with thenozzle430 of thecoupler428. Thenozzle cap454 andnozzle430 are matched using a luer fitting design in order to be a fluid tight seal. Referring toFIG. 17B, there is shown a cutaway view of the lower portion of the barrel, duckbill check valve, and duckbill check valve insert of a fluid dispenser. Referring toFIG. 17C, there is shown a cutaway view of the quad seal of a fluid dispenser.
• FIG. 17A also shows a cutaway view of thecoupler428. Thecoupler428 hasgrooves428B in which the ballcheck valve insert424 snaps. Thegrooves428B act to prevent any leakage of fluid downward or air upward through the walls of the ballcheck valve insert424 and the coupler wall. Thecoupler428 also hasprotrusions428C, which ensure that the dispenser is aligned on thereagent tray10. For example, if the dispenser is misaligned, the dispense cylinder may not engage the dispenser properly. The coupler also has stabilizingbumps428D, which reduce any rocking back and forth of thefluid dispenser400.
• Further, in an alternative embodiment as shown inFIG. 18A, there is shown abarrel408 which has a lower section which acts as apiston454 at its lower end, similar toFIGS. 12A-12C. Instead of a throughhole at the bottom of thepiston454 at the lower section of the barrel in the piston area, there areholes450 in the side of thepiston454 that contact O-ring seals452. In this manner, when thebarrel408 is pushed downward, theholes450 are exposed, dispensing fluid from thereservoir chamber410. When the barrel is returning to the up position, the pressure differential is such that theduckbill check valve482 opens and fills the dispensechamber410 with fluid. Because of the lack of a high pressure differential on the upstroke of the barrel, theduckbill check valve482 inFIG. 18A is a duckbill check valve of low cracking pressure. Further, when the barrel is in the up position, the end of thepiston454A is closed by the O-ring seals452 thereby sealing the bottom of thebarrel408 except for theholes450.
• Referring to another alternative embodiment as shown inFIG. 18B, there is shown abarrel408 which has a lower section which acts as apiston454 at its lower end, similar to FIG.18A. Instead of placing O-ring seals452 to cover thehole450 in the lower end of thepiston454A, aquad seal422, similar to the quad seal used inFIGS. 14A and 14B, is used.
• Referring toFIG. 20, there is shown an alternative embodiment of a cutaway view of the lower portion of the fluid dispenser with acup check valve792. The lower portion of the cup check valve792 (i.e., the cup piece794) abuts against thepiston454 of thebarrel408, thereby disallowing liquid to pass through the lower portion of thebarrel408. The upper portion of thecup check valve792, which is composed of anupper ledge800 andside walls802, abuts against the duckbillcheck valve insert414 and the side of thepiston454. Thecup check valve792 operates in a manner similar to theduckbill check valve416, as shown inFIG. 17A in that it operates based on a pressure differential. During the downstroke of thebarrel408, thecup piece794 of thecup check valve792 remains rigid so that the piston, and the cup piece, push the liquid out of the dispensechamber412. During the upstroke of thebarrel408, theball434 in theball chamber432 seats against the checkvalve ball insert424, as described inFIG. 13A, creating a vacuum in the dispense chamber. This vacuum creates a pressure in the dispense chamber and in the adjacent piston area of thebarrel408, causing thecup piece794 of thecup check valve792 to flex inward, so that thecup piece794 does not abut against thepiston454. When this occurs, fluid in the reservoir chamber is allowed to pass around thecup check valve792 and into the dispense chamber. Thecup piece794 is flexed inward until the pressure equalizes between the dispense chamber and reservoir chamber. As such, the dispense chamber receives fluid on the upstroke of thebarrel408. For better flexing effect due to the vacuum caused in the dispense chamber, thecup piece794 of thecup check valve792 should sit low in thepiston454 of thebarrel408. In this manner, the less area under the cup, the more suction effect caused by the vacuum.
• Referring toFIG. 21 A, there is shown a side view of thecup check valve792. Thecup piece794 spreads outward at angle of approximately 71° from the horizontal. However, thecup piece794 may be curved outward or inward, depending on the flexing needs of thecup piece794. Moreover, theupper ledge800 andside walls802 are formed to abut against the duckbillcheck valve insert414 and the side of thepiston454. This upper piece may be of such a form in order to be held securely in place.
• Referring toFIG. 21B, there is shown a bottom view of thecup check valve792. The bottom796 is round, in order to abut the round sidewalls of thepiston454. The bottom of thecup check valve792 may be any shape that forms against the surface abutting it, in this case, thepiston454.
• Referring toFIG. 21C, there is shown a top view of thecup check valve792. The top798 is round, in order to abut the round sidewalls of the duckbillcheck valve insert414. The top of thecup check valve792 may be any shape that forms against the surface abutting it, in this case, the duckbillcheck valve insert414.
• Referring toFIGS. 21D and 21E, there are shown views of thecup check valve792 at cross-sections A-A and B-B inFIG. 21 C, respectively. Thecup piece794 of thecup check valve792 is forked for ease of flexing. The thickness and shape of thecup piece794 may be varied depending on the flexing needs of the cup piece. Further, the connectingpiece804 may be any shape that connects the upper piece of thecup check valve792 to thecup piece794. In the preferred embodiment, the connectingpiece804 is cylindrical so as not to interfere with the flow of fluid through thepiston454.
• In another embodiment of the invention, there is provided a means by which to transfer data from the manufacturer to the customer. The manufacturer uses a manufacturing database in order to maintain a record of reagents, master lots, and serial numbers for kits and dispensers. The manufacturing database is an Interbase (client/server) database contained in a single file. The manufacturing database definition consists of domains, tables, views, and triggers. Domains define the variable types and requirements used in tables. Tables define the data that is stored for each record. Views (meta-tables) are accessed as tables but do not contain data. The views collect data from tables. Triggers are programs that are executed on the Interbase server in response to defined events.
