Method for automatically filling, packing, and dispensing carbon dioxide snow blocks

Abstract

A method for automatically filling carbon dioxide (CO2) snow blocks into a container in an automated dispensing station. The automated dispensing system includes multiple containers of different volumes. A user can input CO2 snow block volumes into a controller, such as a programmable logic controller (PLC). The controller uses the input volumes and process information to determine which container to utilize for the automated filling process. The controller can configure the selected container in a fill orientation, into which liquid CO2 can flow to produce a CO2 snow block. Upon detecting completion of filling, the controller configures the container in a dispense orientation, from which the CO2 snow block is released into an access area, from which the user can retrieve the CO2 snow block.

Description

[Technical field]

[0001] The present invention relates to a method for automatically generating CO2 snow blocks in selected containers in a dispensing station or by automatically loading them into containers which may be located in a loading station. [Background technology]

[0002] Drug development continues to be a major endeavor in the pharmaceutical industry. Drug development requires clinical trials to establish the safety and efficacy of new treatments. Today, many clinical trials at various stages are underway in the United States, a country. Each clinical trial may involve hundreds to thousands of patients who volunteer to receive an experimental drug. Generally, as part of a clinical trial, biological samples (e.g., tissue, urine, blood samples) are collected from participants at a clinical site, such as a hospital, university, or medical institution, and then transported to a laboratory for analysis or to a facility where they can be frozen and stored for later analysis.

[0003] The ability to evaluate the safety and efficacy of investigational pharmaceuticals requires obtaining reproducible and reliable results during clinical trials. Biological specimens must be stable and preserved during storage and transportation, for example, between clinics and laboratories. Today, a common means of preserving biological specimens is by freezing and storing them in the presence of solid carbon dioxide (i.e., dry ice).

[0004] Dry ice systems typically involve manually loading samples and dry ice into an insulated box, such as a polystyrene box, at the clinical site where the samples are obtained. The insulated box is typically provided to the clinical site by the pharmaceutical company or contract research organization running the clinical trial. The insulated box components may be provided assembled or disassembled. Assembling the insulated box and loading the dry ice can be labor intensive. There can also be significant costs and inconveniences associated with maintaining an adequate supply of dry ice at the clinical site. Additionally, failure to use such dry ice for a limited period of time can cause the dry ice to lose its cooling effect. Furthermore, the insulated box is typically not reusable and must be discarded, resulting in waste.

[0005] Other drawbacks also exist with the shipping of samples in traditional insulated boxes. Dry ice cools the interior of the insulated box by sublimating carbon dioxide vapor. Many insulated boxes are available that can maintain a low internal temperature for various durations, up to 4 or 5 days. Although the internal sample space may be uniformly close to the dry ice temperature upon initial full dry ice loading, as the dry ice sublimes, large temperature gradients may develop within the internal sample space, potentially reducing sample quality. Insulated boxes are generally shipped via expedited delivery methods to ensure that a sufficiently low temperature is maintained within the internal sample space. However, should delays or disruptions occur in shipping lanes, samples may be subject to degradation. As a result of such delays during shipping, additional dry ice may need to be loaded onto the box during shipping, resulting in increased costs and logistical complications for the freight.

[0006] One alternative to traditional dry ice shipping containers is the cryogenic liquid nitrogen-based vapor container. Cryogenic liquid nitrogen-based vapor containers utilize an absorbent to keep the cryogenic nitrogen in a vapor state and avoid the presence of nitrogen in liquid form. However, such liquid nitrogen-based vapor containers suffer from drawbacks. One drawback is the time and labor involved in preparing the container. Specifically, users prepare such containers by spraying the container with liquid nitrogen and waiting several hours until sufficient absorption of the nitrogen on the absorbent occurs, followed by gently decanting the excess liquid nitrogen prior to shipping. Substantial handling of cryogenic liquid nitrogen is required, and much time is required to prepare the liquid nitrogen shipping container prior to use. Furthermore, the costs associated with using liquid nitrogen-based vapor containers are significantly higher than alternative dry ice containers.

[0007] In view of these shortcomings, there is an unmet need for improved methods for preserving samples in containers during storage and transport. Summary of the Invention

[0008] In one aspect, a method for automatically filling a carbon dioxide (CO2) snow block into a container in an automated dispensing station includes receiving a first signal corresponding to a pressure of liquid CO2 into a controller as a first set point; inputting a volume of a CO2 snow block to be generated into the controller as a second set point; the controller determining a fill time to generate the volume of CO2 snow block based on the first set point and the second set point; the controller selecting a container having an internal volume corresponding to the second set point, the container being located in an automated dispensing station, the automated dispensing station including two or more containers with different internal volumes; flowing gaseous CO2 into a fill conduit to pressurize the fill conduit at or above a pressure sufficient to prevent a phase change of the liquid CO2; and when the controller determines that the pressure in the fill conduit is at or above a pressure sufficient to prevent a phase change of the liquid CO2, the controller controls a liquid CO2 control valve to supply liquid CO2 to the fill conduit. 23. A method comprising: allowing O2 to flow into a container along a fill conduit; introducing the liquid CO2 into the container; at least a portion of the liquid CO2 undergoing a phase change and converting to the CO2 snow blocks and off-gas CO2 within the container; collecting the off-gas CO2 from the container via a plate that is permanently or removably affixed to the container, the plate being permeable to off-gas CO2 and at least partially impermeable to solid phase CO2; measuring an elapsed time of filling the container with liquid CO2 and generating a second signal corresponding to the elapsed time; and sending the second signal corresponding to the elapsed time to a controller, the controller (i) allowing the liquid CO2 to continue to flow into the container without an override if the elapsed time is less than the fill time; and (ii) preventing the liquid CO2 from flowing into the container if the elapsed time reaches the fill time.

[0009] In a second aspect, a method of automatically filling carbon dioxide (CO2) snow blocks into a container in an automated dispensing station and bending the CO2 snow block from a selected container includes inputting a set point to a controller used to determine completion of filling of the CO2 snow block into the container, the set point being based on: i) a filling duration, (ii) a predefined weight of the CO2 snow block, (iii) a pressure in the selected container, (iv) a capacitance of the CO2 snow block, (v) a temperature in the container, or (vi) a deformation of a plate, the plate being permanently or removably fixed to the container; the controller receiving a volume of the CO2 snow block to be generated; the controller selecting a container having an internal volume capable of receiving the volume of the CO2 snow block to be generated, the container being located in an automated dispensing station including two or more containers of different internal volumes; flowing a sufficient amount of gaseous CO2 into and along a filling conduit; and the controller transmitting a first signal to the controller to determine completion of filling of the CO2 snow block into and along a filling conduit. transmitting a signal to a CO2 control valve to cause liquid CO2 to flow along a fill conduit into a container where it undergoes a phase change and is converted into CO2 snow blocks and off-gas CO2; collecting the off-gas CO2 from a selected container through a plate, the plate being permeable to off-gas CO2 and at least partially impermeable to solid phase CO2, and further wherein the fill conduit is operably connected to the container; measuring a real-time variable corresponding to a set point and generating a second signal corresponding to the real-time variable; transmitting the second signal to a controller, the controller (i) allowing the liquid CO2 to continue to flow into the container without an override if the controller determines that the real-time variable has not reached the set point; and (ii) preventing the liquid CO2 from flowing into the container if the real-time variable reaches the set point, and in response, the controller transmits a third signal to a dispensing station to configure the container in a dispensing orientation, the container in the dispensing orientation containing the volume of CO2 snow blocks.

