Apparatus for separating a single sheet from a stack and methods thereof

Abstract

An apparatus for separating a single sheet from a stack of sheets. The apparatus contains a stack station configured to retain a stack of sheets having a top sheet on top of the stack, a picker having an attachment portion configured to pick up and release one or more sheets, and a separation station. Methods of using the apparatus to various types of sheets, including without limitation paper sheets and thin film culture plates.

Description

APPARATUS FOR SEPARATING A SINGLE SHEET FROM A STACK ANDMETHODS THEREOF by Alec Teagarden Barry Rob ole Christine A. Binsfeld Deepak Sonawane Hugh Eugene Watson John Cain Lloyd S. Vasilakes Nilesh Lohar Siddesh Bademmi Yashodip ChaudhariCROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Application No. 63 / 661,612, filed onJune 19, 2024, the contents of which are hereby incorporated by reference in its entirety.FIELD OF THE INVENTION

[0002] The field of the invention relates generally to an apparatus for separating culture device sheets from a stack. More particularly, the present disclosure relates to an apparatus for separating sheets, imaging said sheets, and sorting said sheets in an automated manner.BACKGROUND

[0003] Processing high volumes of culture devices, such as PETRIFILM® plates each day using image capture device (PETRIFILM® plate reader advanced, hereafter “PPRA”) can be challenging as it is a manual process.

[0004] This design allows the user to test more than 200 plates via an automated process using an apparatus disclosed herein. No human intervention is required during each cycle. Users only need to load and unload the input / output bins after each plate stack.

[0005] This background information is provided for the purpose of making information believed by the applicant to be of possible relevance to the present invention. No admission is necessarily intended, nor should it be construed, that any of the information disclosed herein constitutes prior art against the present invention.BRIEF DESCRIPTION OF THE FIGURES

[0006] The following drawings form part of the present specification and are included to further demonstrate certain aspects of the present invention. The invention may be better understood by reference to one or more of these drawings in combination with the detailed description of specific embodiments presented herein.

[0007] FIG. 1. displays an exterior view of exemplary configuration of apparatus disclosed herein.

[0008] FIG. 2. displays a detailed view of certain exemplary components of an apparatus as described herein.

[0009] FIG. 3. displays a detailed view of other exemplary components of an apparatus as described herein.

[0010] FIG. 4. displays a detailed view of another exemplary portion of an apparatus as described herein in operation.

[0011] FIG. 5. displays a detailed view of yet another exemplary portion of an apparatus as described herein in operation.

[0012] FIG. 6. displays a detailed view of still another exemplary portion of an apparatus as described herein in operation.

[0013] FIGS. 7A-D. displays a detailed view of another exemplary portion of an apparatus as described herein in operation. In particular, an exemplary pickers for horizontal / vertical mechanism is shown.

[0014] FIG. 8. displays a detailed view of another exemplary portion of an apparatus as described herein in operation. In particular, an exemplary separation station is shown.

[0015] FIG. 9. displays a detailed view of another exemplary portion of an apparatus as described herein in operation. In particular, a receiving station configured with a PPRA is illustrated.

[0016] FIG. 10. displays a detailed view of another exemplary portion of an apparatus as described herein in operation. In particular, an exemplary sorting station is illustrated.

[0017] FIGS. 10A-C. display detailed views of another exemplary portion of an apparatus as described herein in operation. In particular, an illustrates how the input may be removed and mounted in drawer 120.

[0018] FIG. 11A-B. display a detailed view of another exemplary portion of an apparatus as described herein in operation. In particular, an exemplary input station (200) is shown.

[0019] FIGS. 12A-B. display detailed views of another exemplary portion of an apparatus as described herein in operation. In particular, an exemplary input bin lift assembly elevator is shown.

[0020] FIG. 13. displays a detailed view of another exemplary portion of an apparatus as described herein in operation.

[0021] FIG. 14. displays a detailed view of another exemplary portion of an apparatus as described herein in operation.

[0022] FIGS. 15A-C. display a detailed view of another exemplary portion of an apparatus as described herein in operation. In particular, an exemplary photo micro sensor on the separation station is shown.

[0023] FIGS. 16A-C. display a detailed view of another exemplary portion of an apparatus as described herein in operation.

[0024] FIGS. 17A-C. display a detailed view of another exemplary portion of an apparatus as described herein in operation. In particular, an exemplary means of rotating the PPRA is shown.