• Information is stored on the database to define kits (which contain several dispensers) or single dispensers. Each package, whether a kit or a dispenser, will include a barcode identifying the contents. For kits, the barcode will contain the part number, master lot number and serial number. For single dispensers, the barcode will contain the part number, lot number and serial number. Serial numbers are assigned to kits sequentially for each master lot starting at 1 (i.e., the first kit created from each master lot will be assigned serial #1). The package barcodes are separate from the barcodes that appear on the individual dispensers within the package. In particular, in the case of a single dispenser package, the serial on the package barcode label need not match the serial number of the single dispenser contained in the package.
• The barcode is encoded with the Code 128 Symbology. The plain text interpretation of the barcode is to appear as standard ASCII text below the barcode. This allows for operator verification of the data obtained by scanning. The three fields on the package label will be fixed in length and combined into a single barcode by concatenation. For the dispensers, one of the fields is a 4 digit product code, which determines the contents of the dispenser, and another one of the fields is a serial number. The serial number is unique to the type of dispenser (i.e., the serial number for each dispenser of a certain type is incremented by one). By scanning in these two fields, the device that programs the touch memory device, which is described subsequently, recognizes the type of dispenser. Moreover, the host device, which obtains the scanned code from the barcode reader on the remote device, which is described subsequently, also determines the type of the dispenser based on the barcode. For a barcode on a kit, there is a field that corresponds to a particular kit form, so that, when the kit barcode is scanned in, the computer determines, through a look-up table, the particular kit form associated with the kit barcode, as described subsequently.
• Referring toFIG. 22, there is shown a block diagram of the manufacturer's system for programming an external memory device. Themanufacturing computer500 is a typical personal computer, with aprocessor502 including acomparator504, andmemory506 includingRAM508 andROM510. As described subsequently, theprocessor502 is in communication with abarcode scanner512 and amemory device516 such as an EPROM (erasable programmable read only memory). In the preferred embodiment, theprocessor502 is in communication with thememory device516 via amemory wand514, as described subsequently.
• As described in Appendix A, there is software that implements the acquisition of data from registration tables, and stores the data into an external memory device. Referring toFIG. 23, there is shown a flow chart for updating the forms on the manufacturers database. The forms are used as templates for the manufacturing database for kits, dispensers, dispenser models, etc., which are later entered to program the touch memory device. The forms include reagents, dispenser models, dispensers, kits and filled kits. For example, in the reagent form, data about a particular reagent, such as the reagent name, group name, etc. may be entered. The dispenser models include user fillable and prefillable dispensers. Referring toFIG. 23, the operator is asked if he or she wishes to update thereagent form522. If so, the manufacturing database determines if the reagent form is new or old524. If new, a blank template is displayed for the operator to enterdata526. If a reagent form is to be modified, the reagent template is displayed528,530. The contents are entered or modified and the data saved to thedatabase532,534. Likewise, the forms may be modified for the dispenser form, which includes data on the part number, reagent, code, whether the dispenser is prefillable, the dispenser model, whether the reagent is active, etc. The operator is prompted whether the form is new540, and if new a blank template is displayed542. If old, the previous dispenser forms are displayed544 and the user selects aform546. Data is entered548 and saved550. The forms may be modified for the kit configuration as well. The kit configuration includes data on the dispensers included in a kit sent to the end user. This information includes the part number, the description of the kit, whether the dispensers in the kit are active, the number of reagents in the kit, and data on the dispensers in the kit. The operator is prompted whether the form is new556, and if new a blank template is displayed558. If old, the previous dispenser forms are displayed560 and the user selects aform562. Data is entered564 and saved566. The forms interact with one another for ease of updating. For example, if the dispenser model is modified, the dispenser form, which is dependent on the dispenser model, is modified as well. Further, if the dispenser is modified, so is the kit configuration, which in turn depends on the dispenser.
• The updating of the master lot and entering data into the memory device is shown in the flow chart inFIG. 24. The master lot form supports assignment of master lot numbers to predefined kits, as well as lot numbers and expiration dates to each of the dispensers in the kit. The expiration date of the kit is the earliest of the expiration dates of the dispensers in that kit. If the operator wishes to update themaster lot570, the manufacturing database determines if the master lot is old or new572. If new, the list of kits is displayed574 and a blank template for the user selectedkit576. If old, the previous master lot is listed578 and the user selected master lot is displayed580. Data is entered for themaster lot582 and then saved584.
• Once the forms are set, the operator may begin to program thetouch memory device588. In the preferred embodiment, thememory device576 is an EPROM such as the Dallas Semiconductor DS 1985F5 16 Kbit add-only touch memory device. Other memory devices may be used to store the information and allow the end user to retrieve the information. For example, diskettes may be used as memory devices.
• First, the package bar code labels are scanned590. A Welsh Allyn Scanteam 5400/5700 hand held scanner is used. The scanner need only be configured once to identify the hardware platform and bar code symbology. The scanner is programmed to send a ‘!’ as a prefix character and also a ‘!’ as a suffix character. The prefix is used to differentiate input from the scanner from input from the keyboard. The suffix is used to identify completion of acquisition.