[0010] In a third aspect, a method of automatically packing carbon dioxide (CO2) snow blocks into a container includes inputting a set point into a controller used to determine completion of filling of the CO2 snow blocks into the container, the set point being based on: i) a fill duration; (ii) a predefined weight of the CO2 snow blocks; (iii) a pressure within the container; (iii) a capacitance of the CO2 snow blocks; (v) a temperature within the container; or (vi) a deformation of a plate, the plate being permanently or removably secured to the container; the controller performing an integrity check and determining that the integrity check meets an applicable criterion, in response, causing a sufficient amount of gaseous CO2 to flow from a supply manifold into a fill conduit; the controller receiving a first signal corresponding to a pressure in the supply manifold and the fill conduit; the controller determining a first signal corresponding to the pressure in the supply manifold and detecting a phase change of the liquid CO2 in the fill conduit; and if the pressure is greater than or equal to sufficient to prevent the flow of gaseous CO2 through the fill conduit, the controller sends a second signal to a liquid CO2 control valve located along the supply manifold to configure the liquid CO2 valve in an open position; collecting liquid CO2 from a CO2 source in the supply manifold at a pressure greater than the pressure of the gaseous CO2, thereby stopping the flow of gaseous CO2 through the fill conduit, the CO2 source being operably connected upstream of the supply manifold; introducing liquid CO2 into the vessel via the fill conduit; the CO2 liquid undergoing a phase change and converting to the CO2 snow blocks and off-gas CO2 within the vessel; collecting the off-gas CO2 from the vessel; measuring a real-time variable corresponding to a set point, generating a third signal corresponding to the real-time variable, and sending the third signal corresponding to the real-time variable to the controller, wherein the liquid CO2 continues to enter the vessel without an override until the controller determines that the real-time variable has reached the set point.

[0011] In a fourth aspect, a method of preparing a container for automatically packing carbon dioxide (CO2) snow blocks into a single container includes inputting a set point to be used for determining completion of filling of the CO2 snow blocks into the container into a controller, the set point being based on i) a filling duration, (ii) a predefined weight of the CO2 snow blocks, (iii) a pressure within the container, (iii) a capacitance of the CO2 snow blocks, (v) a temperature within the container, or (vi) a deformation of a plate, the plate being permanently or removably fixed to the container; the controller performing an integrity check and determining that the integrity check meets an applicable criterion; and in response, the controller verifies that the container is in a filling orientation, and if it determines that the container is not in a filling orientation, the controller either (i) sends a first signal to actuate the container into a filling orientation, or (ii) sends a warning notification for a user to manually configure the container into the filling orientation.

[0012] In a fifth aspect, a method for selecting a container in an automated dispensing station and automatically filling the container with carbon dioxide (CO2) snow blocks includes inputting a volume of CO2 snow blocks to be generated as a set point into a controller; the controller selecting a container having an internal volume corresponding to the set point, the container being located in the automated dispensing station, the automated dispensing station including two or more containers of different internal volumes; the controller verifies that the container is in a fill orientation, and if it determines that the container is not in a fill orientation, the controller either (i) sends a signal to actuate the container into a fill orientation or (ii) sends a warning notification so that a user manually configures the container into the fill orientation. [Brief description of the drawings]

[0013] [Figure 1a]1 shows a representative perspective view of a container and a top plate with a fill conduit attached to the top plate for making carbon dioxide (CO2) snow blocks in an automated fill-dispensing station in accordance with the principles of the present invention.

[0014] [Figure 1b] FIG. 1b shows a cross-sectional view of FIG. 1a detailing the gas flow of CO2 through the mesh sheet of the top plate.

[0015] [Figure 2a] 1 illustrates an embodiment of an automated dispensing station for generating CO2 snow blocks in two different sized containers, each of which is shown in a corresponding idle orientation, in accordance with the principles of the present invention.

[0016] [Figure 2b] 2b shows an embodiment of the automated dispensing station of FIG. 2a, with two containers each shown in a corresponding filling orientation, in accordance with the principles of the present invention;

[0017] [Diagram 3] 1 shows an exemplary actuation mechanism used to dispense a CO2 snow block from one of the containers pre-selected for filling and located within the automated dispensing station.

[0018] [Figure 4] FIG. 1 illustrates an embodiment of a conveyor system located within an automated dispensing station where boxes can be fed into the entrance of the conveyor system, transported beneath a selected container filled with CO2 snow blocks, and tilted into a dispensing orientation to transfer the CO2 snow blocks from the container into the boxes as part of an automated vending system.

[0019] [Diagram 5] 1 illustrates a control method utilized to operate an automated dispensing station in accordance with the principles of the present invention.

[0020] [Figure 6]9 illustrates a control method utilized to perform an automated filling operation on a single container mounted within the filling station of FIG. 8.

[0021] [Figure 7] FIG. 1 shows a process flow schematic for introducing CO2 liquid into an automated dispensing station housing multiple containers from a CO2 supply manifold that may be utilized.

[0022] [Figure 8] 1 shows a loading station where a container can be mounted to automatically load CO2 snow blocks.

[0023] [Figure 9a] 1 shows a starting orientation of a selected container ready to dispense CO2 snow blocks from the container's interior.

[0024] [Figure 9b] 9b shows an intermediate orientation resulting from a selected container being rotated 90° counterclockwise relative to the position of FIG. 9a as a result of the actuator assembly exerting an upward force along the side of the container.

[0025] [Figure 9c] The selected container is rotated an additional 45° counterclockwise relative to the position in FIG. 9b to show the final tilted orientation of the selected container whereby the CO2 snow blocks can be released from inside the container into a box located below the selected container. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0026] As described, in one aspect, the present invention provides a method for automatically generating CO2 snow blocks of various sizes available from an automated dispensing station. Users can easily access the generated CO2 snow blocks through entrance and exit access windows of a conveyor system located within the dispensing station. The on-demand generation of the present invention eliminates the need for users to maintain an inventory of CO2 snow blocks or dry ice on-site.

[0027] It should be understood that the terms "CO2 snow" and "dry ice" have the same meaning and refer to particles of solidified CO2 and may be used interchangeably throughout this specification.

[0028] "CO2 snow block" or "CO2 block", both of which may be used interchangeably herein and throughout, are intended to mean the creation of CO2 snow particles in a substantially block-like form of any shape consisting of tightly held particles.