[0025] FIGS. 18A-D. display a detailed view of another exemplary portion of an apparatus as described herein in operation.

[0026] FIGS. 19A-B. display detailed views of another exemplary portion of an apparatus as described herein in operation.

[0027] FIGS. 20A-B. display detailed views of another exemplary portion of an apparatus as described herein in operation.

[0028] FIGS. 21A-B. display a detailed view of another exemplary portion of an apparatus as described herein in operation.

[0029] FIGS. 22A-B. display a detailed view of another exemplary portion of an apparatus as described herein in operation.

[0030] Particular non-limiting embodiments of the present invention will now be described with reference to accompanying drawings.DESCRIPTIONDefinitions

[0031] For the purposes of promoting an understanding of the principles of the invention, reference will now be made to certain embodiments and specific language will be used to describe the same. It will nevertheless be understood that no limitationof the scope of the invention is thereby intended, and alterations and modifications in the illustrated invention, and further applications of the principles of the invention as illustrated therein are herein contemplated as would normally occur to one skilled in the art to which the invention relates.

[0032] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0033] All publications mentioned herein are incorporated by reference to the extent they support the present invention.

[0034] For the purpose of interpreting this specification, the following definitions will apply and whenever appropriate, terms used in the singular will also include the plural and vice versa. In the event that any definition set forth below conflicts with the usage of that word in any other document, including any document incorporated herein by reference, the definition set forth below shall always control for purposes of interpreting this specification and its associated claims unless a contrary meaning is clearly intended (for example in the document where the term is originally used).

[0035] The use of “or” means “and / or” unless stated otherwise.

[0036] The use of “a” herein means “one or more” unless stated otherwise or where the use of “one or more” is clearly inappropriate.

[0037] The use of “comprise,” “comprises,” “comprising,” “include,” “includes,” and “including” are interchangeable and not intended to be limiting. Furthermore, where the description of one or more embodiments uses the term “comprising,” those skilled in the art would understand that, in some specific instances, the embodiment or embodiments can be alternatively described using the language “consisting essentially of’ and / or “consisting of.”

[0038] The terms “horizontal” and “vertical” are used for convenience to refer to directions that are generally orthogonal, for example, directions having an angle approximately 60 degrees to approximately 120 degrees, approximately 70 degrees to approximately 110 degrees, or approximately 80 degrees to approximately 100 degrees. They do not necessarily refer to directions with relation to the ground, because the apparatuses described herein may be oriented in different ways and the method described herein may be practiced with apparatuses having a variety of orientations.

[0039] The term “thin film micro-biological media” refers to thin film culture devices that can accommodate living microorganisms within an inoculation zone. Examples of as thin film culture media plates (such as PETRIFILM plates). Biological samples may be deposited onto these devices for testing and / or enumeration.

[0040] The term “culture device” is used interchangeably with the term “sheets” to refer thin film culture media plates (such as PETRIFILM plates). PETRIFILM® plates are commercially available culture devices. PETRIFILM plate is an example of a culture device that may be used in the apparatus disclosed here. The apparatus disclosed herein is not limited to automation of testing of PETRIFILM plates using an image reader such as the illustrated PPRA (an example of a commercially available image capture device).

[0041] The term “PETRIFILM plate” as used herein refer to the commercially available PETRIFILM® plate.

[0042] The term “picker arm” is used interchangeably with the term “picker” to refer to a component of the apparatus disclosed herein that picks up and places sheet at appropriate place in the apparatus.

[0043] The term “input bin slider assembly stack station” is used interchangeably with the term “stack station” to refer to a location in the apparatus disclosed herein wheresheets such as stack of sheets (220), to be scanned by the optical reader is placed before scanning.

[0044] The term “vacuum separation station” is used interchangeably with the terms “separation station” to refer to a location in the apparatus disclosed herein where it is determined whether a single PETRIFILM plate was picked from the input bin (210) and any sheets stuck together are separated.

[0045] The term “receiving station” is used interchangeably with the terms “wait station before optical reader” to refer to the location in the apparatus disclosed herein where a sheet is transfer by picker 300 from a substation. With reference to figure 6, receiving station 500 may be configured to receive one and only one sheet at a time, in this case top sheet 221, while other sheets, in this case sheet 222 remains at separation station 400. In this way picker 300 places one and only one sheet at receiving station 500.