• Based on the information scanned from the package, the kit type is determined based on the information in the kit forms592. In an alternative embodiment, the user is prompted to enter the type of kit. Based on this information, the computer determines the kit type.
• The barcodes for each of the dispensers in the package is then scanned594. Information in the kit form is compared with the information scanned in596. For example, the number of dispensers in the package is checked. If the number is too high or too low, the user is notified and the memory device is not programmed. Further, if the type of the dispensers in the package does not match the type of dispensers in the kit form, the user is notified and the memory device is not programmed. This is one of the methods to increase the quality control. If there was an error in the packaging of the package, (e.g., an incorrect dispenser was placed in the package), the user will be notified to correct theproblem598.
• If the number and type of dispensers are correct, the database collects all data necessary for the current kit anddispensers602. The touch memory data is programmed into the touch memory device using object oriented programming. To do this, a touch_memory object is created which contains the form in which the memory will be stored604. The data for the current kit and dispensers is written to the touch_memory object buffers606. Finally, the touch_memory object buffers are transferred to thetouch memory device608.
• In order to program or read the touch memory device, a probe (Dallas Semiconductor DS9092GT) mounted in a hand heldwand514 is used. Thiswand514 is attached to the serial port of themanufacturing computer500 programming thetouch memory device516 through a Dallas Semiconductor DS9097 or DS9097E serial port (DB-25) adapter. In an alternative embodiment that uses a diskette as a memory device, a disk drive is used to transfer the data on the memory device to thecomputer500.
• At the end user, the memory device accompanies the kit or single dispenser. Referring toFIG. 25, there is shown a flow chart for downloading data from a memory device to the host system. The probe is first connected to thetouch memory device612. The contents of the touch memory device are downloaded to thehost computer614 and displayed to theuser616. It is then determined whether the touch memory device has been downloaded previously618. This is done based on the contents of the touch memory device. If the memory contents were previously downloaded, a flag is set in the memory contents. Therefore, this kit has already been “used” and therefore should not be reprocessed. The user is prompted whether he or she wants to update the user's databases with the kit/dispenser data624. If so, the probe is reconnected to thetouch memory device626, verified that it is the same touch memory device by comparing the current downloading with the previous download ofdata630. The flag indicating that the touch memory device is “used” is set inside thememory device628. In this manner, a memory device may be downloaded only once for purposes of security. The contents of the user's databases are updated with information contained in the touch memory device such as name, type, group, lot, serial number, characteristics, quantity, expiration dates for the reagents, and the usable life, maximum volume, dead volume and registration date for thedispenser632.
• Regulations require that a user must maintain a database of the fluids used in staining. Prior to this invention, users were required to manually input data into the database. This process was not only time-consuming, but also prone to error. In contrast, the current invention uses information in the touch memory device to update the required database.
• The user database, which is required by the regulations, contains various tables including the registration, receive and quality control tables for use by the operator. Within each of the registration, receive and quality control tables, there are five different types of categories: (1) antibodies; (2) reagents; (3) kits; (4) consumables, and (5) control slides. Antibodies are chemicals that have living cells within which attach to the patient's tissue. Reagents are non-antibody chemicals that typically contain no living material. Kits, as described above, contain various combinations of dispensers. Consumables are materials such as the Liquid Coverslip™, wash buffer, etc. Each of these materials are regulated in different manners, thereby requiring different information contained within the registration, receive and quality control tables. For example, since antibodies are living material, they are regulated more highly and therefore require additional information in the tables.
• The registration table contains the background information for the specific material. For example, the registration table contains the name of the material (antibody, reagent, kit, consumable, or control slide), the manufacturer, the clone number (for antibodies) and other information describing the material. As described previously, one field in the dispenser barcode is the type of dispenser. This information is programmed into the touch memory device, which is subsequently downloaded to the registration table. Therefore, when the barcodes for the dispensers are scanned in preparation for a run, as described subsequently, the registration table is used to determine what type of fluid is contained in the dispenser. This table is updated only when the material is first received.
• The receive table is a table which records each time when a certain material is received and the expiration date of that material as well as other information specific to this lot of material including the serial number. Therefore, while the registration table may describe the properties of a certain antibody, the receive table will describe on which dates each dispenser of that antibody was received, the expiration date for that antibody, the serial number and the lot number. This information is used not only to generate reports that are required by regulation, but also to check for the expiration date of the chemical during a run, which is described subsequently.