[0029] As used herein, "CO2 fluid" means any phase, including liquid phase, gas phase, vapor phase, supercritical phase, or any combination thereof.

[0030] As used herein, a "CO2 source" or "CO2 liquid source" includes, but is not limited to, cylinders, dewars, bottles, and bulk or micro-bulk tanks.

[0031] As used herein, "conduit" or "conduit flow network" means tubes, pipes, hoses, manifolds, and any other suitable structures sufficient to create one or more flow paths and / or allow the passage of a fluid.

[0032] As used herein, "connected" or "operably connected" means a direct or indirect connection between two or more components, such as piping and assemblies, including but not limited to instrumentation, valves and conduits, and, unless otherwise specified, allows for fluid, mechanical, chemical and / or electrical communication between the two or more components.

[0033] As used herein, "article" refers to any temperature-sensitive item, product, or supply that may undergo spoilage, deterioration, and / or structural change or denaturation if not frozen or maintained below a certain temperature, including, but not limited to, biological samples such as blood, urine, tissue samples, or components thereof; perishable foods such as meat, poultry, fish, and dairy products; personal care items; and chemicals.

[0034] "Stuffing," as used herein, refers to the process of introducing CO2 fluid from an external CO2 source into a container that is operably connected to the external CO2 source.

[0035] As used herein, "vessel" means any storage, filling, delivery, or transportable vessel capable of receiving CO2 fluid, including, but not limited to, mold cavities, cylinders, dewars, bottles, tanks, barrels, bulk, and microbulk.

[0036] "Transportable" means a device that is capable of being moved, transported, or shipped from a user's location to another destination by any known means, including, but not limited to, air, ground, or sea. Transportation or shipping may occur through various package delivery services, including, but not limited to, parcel post, UPS® shipping services, FedEx® shipping services, etc.

[0037] The embodiments as described below are merely examples, and the present invention is not limited to the embodiments illustrated in the drawings. It should also be understood that the drawings are not drawn to scale, and in some cases, details that are not necessarily required for an understanding of the embodiments, such as conventional manufacturing and assembly details, are omitted. It should also be understood that the precise conduit and valve mechanism configurations are not drawn to scale, and that certain features are purposely omitted in each of the drawings to better illustrate various aspects of the auto-filling and auto-stuffing process according to the principles of the present invention.

[0038] The embodiments are described with reference to the drawings, in which similar elements are referenced by like numerals. The relevance and function of the various elements of the embodiments will be better understood by the following detailed description. The Detailed Description contemplates various permutations and combinations of features, aspects, and embodiments as being within the scope of the disclosure. Thus, the disclosure may be specified to comprise, consist of, or consist essentially of any of such combinations and permutations of these specific features, aspects, and embodiments, or selected one or more of them.

[0039] In one aspect of the present invention, a method for automatically filling carbon dioxide (CO2) snow blocks into selected containers in an automated dispensing station is discussed with reference to Figures 1a, 1b, 2a, 2b, 3, 4, 5, 7, 9a, 9b, and 9c. Figures 1a and 1b show a first container 10 for use with an automated dispensing station 1 (Figures 2, 3, 4, and 5) for bending a CO2 snow block 2 from the first container 10 into any suitable user box. The first container 10 includes a mold cavity 13 having a first top plate 15. The mold cavity 13 has a volume sized to receive the volume of the CO2 snow block 2. The desired volume of the CO2 snow block 2 is input into a programmable logic controller (PLC) 1085 of the automated dispensing station 1. The PLC 1085 selects a mold cavity 13 located within the automated dispensing station 1 only if it determines that the mold cavity 13 has a volume equal to or greater than the volume of the CO2 snow block 2 inputted into the PLC 1085. The PLC 1085 orients the selected mold cavity 13 in a fill orientation (FIG. 2b) and executes an automated filling process that fills the mold cavity 13 with the required amount of CO2 snow block 2. The filling process is preferably based on a fill time to obtain a desired volume of the CO2 snow block 2.

[0040] Once filling is complete, the CO2 snow blocks 2 are transferred from the mold cavity 13 to a user box 22 (FIG. 4) and bent over to a user for pick-up. Specifically, the user box 22 is delivered to an entrance window 21 and then transported along a conveyor belt 20 to the dispensing window 14 of the automated dispensing station 1 for access and pick-up by the user.

[0041] The structural details of the first container 10 are shown in Figures 1a and 1b. The mold cavity 13 generally includes a top plate 15, a bottom wall 16, and a plurality of vertically oriented side walls 17. The top plate 15 is characterized by a separation barrier support that is permeable only to gaseous CO2 and substantially impermeable to CO2 snow so that gaseous CO2 may escape from the interior of the mold cavity 13 without significant loss of CO2 snow. Referring to Figure 1b, the separation barrier support includes a support structure 19 and a mesh sheet 18. It should be understood that any type of material may be utilized to define the passage for the escape of gaseous CO2.

[0042] The fill conduit 23 is connected at one end to the top plate 15 and at the other end to the CO2 supply manifold 1000. In a preferred embodiment, a total of four nozzles 12 are evenly distributed at one end of the fill conduit 23. Each nozzle 12 is spaced approximately 90° apart from one another, and each nozzle 12 has the same size opening and shape. The nozzle 12 configuration creates a substantially uniform flow of CO2 fluid therethrough, enabling the creation of a substantially uniform formation and distribution of CO2 snow blocks 2 within the mold cavity 13. The nozzles 12 are oriented away from the normal of the fill conduit 23 at an angle ranging from about 30° to 60°, whereby the normal extends perpendicular to the horizontal plane of the mold cavity 13. It should be understood that other nozzle designs and orientations are contemplated without departing from the scope of the present invention.

[0043] FIG. 2a shows an automated dispensing station 1 designed to accommodate multiple containers. The dotted lines represent the structural enclosure of the automated dispensing station 1 in which multiple containers of different volumes may be accommodated. Specifically, for brevity and to better illustrate the principles of the present invention, only two containers are shown, namely the first container 10 and the second container 26 in FIG. 1a. The first container 10 has a smaller volume than the second container 26. The automated dispensing station 1 is removably connected to a CO2 supply manifold 1000, the details of which are shown in FIG. 7. The first container 10 is shown in an idle orientation, with the first top plate 15 of the first container 10 removed from the top of the first mold cavity 13. Similarly, the second container 26 is shown in an idle orientation, with the second top plate 28 of the second container 26 removed from the top of the second mold cavity 25. Neither the first container 10 nor the second container 26 in the idle orientation is housing a CO2 snow block 2. Vertical actuators 29a and 29b are attached to the first top plate 15 and are configured to retract to raise the first top plate 15 away from the first container 10 to create the idle orientation. Vertical actuators 29a and 29b are configured to extend to lower the first top plate 15 onto the first container 10 to create the fill orientation of Figure 2b. Similarly, vertical actuators 30a and 30b are attached to the second top plate 28 and are configured to raise the second top plate 28 away from the second container 26 to create the idle orientation, and can be reconfigured to extend to lower the second top plate 28 onto the second container 26 to create the fill orientation of Figure 2b.