[0046] The term “sorting station” as used herein refers to a location in the apparatus disclosed herein where sorting of scanned sheets (such as PETRIFILM plates) is done based on the results of optical reader (e.g., PPRA system) into “positive” and “negative” results based on pre-defined paraments, such as the presence of microbe or a certain enumeration amount (“positive”), or the absence of microbe or a certain enumeration amount (“negative”).

[0047] The term “input bin lift assembly elevator” is used interchangeably with the terms “lift assembly elevator” to refer to a component in the apparatus disclosed herein which provides upward movement of a stack of sheets such as a PETRIFILM plate stack (220) in the input bin for ease of picking it by the picker arm. It may include two or more IR sensor s for its home position (233) and end position (234) at its extreme positions. See e.g., Figures 13a and 13b).

[0048] The term “sorter block with output bins ” is used interchangeably with the term “sorter block” to refer to a location in the apparatus disclosed herein which includes a sorter block (700) with at least 2 output bins which will sort the top sheet (e.g., PETRIFILM plate (221)) ejected out from image reader (610) into appropriate bin (i.e., “output bin”) depending on whether the image the sheet tests positive or negative for the microorganism being tested and / enumerated.

[0049] The term “feed mechanism” refers a means for transferring a plate from the receiving station to the PPRA. Examples include a gripper in the form of a pusher but could also be a set of one or more rollers, belts, springs, movable trays, or other types of movers.

[0050] The description herein includes the disclosure of PETRIFILM automated feeder (PAF) (which is used interchangeably with the term “PAF or PAF system”) to refer to an exemplary configuration of an apparatus disclosed herein.

[0051] In certain configurations, the apparatus disclosed herein includes an image reader such as an optical reader. The terms “reader”, “image reader” and “image capture device” are used interchangeably. PPRA is an example of a commercially available optical reader and is used herein to illustrate various embodiments.

[0052] As used herein, the term “about” refers to a ±10% variation from the nominal value. It is be understood that such a variation is always included in any given value provided herein, whether or not it is specifically referred to.

[0053] Any ranges given either in absolute terms or in approximate terms are intended to encompass both, and any definitions used herein are intended to be clarifying and not limiting. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Moreover, all rangesdisclosed herein are to be understood to encompass any and all subranges (including all fractional and whole values) subsumed therein.

[0054] It is to be understood that both the foregoing descriptions are exemplary, and thus do not restrict the scope of the invention.Apparatus For Separating A Single Sheet From A Stack And Methods

[0055] This disclosure relates to separation of sheets from a stack of sheets (220), and more specifically, separation of one and only one sheet from a stack of sheets, by use of a machine. When a single sheet, in particularly the top sheet is to be separated from a stack, it may stick to other sheets in the stack, such as, for the top sheet, sheets underneath it in the stack, for example, the sheet directly underneath the top sheet, and in some cases additional sheets beneath that. This tendency of adjacent sheets in a stack to stick to one another is prevalent, and the magnitude of the sticking forces may vary, depending, for example, on the nature of the material that constitutes the sheet, the thickness of the sheets, environmental conditions such as atmospheric humidity, as well as other factors.

[0056] When sheets stick together, it is typically not difficult for a typical human to separate them so as to obtain only one sheet from a stack. This may be because a typical human recognizes that there are multiple sheets stuck together and then perform complex manipulations with one or both human hands. Such manipulations can involve squeezing, pinching, or sliding the sheets past each other, or even using a second hand to assist in separating the sheets. Moreover, a typical human can observe when the sheets have been separated. Machines, however, are not typically capable of performing the same type of complex observations and manipulation as a human.

[0057] This disclosure addresses the challenge of how to design a machine, and more particularly a pick-and-place type machine, that can separate one and only one sheetfrom a stack of sheets and placing the one and only one sheet in a desired location. This disclosure addresses the challenge of how to design a machine having a separating function that can separate sheets that may stick together when removed from a stack such that one and only one sheet can be placed in a desired location.

[0058] Turning to the figures, Figure 1 illustrates certain exterior views of exemplary embodiments of the apparatus disclosed herein. The apparatus disclosed herein may include a housing 100 which includes a drawer with input bin 120 and a drawer with output bins 140. In figure 1, an exemplary arrangement of input bin 110, output bins 130, and PPRA 150 is shown.