• The quality control table records when a particular chemical was validated. Regulations require that when a new chemical or when a new lot for a previously received chemical is received, the lab must check to make sure the material performs in the expected manner (i.e., the material was processed correctly and not damaged in shipment). To determine if the material is “acceptable” to use in testing on patient tissue samples, end users have tissue samples that are known to test positive with undamaged reagents. The quality control table will track whether the chemical was tested for effectiveness and which tissue sample was used to test the chemical. In this manner, the tables, which are generated in large part by information from the touch memory, allow the end user to comply with the regulations without the need for time consuming data entry.
• Other tables are used during a run which provide for better quality assurance in testing. For example, there is a dispenser table that contains, for each dispenser, the pertinent information for quality assurance during a run. For example, for each dispenser with a corresponding barcode (which contains the serial number for the dispenser), the table contains the expiration date, and the number of drops in the dispenser.
• Referring toFIG. 26, there is shown a flow chart for updating the registration, receive and quality control tables on the host computer for use by the operator. Based on the data in the touch memory device, the computer determines whether the touch memory holds kit information, prefilled antibody information or prefilled reagent information. In particular, the computer may examine the format of the data in the touch memory device and determine what type of data the touch memory object holds. In the alternative, the touch memory device may specifically state whether the data relates to kit information, prefilled antibody information or prefilled reagent information. In particular, one of the fields in the touch memory device signifies what is the type of information.
• Dispenser/kit information is read from the touch memory device. The computer determines if the touch memory device holdskit information638. If so, the touch memory device searches the registration table to determine if the kit was previously received640. If the kit was not received previously, the registration table must be updated with the kit registration information (i.e. background information) such as manufacturer andcatalog number642. This kit registration information is obtained from the touch memory device. The individual dispenser information within the kit, also obtained from the touch memory device, is updated in the dispenser table including the serial number, product code, master lot number, total dispenses (by number of drops) andexpiration date644.
• The receive table is also updated to include the receive date, lot number, serial number, andreceiver646. The receive date is generated based on the date in the host device processor and the serial number is obtained from the touch memory device. The receiver field in the receive table is the person that has input the data from the touch memory device. In the preferred embodiment, thehost device32 determines who is currently logged on to the host device and writes the user's name as the receiver.
• The quality control table is searched to determine if there is an entry in the table for this kit's lot number (i.e., if this is a new kit or a new kit lot number)648. If the kit lot number (as obtained from the touch memory device) has already been quality control tested, the user is informed that this has already been done650. If not, the user is informed that a quality control test must be performed676. In an alternative embodiment, a separate look-up table is used to select known tissue samples to test the effectiveness of a received chemical received. Based on the chemical received, the known tissue samples are suggested to the user to test the effectiveness of the chemical in order to update the quality control table.
• The computer determines if the touch memory device holds prefilledantibody information652. If so, the touch memory device searches the registration table to determine if the antibody information was previously received654. If the antibody information was not received previously, the registration table is updated with the antibody registration information (located in the touch memory device) such as name, manufacturer, catalog number, clone, Img subclass, presentation, andspecies656. The individual dispenser information is also updated in the dispenser table including the serial number, product code, master lot number, total dispenses (by number of drops) andexpiration date658. The receive table is updated to include the receive date (as determined from the host device), lot number, serial number, andreceiver660. The quality control table is searched to determine if there is an entry in the table for this antibody lot number (i.e., if this is a new antibody or a new antibody lot number)662. If the antibody lot number has already been quality control tested, the user is informed that this has already been done650. If not, the user is informed that a quality control test must be performed676.
• The computer determines if the touch memory device holdsprefilled reagent information664. If so, the touch memory device searches the registration table to determine if the reagent information was previously received666. If the reagent information was not received previously, the registration table is updated with the reagent registration information (located in the touch memory device) such as name, manufacturer, andcatalog number668. The individual dispenser information (located in the touch memory device) is updated in the dispenser table including the serial number, product code, master lot number, total dispenses (by number of drops) andexpiration date670. The receive table is updated with information from the touch memory device to include the receive date, lot number, serial number, andreceiver672. The quality control table is searched to determine if there is an entry in the table for this reagent lot number (i.e., if this is a new reagent or new reagent lot number)674. If the reagent lot number has already been quality control tested, the user is informed that this has already been done650. If not, the user is informed that a quality control test must be performed676.