[0044] The PLC 1085 is in electrical communication with various components of the supply manifold 1000 and the automated dispensing station 1, and may therefore regulate various actuators, valving including automatic control valves and pressure regulators, pressure transducers, and ventilation systems, as shown in FIG. 7. The dotted lines in FIG. 7 extending between the PLC 1085 and the various components represent electrical communication. It should be further understood that the PLC 1085 communicates between the PLC 1085 and various components, such as the first container 10, the second container 26, and the various actuators 29a, 29b, 30a, 30b responsible for raising and lowering the top plate, as well as other actuator assemblies 91a, 91b (as will be described with reference to FIGS. 9a, 9b, and 9c) responsible for rotating the mold cavities to a distributed orientation.

[0045] 2b shows the first container 10 and second container 26 in a fill orientation with corresponding top plates 15 and 28 being lowered onto their corresponding mold cavities 13 and 25 with sufficient pressure to form a seal along the perimeter of their corresponding containers 10 and 26. The peripheral seal ensures that gaseous CO2 within the mold cavities 13 / 25 can only escape through the mesh sheets 18 and 31 of the first container 10 and second container 26, respectively. Specifically, vertical actuators 29a and 29b are extended relative to FIG. 2a to lower the first top plate 15 onto the first mold cavity 13 with sufficient pressure to form a seal along the perimeter of the first mold cavity 13. Vertical actuators 30a and 30b are extended relative to Fig. 2a to lower second top plate 28 onto second mold cavity 25 with sufficient pressure to form a seal along the perimeter of second mold cavity 25. Fig. 2b shows that first fill conduit 23 and second fill conduit 27 are removably connected to a CO2 supply manifold 1000 along which CO2 liquid may flow from a CO2 source 1090, which may include any suitable container including, but not limited to, a cylinder, a dewar, a bottle, a microbulk, or a bulk tank, etc.

[0046] The automated process associated with the automated dispensing station 1 will now be described. In a preferred embodiment, the PLC 1085 is utilized to control the filling and vending of the CO2 snow blocks 2 via the control method 5000 of FIG. 5. The PLC 1085 may be located in close proximity to the automated dispensing station 1. In this example, for simplicity and to better illustrate the principles of the present invention, the automated dispensing station 1 contains a first container 10 and a second container 25. However, it should be understood that the automated dispensing station 1 is preferably designed to accommodate more containers of different volumes. In one example, the PLC 1085 is located as part of the CO2 supply manifold 1000 shown in FIG. 7. The PLC 1085 is preferably pre-programmed with the density of the CO2 snow blocks 2 to be manufactured. The PLC 1085 may use any density, but preferably uses 50-65 lb / ft3, more preferably 55-60 lb / ft3. In step 501, the PLC 1085 may be activated. Next, the user inputs into the PLC 1085 the desired volume of CO2 snow block 2 to be produced (step 502). The user may also select the size and / or shape of a particular CO2 snow block or container 10 / 26 on the human machine interface (HMI). In response to the input volume, the PLC 1085 selects and activates a suitable container in the automated dispensing station 1 having a volume capable of producing the input volume of CO2 snow block 2. The PLC 1085 determines that the volume of the mold cavity 13 corresponding to the first container 10 is smaller than the input volume. The PLC 1085 further determines that the volume of the mold cavity 25 corresponding to the second container 26 is equal to or greater than the input volume of the CO2 snow block 2. As a result, the PLC 1085 selects the second container 26 to be used for filling with CO2 and sends a signal to the second container 26 accordingly.

[0047] A box 22 (e.g., a cardboard box) is fed (step 503) to an entrance window 21 of a conveyor system 4 located within the automated dispensing station 1. The box 22 may be fed manually by a user or automatically. The box 22 has a volume sized to receive an input volume of CO2 snow blocks 2 to be produced in the mold cavity.

[0048] Once the appropriate container for filling with CO2 has been selected and the box 22 is placed along the entrance 21 of the conveyor belt 20 (step 503), the PLC 1085 is ready to perform a pre-fill integrity check (step 504). A number of criteria must be passed before the filling operation can begin. The PLC 1085 verifies that the ventilation system 1050 (FIG. 7) is turned on via a pressure switch "PS1000" shown in communication between the exhaust 1050 and the PLC 1085. Specifically, the PLC 1085 verifies that the exhaust system is turned on and that CO2 gas and CO2 off-gas can be vented from the mold cavity 25 through the exhaust conduit 1050 and then into the exhaust system. The PLC 1085 also determines whether pressure in the supply manifold 1000 and second fill conduit 27 can be maintained without leakage. If any of these prefill integrity criteria are not met, the PLC 1085 will cease operation and send a message and status to the human machine interface (HMI) for the user to take appropriate corrective action until all of the prefill integrity checks pass (step 505).

[0049] Once each of the pre-fill completeness checks is satisfied, the PLC 1085 selects a suitable mold cavity and activates the selected suitable mold cavity from the idle orientation to the fill orientation (step 506). In response to the input volume of the CO2 snow block, the PLC 1085 selects a suitable container in the automated dispensing station 1 having a volume capable of producing the input volume of the CO2 snow block 2. The PLC 1085 determines that the volume of the mold cavity 13 corresponding to the first container 10 is smaller than the input volume. The PLC 1085 further determines that the volume of the mold cavity 25 corresponding to the second container 26 is equal to or greater than the input volume of the CO2 snow block 2. As a result, the PLC 1085 selects the second container 26 to be used for filling with CO2 and accordingly transmits a signal to the second container 26 to activate the second container 26 from the idle orientation (FIG. 2a) to the fill orientation (FIG. 2b) in connection with step 506. The selected second mold cavity 25 in FIG. 2a is shown in an idle orientation with the second top plate 28 spaced away from the top of the second mold cavity 25. At this point, no CO2 snow block 2 is received within the second mold cavity 25. The PLC 1085 sends a signal to the vertical actuators 30a and 30b to extend the vertical actuators 30a and 30b longitudinally downward, as shown in FIG. 2b, thereby moving the second top plate 28 downward toward the top of the second container 26. The vertical actuators 30a and 30b continue to move downward until the second top plate 28 is evenly positioned on the top of the second mold cavity 25, as shown in FIG. 2b. FIG. 2b shows that the second plate 28 has been lowered onto the top of the second container 26 with sufficient pressure to form a seal along the perimeter of the second container 26.