[0059] Figure 2 shows one configuration of apparatus disclosed herein having an input bin 200, picker 210, horizontal / vertical pick mechanism 220, processing center 230 (an exemplary means where thin culture device plates are separated and fed into PPRA 240), output bin 250, opening for housing a vacuum apparatus 270, and separation station 280, as well as optional receiving station 290, optical reader 240 for thin-film pates. Picker 210 may be located in first position Hl horizontally proximal to input bin 200, and may be movable in a horizontal direction, for example along horizontal track 220 between first position Hl, second position H2, which may be distal to input bin 200 and, in this figure, proximal to separation station 280, and, optionally, a third position H3 that may be distal to stack station 200 and proximal to optional receiving station 290. Picker 210 may include optional press 260, which exemplified in the form of a loop in figure 2 but can have other configurations.

[0060] Figure 3 shows an exemplary picker in more detail. Picker, as exemplified is able to move in a vertical direction by way of horizontal / vertical pick mechanism (see e.g. Figure 2) and / or pistons 3120 and 320. When in first position Hl, the picker may be able to move vertically between a position where it engages with the top sheet of thestack of sheets (not shown in this figure) and a position where it may be above the stack of sheets. Similarly, when in second position H2 the picker can move in a vertical direction between a vertical position where the picker engages with the separation station and a fourth vertical position that may be above the separation station.

[0061] Picker includes attachment portion 340 that can be used to attach the top sheet, and in some cases one or more sheets under the top sheet, of the stack of sheets to picker. In this case, attachment portion 340 includes suction cups 350, but other types of attachment portions, such as grippers could also be employed. Such grippers could grip sheet from the side and potentially measure the thickness to determine how many had been grabbed before the sheets are moved to the separator station to be separated.

[0062] Optional press 330, which exemplified in the form of a loop in figure 2 but can have other configurations. For example, press 330 can be used to push down on the stack and / or a sheet that may be carried by the picker in order to facilitate picking up the top sheet, and in some cases additional sheets, from the stack. Optional press 330 may also be configured contact the top sheet of the stack and apply pressure to the stack when the picker may be engaged with the stack to flatten the stack of sheets.

[0063] Figure 4 shows exemplary separation station 400 in more detail. Substations 410, 420, and 430, which in this figure are in the form of suction cups. The suction cups can be attached to a vacuum source, such as a vacuum pump, (not shown) to engage or disengage with sheets as required. It may also be possible to have one or more detectors, such as one or more optical detector, weight detector, or pressure detector, to detect whether a sheet may be present at a substation.

[0064] Figure 5 shows picker 520 in first position Hl a vertical position above stack 500, which includes a number of thin sheets including top sheet 530, retained withinthe input bin540 at input bin 540. The number of sheets in stack 500 is, typically, limited by ability of input bin 540 , to retain the sheets that constitute stack 500.

[0065] In some cases, other practical considerations relating to the nature of the sheets and the intended use of the apparatus, can be limiting even when input bin 540 may be physically able to retain a larger stack 220.

[0066] In use, picker 520 can move to engage with stack 500, and particularly with top sheet 530 to pick up top sheet 530 from stack 500. The sheets in stack 500 are not particularly limited by way of their size or shape, because while the figures show only particular exemplary dimensions for input bin 540, other sizes and shapes can be used to accommodate the type of sheets that are to be handled by the apparatus disclosed here. Likewise, the size of picker520 , as well as the size and nature of attachment portion 550 can vary to accommodate a wide range of sizes and materials that may constitute the sheets of stack500. Exemplary sheets that can be handled by apparatus disclosed herein include paper sheets, plastic sheets, nonwoven sheets, and the like. The sheets can be, for example, laboratory equipment such as slides, which can be plastic or glass, coverslips, or, particularly, culture plates, more particularly thin film culture plates such as those available under the PETRIFILM® brand. After picker 520 has removed top sheet 221, and optionally one or more additional sheets from stack 500, lift plate 510, can move stack 500 upwards to maintain the height of the top of stack 500 so that picker 520 can, when ready, return to position Hl to pick up an additional sheet or sheets.

[0067] Returning to the figures, when top sheet 530 is picked up from stack 500 by picker 520 press 560, when employed, can put pressure on stack 500 while attachment portion 550 engages with stack 500 to pick up top sheet 530 , thereby facilitating the engagement of attachment portion 550 with stack 500. In many cases, one or moreadditional sheets below top sheet 530 will also be picked up because they can stick to top sheet 530.