• The computer determines if the touch memory device holds customerfillable dispenser information678. If so, the individual dispenser information (located in the touch memory device) is input including the serial number, product code, master lot number, total dispenses, expiration date, dispenser drop life, maximum volume, dead volume and primingwaste680. In an alternative embodiment, the user is prompted to input the amount of liquid, in milliliters, which is placed in the dispenser. This amount in milliliters is converted into a number of drops and stored in the table. The user may, at a later time, fill the user fillable dispenser and, at that later time, update the dispenser table with the amount of fluid put in the dispenser.
• In an alternative embodiment of the invention, the host device performs a series of checks using the information from the touch memory. Referring toFIG. 27, there is shown a flow chart for determining if the kit/dispensers for use by the operator is the correct number and correct complement, similar to the check performed while programming the touch memory device, as described inFIG. 24. The kit barcode information from the touch memory is read to determine the type of kit and dispensers contained in thepackage682,684. Based on this barcode information, there is a look-up table which describes the number of reagents in the kit and the type or complement of reagents in the kit. This historical information in the look-up table is compared with what was actually sent in the package. If there is a discrepancy as to the number of dispensers in the kit or in the type of reagents in thekit686,688, the user is notified and the user's database is not updated with thekit barcode information690. In this manner, checking whether the proper dispensers were included in the kit may increase the quality control.
• After the downloading of the data from the touch memory device, thehost device32 andremote devices166 may execute a run. As described previously, thehost device32 andremote devices166 are modular in design. The host handles higher level system functions whereas theremote devices166 perform the execution of the steps for staining. This modularity of design utilizing a personal computer as ahost device32 is beneficial in several respects. First, the host computer can be used to start runs on otherremote devices166. Second, thehost device32 can periodically update the software more efficiently on theremote device166 based on upgrades in the operating system. For example, the lowest level code in theremote devices166, which handles the basic input and output for theremote device166 and the execution of programs, may be updated based on changes in error messaging, changes in output device design (such as different types of valves), and changes in the messaging protocols between the host and the remote. Third, the modularity multiplies the number of staining modules that may be run by a single machine. Fourth, since thehost device32 is comprised, in the preferred embodiment, of a personal computer, the host machine may be easily upwardly compatible, as opposed to previous standalone staining modules. Further, the personal computer can be integrated with a network environment to integrate with other computers. For example, there is a trend in hospitals to standardize the computer hardware used and to interconnect the computer hardware. Thehost device32 may be connected to a hospital network, receiving commands from other computers on the network to execute a staining run, described subsequently, or sending results of a run to another computer on the network. Fifth, thehost device32 may serve as a platform through which various staining modules may be integrated. For example, there are various types of staining modules, some of which use dispensers versus vials, some of which use horizontal slide trays versus vertical slide trays, etc. Thehost device32 may be integrated with a variety of staining modules, downloading programs to the different modules, described subsequently, depending on the particular configuration of the module. Sixth, theremote device166, as a modular piece in the automated biological reaction system, may be serviced more easily. Instead of having a large machine dedicated to staining, theremote device166 is smaller and can be shipped through the mail easily. In this manner, when an end user has difficulty with aremote device166, the user may receive a second remote device through the mail, and send the faulty remote device back to be fixed. Therefore, the user need not rely on on-site maintenance for the remote device, and the attendant cost associated with on-site maintenance.
• The host device may execute three different types of runs. The first run is a test run, which is described subsequently. The second run is a system run, whereby theremote device166 reads the barcodes for the slides or the dispensers, or other non-staining functions required to setup a staining run. The third run is a staining run whereby theremote device166 stains the slides. The second and third runs are described inFIG. 28. When executing a run, the host downloads a sequence of steps in a run program to theremote device166. The run program is comprised of two separate pieces: (1) a main program (defined as macro 0); and (2) subroutines (defined as macros 1-255). The main program is composed of, but is not necessarily limited to, calls to the subroutines. Therefore, the entire length of the run program through calls to subroutines is less than a line by line execution of the entire program. For example, if a subroutine is called 50 times, the main program calls thesubroutine 50 times rather than downloading a program which includes the code for thesubroutine 50 times. In addition, the subroutines are defined by a programming language of thirty-one low-level commands which perform basic functions on the remote such as checking the timer, turning on an output such as a valve or a heater, or moving the carousel. When downloading the run program, the macros are downloaded as needed to execute a single run.