[0050] The PLC 1085 verifies that the selected container 26 is in the fill orientation, and if not, the PLC 1085 relays the appropriate signal to orient the selected container 26 in the fill orientation. Upon confirming that the second container 26 is activated into the fill orientation as shown in FIG. 2b, the PLC 1085 may determine a predetermined or expected fill time of the CO2 snow block 2 into the selected container 26 (step 507) as follows: The PLC 1085 receives a signal from a pressure transducer 1071 (FIG. 7) that measures the pressure of the CO2 in the vapor headspace of the source 1090. The pressure transducer 1071 relays a signal corresponding to the pressure of the CO2 to the PLC 1085. Based on this pressure reading and the total volume of the nozzle 12 in the second fill conduit 27 (a representative schematic of which is shown in FIG. 1b), the PLC 1085 may determine an expected mass flow rate of the CO2 liquid-containing stream, which is empirically determined by a look-up table of pressure versus total volume of the nozzle 12. With the mass flow rate determined, the expected fill time (i.e., the predetermined fill time) into the selected second container 26 is calculated by the PLC 1085 as the product of the inputted volume of the desired CO2 snow block and the pre-programmed density of the CO2 snow block to be produced (e.g., preferably 55-60 lb / ft3), divided by the empirically determined mass flow rate.

[0051] Once the PLC 1085 has calculated the predetermined fill time, the PLC 1085 prompts the user with a message to activate the start button (step 508) to begin pressurizing the supply manifold 1000 prior to the fill process. The valve mechanism, instruments, and components of FIG. 7 associated with the second fill conduit 27 are configured to connect with the CO2 source supply manifold 1000 and receive CO2 gas and CO2 liquid, as described below. The gas conduit 1091 includes pressure transducers 1071 and 1070, and a pressure indicator 1078. The pressure transducer 1071 measures the pressure of the headspace in the CO2 source 1090, the pressure indicator 1078 measures the pressure of the CO2 gas stream after it has been reduced by the pressure reducing valve 1080 ("PRV 1100"), and the pressure transducer 1070 measures the pressure of the CO2 liquid-containing stream entering the selected second container 26. When the CO2 vapor valve 1094 is configured in an open position, the CO2 control valve 1100 is configured in an open position, the CO2 liquid recovery valve 1093 is configured in a closed position, and the CO2 control valve 1200 is configured in a closed position, CO2 gas is recovered from the vapor headspace of the CO2 source 1090 and flows into the gas conduit 1091. The pressure regulator 1080 ("PRV 1100") reduces the pressure of the CO2 gas recovered from the CO2 source 1090 from the source pressure (e.g., 350-400 psig) to about 150 psig, as measured by the pressure indicator 1078. The CO2 gas is preferably added in an amount that prevents the pressure of the liquid-containing CO2 from dropping below a certain pressure (e.g., about 150 psig) to ensure that the pressure does not drop to a pressure that would cause the liquid to prematurely change phase to solid and / or gas within a portion of the supply manifold 1000 and second fill conduit 27 conduits.

[0052] In addition to appropriately pressurizing the conduits of the manifold 1000, CO2 gas can be optionally added and allowed to flow for any amount of time to purge any residue and / or impurities. In one embodiment, the purge process can last from approximately 30 seconds to about 2 minutes. As the CO2 gas flows through the various portions of the gas conduit 1091, any residue and / or impurities can also be purged. The CO2 gas may be directed to a selected second container 26 by setting valve 1301 to an open state and valve 1302 to a closed state. The container 26 at this stage of the filling process does not contain any substantial amount of CO2 snow particles or CO2 snow blocks 2. The CO2 gas flows in a downward direction through the filling conduit 27 and into the mold cavity 25. The CO2 gas then exits the container 26 through the mesh sheet 31 of the second top plate 28 (e.g., is collected in a substantially vertical direction as shown in more detail in FIG. 1b by the up arrow).

[0053] If the PLC 1085 determines that the pressure within the selected fill conduit 27 and CO2 supply manifold 1000 is at or above sufficient pressure to prevent phase change of the liquid CO2 (e.g., preferably at or above 150 psig, more preferably between 200 psig and about 350 psig), then filling of the CO2 snow block 2 into the selected container 26 begins (step 509). The CO2 steam valve 1094 may remain in an open position and the control valve 1100 may remain in an open position, thereby ensuring that adequate gas pressurization within the manifold 1000 exists prior to and during the filling of the container 26 with liquid CO2. To initiate the flow of liquid CO2 from the CO2 source 1090, the control valve 1302 is set to a closed position to ensure that liquid-containing CO2 does not flow to the first container 10 (i.e., the container not selected as determined by the PLC 1085) and the control valve 1301 is set to an open position to allow liquid-containing CO2 to flow into the second container 26 (i.e., the container selected as determined by the PLC 1085). With reference to FIG. 7, the liquid-containing CO2 from the CO2 source 1090 flows through the control valve 1301 along the liquid conduit 1092 and is then introduced downwardly into the second fill conduit 27 of the selected second container 26 (as shown in FIG. 1b). The check valve 1067 prevents the pressure of the liquid-containing CO2 from causing the CO2 gas in the conduit 1091 to flow back into the CO2 source 1090.

[0054] The CO2-containing liquid exits the nozzles 12 of the second fill conduit 27 and enters the selected mold cavity 25 of the selected second container 26. In a preferred embodiment, the end of the second fill conduit 27 has four nozzles 12 angled to direct or enter the CO2-containing liquid into the selected mold cavity 25, as shown in FIG. 1b. As the liquid containing CO2 passes through the nozzles 12 and enters the selected mold cavity 25, a drop in pressure and temperature occurs, producing CO2 snow and solid particles of CO2 off-gas therein. The CO2 off-gas passes through the mesh sheet 18 of the second top plate 28, but the solid particles are too large to flow through the mesh sheet 18 and therefore remain within the mold cavity 25. As a result of the actuators 30a and 30b keeping the second top plate 28 fully pressed against the top of the mold cavity 25 during filling, the periphery of the second container 26 is sealed so that particles and gas do not escape along the top edge of the container 26. The CO2 off-gas passing through the mesh sheet 31 as an aeration gas has the desired effect of packing the solid particles of CO2 snow for forming the CO2 snow block 2 in the mold cavity 25, thereby initiating the production of the CO2 snow block 2. As used herein with respect to automatic filling, the term "packing" refers to compressing the snow particles into a CO2 snow block 2 of a suitable density. Packing can affect the amount of CO2 snow block 2 that can be produced in a selected mold cavity 25. Thus, the present invention has the ability to utilize the formation of aerated gas to improve the packing density of the snow particles for forming the CO2 snow block 2. The vented CO2 gas flows through the openings F in the mesh sheet 31 of the second top plate 28, as shown by the arrows in FIG. 1b, thereby preventing excess pressure from building up in the second mold cavity 25. It should be understood that the gas may be withdrawn at any angle relative to the vertical of the second fill conduit 27, whereby the vertical extends perpendicular to the horizontal plane of the selected mold cavity 25. The vented gas may then be directed into an exhaust conduit 1050 operably connected to the second fill conduit 27.