• In addition to downloading a run program, thehost device32 downloads the sensor monitoring and control logic called the run rules. This program is made up of a series of continuous checks that must be done during the execution of the run program. As discussed previously, one of the checks is the upper and lower limit of the temperature of the slides. If, during a run, the environmental temperature is below the lower limit, as indicated by slidetemperature monitoring sensor68, theslide heater302 is turned on. Likewise, if the environmental temperature is above the upper limit, as indicated by slidetemperature monitoring sensor68, theslide heater302 is turned off. Another run rule relates to the opening of a system door. Additional run rules relate to the environment in which theremote device166 executes the run. If any of the sensors are outside of the boundaries sent by the run rules, theremote device166 sends a message which is retrieved by thehost device32. As discussed generally inFIG. 5C with respect to placing messages in the queue, the first priority is the execution of the steps in the run program. In addition to this, where spare processing is available, thehost device32 polls theremote device166 for status. Thehost device32 does this approximately every 1½ seconds to receive the status of theremote device166 including the current temperature of theremote device166, current step number being processed in the run program, elapsed time of the run, and any errors during the run. Thehost device32 makes a record of any anomalies during the remote device run and prints the final report at the end of the run.
• An example of a staining run is shown in flow chart form inFIG. 28. In preparation for a run, the operator determines the type of staining for the particular slides. Each slide has a barcode attached to it. Based on this barcode, the operator may program the type of staining. In order to assist the operator, the host device provides a set of recipes. For example, one test is a DAB paraffin test. Because this test is commonly used, the user may assign the barcode for the particular slide to that recipe thereby choosing the particular steps to perform the test. In addition, some of the recipes require the operator to enter certain parameters, called protocols. For example a protocol may be the specific temperature for the test or the time period for heating. In contrast to the protocols, the recipes define steps which the user does not control. For example, turning on valves, heating the slides, etc. are operations which the users cannot alter. In an alternative embodiment, each barcode on a slide may be standardized In order to simplify the procedure. For example, if the staining for the slide is to test for prostate cancer, a particular field within the barcode is placed on that slide which is used for every slide which is to be tested for prostate cancer. In that manner, the user is not required to enter a recipe for the particular slide, but rather the reading of the barcode determines the type of test.
• After the operator has entered the recipes and protocols corresponding to each slide barcode for the staining run,step695 inFIG. 28, thehost device32 may prepare for a staining run.
• After the inputting of the recipes and the protocols, and prior to executing a run, the operator is prompted by the host device32 (696). The host device first questions whether there is sufficient buffer solution in thewash buffer bottle246, whether there is sufficient Liquid Coverslip™ in the LiquidCoverslip™ bottle244, whether the level of waste in thewaste tub254 is acceptable, and whether the reagents andreagent tray10 is loaded. The operator is then prompted for the number of slides that are loaded on the slide tray.
• The first run is a system run to read the barcode on the slides. The operator then begins the run by downloading the file of steps to read the barcode on the slides and to wait for thehost device32 to retrieve thebarcode697. The remote device reads a barcode on theslide698, stores the barcode in afile699, to be used subsequently, then waits for thehost device32 to retrieve the barcode and retrigger theremote device166 to read another barcode on theslide700. Theremote device166 does this until the last slide is read702.
• The second run is another system run wherein thehost device32 downloads the run program and run rules in order to read the barcodes on thedispensers704. Similar to the first system run, theremote device166 reads a barcode on thedispenser706, stores the barcode in afile707 to be used subsequently, then waits for thehost device32 to retrieve the barcode and retrigger theremote device166 to read another barcode on thedispenser708. Theremote device166 does this until the last dispenser is read710.
• Thehost device32 then reads the slide barcodes already stored in thefile712. If the number of entries in the file is different from the number previously entered by the operator (696), as performed in the loop atstep698, an error message is generated730. This is done since the barcode reader, at times, may not read one of the barcodes on the slide. In that case, the run is stopped.
• Thehost device32 then reads the barcodes for the reagents already stored in thedatabase716. Based on the barcodes, the host device loads the protocols for the slides from the database. For each specific recipe, there are a series of macros which are to be executed by theremote device166. In the case of a DAB paraffin test, a look-up table indicates the series of steps or macros. As discussed previously, there are macros from 1 to 255 which define basic operations of theremote device166. For the specific task of a DAB paraffin test, the look-up table includes all the necessary macros, in the proper sequence, to perform the test. Based on these macros, thehost device32 determines the types of reagents and amount of drops required to execute thesteps714. Moreover, in creating the run program, calls to the macros are included inmacro 0 and macros 1-255 which are to be called are included aftermacro 0. All the protocols for the particular recipes are loaded and determined if they exist in thedatabase718. Those protocols were previously entered atstep695. If so, the host device loads data from the dispense table720 and determines if all of the dispensers are present and loaded722. If so, the recipes are loaded from thedatabase724. Thehost device32 then verifies that the recipes can be run together726 (i.e., whether there are any procedures which are incompatible or unsynchronized). For example, if there are two recipes which dictate the temperature of the slides (where the slides are in close proximity), and the temperatures are different, the two recipes cannot be executed; therefore, an error message is generated730. The steps for the run are then computed728. Because there are several slides being tested, and each slide has a series of steps associated with it, thehost device32 generates the run program which can execute all the steps for all of the slides. Thehost device32 is constrained by being able, for example, to mix with thevortex mixers271 at a certain station on theslide carousel24, to dual rinse at a certain station, to add fluid at the volume adjust, etc. Based on these constraints, the run program is generated which tells the remote to execute the steps in the proper sequence at theproper station728.