[0055] Particles of CO2 snow continue to form in block-like form within the selected mold cavity 25. The timer may continue to monitor the elapsed time and generate a signal corresponding to the elapsed time that is sent to the PLC 1085. The PLC 1085 continues to allow the CO2-containing liquid to flow along the conduit 1092 as long as the elapsed time is less than the predetermined fill time (step 510).

[0056] When the PLC 1085 determines that the elapsed time has reached a predetermined fill time, the fill is stopped. Specifically, the PLC 1085 sends a signal to the control valve 1301 to configure the control valve 1301 to a closed position, thereby preventing the CO2-containing liquid from continuing to flow into the selected container 26. The main liquid recovery valve 1093 is also closed. The fill process is thus stopped (step 511). In response to the flow of liquid CO2 being stopped, gaseous CO2 may resume flowing into the fill conduit 807 along the gas conduit 1091 and into the container for a certain period of time, as desired, as a means of purging any impurities or residues within the conduits of the manifold 1000 and / or the selected container 26. As the CO2 gas flows into the selected container 26 and then vents, the snow block 2 may become further packed.

[0057] Shutdown of the manifold 1000 may also be performed as part of step 511. The remaining liquid CO2 may be trapped along the portion of the liquid conduit 1092 that extends from the control valve 1200 to the main liquid recovery valve 1093. The safety relief valves 1086 and 1087 ("SRV 1102" and "SRV 1200") are designed to relieve residual pressure that may be trapped in the gas conduit 1091 and / or liquid conduit 1092. Pressure buildup can be relieved by the safety relief valve 1087, which in one embodiment is set to operate at 400 psig, when the liquid CO2 trapped along them may eventually sublimate into CO2 gas. The safety relief valve 1086 also acts to relieve pressure when the pressure buildup in the CO2 gas 1091 conduit reaches an upper limit (e.g., 400 psig).

[0058] Upon finishing the filling process, the PLC 1085 activates the selected mold cavity 25 from the filling orientation to the dispensing orientation (step 512). First, the actuators 30a and 30b are retracted to raise the top plate 28 away from the top of the mold cavity 25, similar to that shown in FIG. 2a. FIG. 3 shows a close-up view of the selected mold cavity 25 containing a desired volume of CO2 snow blocks 2 with the top plate 28 removed. The mold cavity 25 is now ready to dispense the CO2 snow blocks 2 into the box 22, which is transported along the conveyor belt 20 to a position below the mold cavity 25 so that the box 22 can receive the CO2 snow blocks 2 as they drop from inside the mold cavity 25 into the box 22. FIG. 4 shows the movement of the box 22 along the conveyor belt 20. Specifically, FIG. 4 shows the conveyor system 4 moving the box 22 from the entrance 21 of the conveyor window to a position below the mold cavity 25 where it receives the CO2 block 2, and finally to the distribution window of the conveyor system 4 where the desired CO2 block 2 can be loaded into the box and picked up. If the box 22 is determined to be in the desired position (step 513), the mold cavity 25 is tilted to dispense the CO2 snow block 2 therein into the box 22, as described in the series of FIGs. 9a, 9b, and 9c. FIGs. 3 and 9a show the mold cavity 25 at the start of the dispensing process. FIG. 3 shows that the actuator assembly 91a and actuator assembly 91b are operatively connected to the first side 17a and second side 17b of the selected mold cavity 25, respectively. As used herein, with reference to FIG. 3, a part number with an "a" is intended to refer to a first side 17b of mold cavity 25, the same part number with a "b" is intended to refer to a second side 17b of mold cavity 25, and the same part number without an "a" or "b" is intended to generally refer to structure associated with mold cavity 25 when mold cavity 25 is not shown in a perspective view (see, for example, FIGS. 9a, 9b, and 9c).By way of example, actuator assembly 91a refers to an actuator assembly operably connected to a first side 17a of a mold cavity 25 as shown in FIG. 9a, actuator assembly 91b refers to an actuator assembly operably connected to a second side 17b of a mold cavity 25, and actuator assembly 91 generally refers to an actuator assembly of a mold cavity 25 as shown in the cross-sectional views of FIGs. 9a, 9b, and 9c. Each of actuator assemblies 91a and 91b remains engaged to the first side 17a and second side 17b of a selected mold cavity 25 by corresponding pins 93a, 93b engaged in corresponding slots 92a and 92b. The actuator assemblies 91a and 91b rotate the mold cavity 25 (as described below) as the pins 93a, 93b slide along the corresponding slots 92a, 92b. Mold cavity 25 can pivot about pivot points 94a and 94b connected to support leg structures 90a and 90b that suspend mold cavity 25 as shown in Figures 2a, 2b, 3, and 4. It should be understood that the details of the actuator assembly shown in Figure 3 have been omitted from the conveyor system of Figure 4, and the other figures show automated dispensing station 1 for purposes of clearly illustrating salient aspects of the invention in connection with these figures.

[0059] Starting from the orientation of Figures 3 and 9a, actuator assembly 91a and actuator assembly 91b are activated (e.g., programmed by PLC 1085) to exert an upward force that is transferred to pins 93a, 93b, respectively, on first and second sides 17a, 17b of mold cavity 25. Pins 93a, 93b are constrained from moving upward within slots 92a, 92b. As a result, pins 93a, 93b, which are spaced the same distance from pivots 94a, 94b, respectively, exert a torque that rotates mold cavity 25 in a counterclockwise direction. As mold cavity 25 rotates in a counterclockwise direction, slots 92a, 92b become vertically oriented, thereby allowing the corresponding arms of actuator assemblies 91a, 91b to extend upward along slots 92a, 92b. FIG. 9b shows an intermediate configuration of the rotating mold cavity 25 rotated 90 degrees counterclockwise about pivots 94a, 94b, with the arms of the actuator assemblies 91a, 91b partially extended upward into and along the slots 92a, 92b. The arms of the actuator assemblies 91a, 91b continue to exert an upward force through the corresponding pins 93a, 93b to cause additional counterclockwise rotation of the mold cavity 25 until the arms and corresponding pins 93a, 93b move to the top edge of the slots 92a, 92b, as shown in FIG. 9c. FIG. 9c represents another 45° counterclockwise rotation relative to FIG. 9b. The tilted orientation of FIG. 9c allows the CO2 snow block 2 to be expelled from the interior of the mold cavity 25 into the box 22 (step 515), which is now positioned below the mold cavity 25 as shown in FIG. 4. 4 shows the mold cavity 25 inverted to show that the CO2 snow block 2 has been released into the box 22. The notation "2" within the box 22 is intended to indicate that the box 22 contains a CO2 snow block 2.

[0060] Once the CO2 snow blocks 2 have been released from the mold cavity 25 and dispensed into the box 22, the actuator arms are retracted to move the pins 93a, 93b and their attached arms down along the slots 92a, 92b, reconfiguring them to the orientation of FIG. 9a, which at this stage represents the idle orientation of the mold cavity 25 (step 516). The box 22 with the CO2 snow blocks 2 therein is transported along the conveyor belt 20 to the exit / distribution window 14 of the pick-up capable conveyor system 4 (step 517).