• Thehost device32 determines if there are multiple dispensers of thesame reagent732. If so, an error message is generated since, for quality control purposes, dispensers from the same kit may only be used in a run. In addition, if a step requires applying two different reagents at the same station, thehost device32 requires that the reagents be next to each other. Otherwise, it would take too long to move the carousel and dispense both reagents. As a guideline, each step should be performed within 6 seconds in order to speed up the process of staining.
• Thehost device32 then determines if this is atitration run734. In a user filled dispenser, the user may wish to test varying concentrations of reagent in the fluid dispenser. If so, the user executes a titration run whereby the user is allowed, via the program, to stop the run in the middle and titrate different concentrations. The amount of time for the titrations must be short enough so that the slide will not dry out736. Otherwise, an error message is generated750. The macro functions are loaded from a database for therun738 and determined if all the macro functions loaded properly740. Thehost device32 determines, based on the dispenser table, whether any of the dispensers are past theexpiration date742. If so, the operator is notified744. Similarly, the dispenser table is checked to determine if the dispensers have sufficient fluid to conduct therun746. If not, the operator is notified to refill or replace thedispensers748. Optionally, quality control can be checked to determine if all of the dispensers have been tested underquality control protocols752.
• Therefore, thehost device32 looks up in the dispenser table716, described inFIG. 26, to determine if the reagents necessary (1) are past their expiration date; (2) are present to perform the run; (3) have enough drops in the dispensers to execute the run; or, optionally, (4) have been tested for quality control. If any of the first three conditions fail, the run cannot be executed and the operator is notified (i.e., one of the dispensers is past its expiration date, one of the dispensers is missing, or one of the dispensers is low on fluid).
• Optionally, for quality control purposes, the dispenser table is searched to determine if quality control was performed on thedispenser752. If it has not yet performed, the operator is notified754 and asked if he or she wishes to proceed756. If the operator wishes to proceed, he or she must enter his or her name, and the date and time in order to continue therun758. Finally, when the run is executed, the information entered by the operator is included in the history of the run, described previously, to indicate that at least one of the dispensers had not been tested in compliance with the regulations, but that the run was performed anyway760. In this manner, the quality of the run may be increased due to monitoring of the dispensers used in the testing of the tissue samples. Thehost device32 then saves the dispense data for the run to adatabase762 and merges the run rules, which determine the operating environment of the run, together for therun764. Thehost device32 downloads the run program and the run rules for thecurrent staining procedure766. Thehost device32 commands the remote to run the steps and to run the checks or the run rules768. Thehost device32 then updates the tables based on the execution of the run. For example, thehost device32 decrements the number of drops in the dispenser table for each of the dispensers used in therun769. As discussed previously, thehost device32 periodically checks the status of theremote device770. After theremote device166 finishes execution of therun program772, thehost device32 compiles the history of the run and stores the information sent from the remote774.
• Thehost device32 also communicates with theremote devices166 by reading and writing information regarding the operation of theremote devices166. For example, thehost device32 downloads a command indicating to the remote device the amount of time (in 10's of milliseconds) thevalve248G for the volume adjust line is on. This value is stored in non-volatile RAM on theremote device166. Further, thehost device32 may poll theremote device166 to send its stored value for the volume adjust time stored in non-volatile RAM. Other information, such as the slidetemperature monitoring sensor68, bufferheater temperature sensor66 andsystem pressure transducer290, as described inFIG. 6A, may be read by thehost device32 and may be calibrated by thehost device32. When reading the sensor information from theremote device166, the calibration data is sent back to the host. Calibration data is used to adjust for constant errors inherent in each temperature sensor and pressure transducer. In order to correct for errors, thehost device32 writes to theremote device166. For example, when calibrating the pressure sensor, thehost device32 commands theremote device166 to perform span calibration of thesystem pressure transducer290 at the preset pressure of 13.0 psi. Theremote device166 registers the current raw pressure as the 13.0 psi analog to digital point.
• Referring toFIG. 29, there is shown a flow chart of the testing run for the remote device. One of the commands or steps downloaded to the remote device is atest command776. The remote processes the commands in therun program778 until theremote device166 receives thetest command780. Theremote device166 then waits until abutton295 is pressed on theremote device782, as described in reference toFIG. 6A. When thebutton295 is pressed, theremote device166 re-executes the run program, and then waits for thebutton295 to be depressed again. In this manner, the operator may test individual steps or commands by pressing thebutton295 and re-executing the previous set of commands. In an alternative embodiment, theremote device166 interprets the test mode as a means by which to single step through the program. Every time thebutton295 is pressed, theremote device166 executes a command. In this manner, the operator may step through the run program and determine if there are any errors in the sequence of steps.
• From the foregoing detailed description, it will be appreciated that numerous changes and modifications can be made to the aspects of the invention without departure from the true spirit and scope of the invention. This true spirit and scope of the invention is defined by the appended claims, to be interpreted in light of the foregoing specification.