[0061] Although automatic filling of the automatic dispensing station 1 is performed based on a predefined fill time, automatic filling may also occur based on other criteria. For example, the PLC 1085 may use another set point for filling, including, by way of example, a predefined weight of the CO2 snow block 2, pressure in a selected mold cavity, capacitance of the CO2 snow block 2, temperature in the container, or deformation of the top plate of a selected mold cavity.

[0062] In another embodiment, as an alternative to using the automatic dispensing station 1, a method may be implemented to automatically pack CO2 snow blocks into a single container in a packing station. FIG. 6 illustrates an associated control method 6000, and FIG. 8 illustrates an exemplary packing station 800. The inlet of the packing station 800 is connected to a CO2 supply manifold 1000, and the outlet of the packing station 800 is connected to a ventilation system 801. The CO2 supply manifold 1000 is substantially identical, except that the automatic dispensing station 1 is now replaced with the packing station of FIG. 8. The PLC 1085 is in electrical communication with the packing station 800, the CO2 supply manifold 1000, the ventilation system 801, and its associated components. Once the PLC 1085 is activated (step 600), a container is selected for filling (step 601). The container may be any suitable box into which CO2 snow blocks can be packed. The container is placed in the packing station 800 (step 602). As described above, a prefill integrity check (step 603) is performed by the PLC 1085. As an additional prefill integrity check, a door sensor determines if the door 803 is locked. If any of the prefill integrity checks are not satisfied, the PLC 1085 is prompted to generate an appropriate HMI message for the user to take appropriate action (step 604).

[0063] Once all preload integrity checks are completed, the container is actuated from the idle orientation to a fill orientation (step 605). By way of example, and not intended to be limiting, the fill orientation may include configuring a top plate on the top of the container with one or more vertical actuators placed on the top of the container to create a seal along the perimeter. It should be understood that the container need not utilize a top plate and mold cavity as described with reference to Figures 1a, 1b, 2a, and 2b. Thus, if a top plate and mold cavity as described above are not required, the fill orientation may include introducing and orienting a suitable stuffer operably connected to the fill conduit and the top of the container. The fill orientation also provides for a safety interlock to be provided within the stuffing station 800 such that the door 803 remains locked during stuffing of CO2 and the container is securely loaded inside the stuffing station 800.

[0064] Once the vessel is verified to be in the fill orientation, the user may input the desired volume of CO2 snow block 2 desired to be produced in the vessel. In step 606, the PLC 1085 determines the predetermined fill time, as described above with respect to step 507 of the example of FIG. 5. The density of the CO2 snow block (e.g., 55-60 lb / ft3) is pre-programmed into the PLC 1085, and the mass flow rate is empirically determined from a look-up table of CO2 pressure versus total volume of the nozzle in the stuffer.

[0065] The user activates the start button (step 607) to initiate the automated packing process. Filling begins (step 608) as follows: A sufficient amount of gaseous CO2 from the supply manifold 1000 is introduced from the vapor headspace of the CO2 source 1090 into the fill conduit 807 that extends between the supply manifold 1000 and the container. The supply manifold 1000 is operatively connected to the fill conduit 807. CO2 gas is added into the conduit to pressurize the manifold 1000 conduit to a level sufficient to prevent the liquid CO2 from dropping below a certain pressure (e.g., below about 150 psig) at which the liquid CO2 may prematurely undergo a phase change to solid and / or gas within the manifold 1000 conduit and the fill conduit 807. The PLC 1085 continues to monitor the pressure within the supply manifold 1000 from a pressure transducer 1070 (FIG. 7) that measures the pressure of the CO2 and the fill conduit 807. If it is determined that the pressure is equal to or greater than the specified pressure and the liquid CO2 does not change phase, the PLC 1085 sends a signal to the control valve 1200 to configure the control valve 1200 to an open position. With the control valve 1200 in the open position, liquid CO2 is withdrawn from the CO2 supply 1090 and flows along the conduit 1092. The pressure of the liquid CO2 is greater than the pressure of the gaseous CO2 occupying the manifold 1000, and as a result, the gaseous flow of CO2 into the vessel stops as the liquid CO2 flows into the vessel at the filling station 800 along a first direction (e.g., substantially vertically and downward into the vessel). Once in the vessel, the CO2 liquid undergoes a phase change to convert to CO2 snow blocks and off-gas. The off-gas flows out of the vessel and valve through the exhaust conduit 1050. The CO2 liquid continues to enter the vessel until the PLC 1085 determines that the elapsed fill time has reached a predetermined time. If the elapsed time has reached a predetermined time, the PLC 1085 relays a signal to the control valve 1200 to configure the control valve 1200 to a closed position, thereby ceasing the recovery of liquid CO from the CO source 1090 (step 610). The main liquid recovery valve 1093 is also closed.In response to the flow of liquid CO2 being stopped, gaseous CO2 may resume flowing along gas conduit 1091 into fill conduit 807 and into the vessel for a period of time, as desired, as a means of purging any impurities or residue within the conduits and / or vessel of manifold 1000. As CO2 gas flows into the vessel and then vents to exhaust conduit 1050, the snow block may become further packed. Although valves 1093 and 1094 are shown in FIG. 7 as manual valves, it should be understood that automatically controlled valves may be used in place of valves 1093 and 1094, respectively.

[0066] Shutdown may now be performed (step 611). The remaining liquid CO2 may be trapped along the portion of the liquid conduit 1092 that extends from the control valve 1200 to the main liquid recovery valve 1093. The safety relief valves 1086 and 1087 ("SRV 1102" and "SRV 1200") are designed to relieve residual pressure that may be trapped in the gas conduit 1091 and / or liquid conduit 1092 when various system components of the stuffing station 800 and manifold 1000 are shut down. Pressure buildup along which the accumulated liquid CO2 may eventually sublimate into CO2 gas may be relieved by the safety relief valve 1087, which in one embodiment is set to operate at 400 psig. The safety relief valve 1086 also acts to relieve pressure when the pressure buildup in the CO2 gas 1091 conduit reaches an upper limit (e.g., 400 psig).

[0067] After shutdown is completed in step 611, the PLC 1085 disables the safety interlock of the loading station 800, so that the loading station door 803 is opened to access the container and remove the container with the CO2 snow block 2 filled therein.

[0068] It should be appreciated that automatic filling of the vessel may also occur based on other criteria, for example, the PLC 1085 may use another set point for filling, including, by way of example, a predefined weight of the CO2 snow block 2, pressure within the vessel, capacitance of the CO2 snow block 2, temperature within the vessel, or deformation of the top plate that may be utilized to seal the vessel.