Claims (25)

1. A fluid dispenser comprising in combination:

a barrel having a cap, the cap having a surface with at least one hole; and

a valve having a biasing member and a hole sealer, the biasing member having at least two positions,

wherein in a first position of the biasing member, the hole sealer seals the hole and wherein in a second position, the hole sealer does not seal the hole, and

wherein a force places the biasing member in at least one of the two positions.

2. The fluid dispenser ofclaim 1, further comprising a passageway from the hole to outside the fluid dispenser.

3. The fluid dispenser ofclaim 2, wherein the passageway includes breaks.

4. The fluid dispenser ofclaim 1, wherein the hole sealer is a bulge substantially spherical in shape.

5. The fluid dispenser ofclaim 1, wherein the biasing member has an umbrella shape with a flat surface, the periphery of the flat surface contacting the cap.

6. The fluid dispenser ofclaim 5, further including breaks, wherein the breaks are abutting at least a portion of the flat surface of the biasing member, and provide a fluid path.

7. The fluid dispenser ofclaim 1, further comprising a vent inside the barrel.

8. The fluid dispenser ofclaim 7, wherein the vent comprises an oliophobic material.

9. The fluid dispenser ofclaim 7, wherein the barrel comprises a reservoir chamber and wherein the vent allows air into the reservoir chamber.

10. The fluid dispenser ofclaim 1, wherein at least a portion of the valve is comprised of an elastomeric material.

11. The fluid dispenser ofclaim 1, wherein the force is mechanical.

12. A method of equilibrating pressure within a fluid dispenser comprising the steps of:

providing a fluid dispenser with a barrel having a cap, the cap having a surface with at least one hole, and a valve having a biasing member and a hole sealer, the biasing member having at least two positions; and

placing the biasing member in one of the two positions by applying a force to the valve,

wherein in a first position of the biasing member, the hole sealer seals the hole and wherein in a second position, the hole sealer does not seal the hole.

13. The method ofclaim 12, wherein the force places the biasing member in the second position.

14. The method ofclaim 12, wherein the force places the biasing member in the first position.

15. The method ofclaim 12, wherein the biasing member is a shaped surface with a top, and wherein the mechanical force is applied at the top.

16. The method ofclaim 12, further comprising providing a passageway for air between inside and outside of the barrel when the barrel is in the second position.

17. The method ofclaim 12, wherein the barrel includes a reservoir chamber, and wherein the fluid dispenser further comprises a vent inside the barrel, and wherein the vent allows air into the reservoir chamber.

18. The method ofclaim 12, wherein placing the biasing member in one of the two positions includes applying a mechanical force.

19. A method of mechanically operating a valve for a fluid dispenser, the valve having a head and a bulge, the method comprising the steps of:

abutting the bulge against a hole in the fluid dispenser to create a seal;

applying a mechanical force to move the head so that the bulge does not abut the hole; and

reducing the mechanical force so that the bulge abuts the hole.

20. The method ofclaim 19, wherein the head includes a biasing member and wherein the step of abutting is performed by the biasing member.

21. The method ofclaim 19, wherein the step of reducing the mechanical force includes removing the mechanical force thereby creating the seal between the bulge and the hole.

22. The method ofclaim 19, wherein the head has a center portion, and wherein the mechanical force is applied to the center portion of the head.

23. The method ofclaim 19, wherein the step of applying a mechanical force to the head creates an opening between the bulge and the hole to allow a passageway between inside the fluid dispenser and outside the fluid dispenser.

24. The method ofclaim 19, wherein the barrel includes a reservoir chamber, and wherein the fluid dispenser further comprises a vent inside the barrel, and wherein the vent allows air into the reservoir chamber.

25. The method ofclaim 24, wherein the vent prevents liquid from leaving the reservoir chamber.

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