[0069] As described, the container with the CO2 snow block 2 may be used with any "article" as defined herein below, but the present invention particularly contributes to maintaining compliance with packaging protocols necessary to reproducibly preserve biological samples, thereby avoiding sample degradation and allowing the sample to return to its original functional state and undergo appropriate testing upon arrival at its destination. Furthermore, the CO2 snow block 2 is preferably produced with improved packing density that can maintain the required temperature of the container with an extended duration of cooling effect compared to standard dry ice shipping containers containing CO2 dry ice produced by prior art. The extended duration of cooling effect can reduce the risk of sample degradation during transportation and allows the user to be more flexible and optimize the cost and convenience of preparing and assembling the transportable container of the present invention, the timing of obtaining the article (including samples such as biological samples), and the type of shipping method that can be utilized.

[0070] Several modifications to the present invention are contemplated without departing from the spirit of the present invention. For example, the sequence of steps in the control method of the automatic filling station (FIG. 5) may be modified so that the box 22 is positioned in place after passing the pre-fill integrity check. For the stuffing station (FIG. 6), the PLC may be activated after the container is loaded into the stuffing station. In addition, the entrance direction of the CO2 stream into the selected container can be changed. For example, the CO2-containing liquid may be entered upward, or sideways, or downward at various angular orientations, with the exact angle determined by the nozzle shape, design, and geometry in the filling conduit. Similarly, the CO2 gas and off-gas in the selected container can be changed to vent in a downward or sideways or upward angled direction. In addition, for the automatic stuffing station, the control method can be modified so that the user inputs the volume of the snow block 2 and selects a container listed on the HMI of the automatic dispensing station 1.

[0071] The automated control method of the present invention may be applied to any container. In one embodiment, the automated control method and process may be used in connection with containers such as those described in U.S. Patent Application No. 15 / 645,152, the details of which are incorporated by reference herein in their entirety for all purposes. Such containers may be utilized as part of the automated filling and dispensing station or filling system of the present invention.

[0072] While what are considered to be particular embodiments of the invention have been shown and described, it will of course be understood that various modifications and changes in form or detail can be readily made without departing from the spirit and scope of the invention. It is therefore intended that the invention not be limited to the exact forms and details shown and described herein, nor be limited to anything less than the full scope of the invention disclosed herein and claimed below.

Claims

1. 1. A method for automatically filling a container in an automated dispensing station with carbon dioxide (CO2) snow blocks, comprising: receiving a first signal corresponding to a pressure of the liquid CO2 into a controller as a first set point; inputting the volume of the CO2 snow block to be produced as a second set point into the controller; the controller determines a fill time to produce the volume of the CO2 snow block based on the first set point and the second set point; the controller selects the container having an internal volume corresponding to the second set point, the container being located within the automated dispensing station, the automated dispensing station including two or more containers of different internal volumes; flowing gaseous CO2 into a filling conduit to pressurize the filling conduit at or above a pressure sufficient to prevent a phase change of the liquid CO2; when the controller determines that the pressure in the fill conduit is equal to or greater than the pressure sufficient to prevent the phase change of the liquid CO2, the controller causes a liquid CO2 control valve to allow the liquid CO2 to flow along the fill conduit into the container; Introducing the liquid CO2 into the container; at least a portion of the liquid CO2 undergoes a phase change and is converted to the CO2 snow block and off-gas CO2 within the vessel; collecting the off-gas CO2 from the vessel via a plate permanently or removably fixed to the vessel, the plate being permeable to the off-gas CO2 and at least partially impermeable to solid phase CO2; measuring an elapsed time for filling the container with liquid CO2 and generating a second signal corresponding to the elapsed time; transmitting the second signal corresponding to the elapsed time to the controller; The method includes the controller (i) allowing the liquid CO2 to continue to flow into the container without an override when the elapsed time is less than the fill time, and (ii) preventing the liquid CO2 from flowing into the container when the elapsed time reaches the fill time.

2. The controller detects when the elapsed time reaches the fill time, and in response thereto:

2. The method of claim 1, further comprising: the controller sending a third signal to configure the container from a fill orientation to a dispense orientation, the container in the dispense orientation containing the volume of the CO2 snow block.

3. 3. The method of claim 2, further comprising releasing the CO2 snow block from the container into an access area of ​​the automated dispensing station.

4. The method of claim 3 further comprising configuring the container in the automated dispensing station in an idle orientation or in the fill orientation.

5. The method of claim 1 , further comprising the plate being positioned over the container with sufficient pressure to form a seal along a perimeter of the container.

6. 10. The method of claim 1, further comprising introducing the liquid CO2 into the container without incurring substantial blockage of the liquid CO2.

7. The method of claim 1 , further comprising the controller performing an integrity check prior to allowing the sufficient amount of gaseous CO2 to flow into the fill conduit.

8. The method of claim 1 , wherein the controller is configured to actuate the container from an idle orientation to a filling orientation.

9. 1. A method for automatically filling carbon dioxide (CO2) snow blocks into containers in an automated dispensing station and dispensing the CO2 snow blocks from a selected container, comprising: inputting into a controller a set point used to determine completion of filling of the CO2 snow block into the container, the set point being based on (i) a filling period, (ii) a predefined weight of the CO2 snow block, or (iii) deformation of a plate, the plate being permanently or removably fixed to the container; The controller receives a volume of the CO2 snow block to be generated; the controller selects the container having an internal volume capable of receiving the volume of the CO2 snow block to be produced, the container being located within the automated dispensing station including two or more containers of different internal volumes; flowing a sufficient amount of gaseous CO2 into and along a fill conduit; the controller sends a first signal to a liquid CO2 control valve to cause the liquid CO2 to flow along the fill conduit into the vessel where it undergoes a phase change to be converted into CO2 snow blocks and off-gas CO2; recovering the off-gas CO2 from the selected vessel through the plate, the plate being permeable to the off-gas CO2 and at least partially impermeable to solid phase CO2, and further wherein the fill conduit is operably connected to the vessel; measuring a real-time variable corresponding to the set point and generating a second signal corresponding to the real-time variable; transmitting the second signal to the controller; The controller: (i) allows the liquid CO2 to continue to flow into the vessel without an override if the controller determines that the real-time variable has not reached the set point; The method includes: (ii) preventing the liquid CO2 from flowing into the container when the real-time variable has reached the set point, and in response, the controller sends a third signal to configure the container into a dispensing orientation, the container in the dispensing orientation containing the volume of the CO2 snow block.

10. 10. The method of claim 9, further comprising the controller performing an integrity check prior to initiating the automatic filling of the CO2 snow block into the container.

11. 10. The method of claim 9, wherein the controller receives the second signal corresponding to the real-time variable equal to the set point, and in response, the controller sends a fourth signal to the liquid CO2 control valve to configure the liquid CO2 control valve in a closed position.

12. 10. The method of claim 9, further comprising: the controller verifying that the container is in a fill orientation; and if the controller determines that the container is not in the fill orientation, the controller either (i) sending one or more signals to actuate the container into the fill orientation, or (ii) sending an alert notification for a user to manually configure the container into the fill orientation.

Images