[0068] As shown in figure 6A, once the attachment portion of picker (550) has picked up top sheet 530, plus any additional sheets that may have stuck to top sheet 530, it moves to second position H2, which may be distal to input bin 540 , but, as depicted in figure 2, proximal to separation station. In this figure, two sheets, top sheet 610 and another sheet 600 that stuck to top sheet 610, are removed from stack of plates by picker 640. Picker 640 then engages with substation 620a and places sheet 600 at substation 620a.

[0069] Once all sheets that are removed from the input bin have been separated so that no more than one and only one sheet is at any substation, picker 640 returns to the input bin to pick another sheet from a substation and moves it to a receiving station.

[0070] With reference to figure 6A, receiving station 680 may be configured to receive one and only one sheet at a time, in this case top sheet 610, while other sheets, in this case sheet 600 remains at separation station 660. In this way picker 640 places one and only one sheet at receiving station 680.

[0071] As illustrated in figure 6B , receiving station 680 includes a gripper 670, a type of a pusher but could also be a set of one or more rollers, belts, springs, movable trays, or other types of movers. Gripper 670 may be configured to move a sheet, here top sheet 610 from receiving station 680 to another destination such as optical reader (e.g. PPRA), but other destinations such as other types of machines, sorters, and the like are contemplated.

[0072] The operation described herein may be controlled by software, which may be located on a computer readable, non-transient storage medium. A computing device containing a storage medium may be used.

[0073] Exemplary Horizontal / Vertical Mechanism (Figure 7A)

[0074] Figures 7A-C shows exemplary horizontal / vertical mechanism. In some embodiments, picker arm 720 functions primarily for the transfer of PETRIFILM plates from the input bin to the separation station.

[0075] In some embodiments, the picker consists of a horizontal slide 700 and a vertical slide 710 which are belt driven. The horizontal slide 700 controls the x-axis movement, while the y-axis is controlled by the vertical slide 710. The vertical slide 710 consists of a picker arm with assembly of picker arm vacuum manifold and bellow shaped vacuum cups (see 720) which helps in transfer of PETRIFILM plate from input bin to receiving station. The vacuum cups and manifold assembly mounted on a pick arm (720).

[0076] In some embodiments, the vertical slide (710) controls the y direction movement of the system i.e., picking the plate from input bin, going back to the home position of vertical slide, placing it on the separation station, back to home position, and then to the receiving station. The position of horizontal slide 700 may be controlled by photo-micro sensors (e.g., mounted on the back panel of separation station which are triggered by a sensor mounted on the vertical slide). During transfer of PETRIFILM plate from input bin to receiving station the horizontal slide first positions itself at input bin which picks a PETRIFILM plate from the stack of PETRIFILM plates. The next step of the process on the separation station is to determine whether a single PETRIFILM plate was picked from the input bin. This is accomplished with the suction cups mounted on the separation station. The positioning of the horizontal slide 700 with respect to vacuum points may be controlled by the sensor plate mounted at the bottom of the vertical slide 710, which also initiates vacuum on the vacuum points (e.g., 410, 420, and 430). Once a single PETRIFILM plate remains on the picker 720,it delivers it to receiving station (e.g., 680) whose positioning may be done in such a way that the receiving station (e.g., 680) can easily insert it into the PPRA (e.g. 240). The horizontal slide (700) returns to its home position, or the last vacuum point, (e.g., 430) where separation has been done to deliver the next PETRIFILM plate to receiving station (e.g., 680).

[0077] Firmware function:

[0078] The combination of distance and sensor based 2-dimensional array may be used for controlling picker movement in x and y direction (co-ordinates for picking and placing of PETRIFILM plate from input bin, vacuum points, and receiving station.

[0079] Photo micro sensors are also used for detecting home and end positions of horizontal and vertical arms. During movement if the photo-micro sensor is activated, the motor is stopped considering the arm has reached either at home or end position. During device power on, or while starting the device operation, picker is moved to its origin (0, 0). The picker also controls the turning on / off suction at each vacuum point substation (“vacuum point”) and bellow shaped vacuum cups (e.g. 410, 420, 430) and vertical slide (710). For detecting placement of PETRIFILM plate on vacuum points, position sensors are also used along with the distance.

[0080] If any error occurs during operation, the device goes into error state. The error is notified on UI and an alarm is generated.

[0081] Hardware function:

[0082] In some embodiments, the horizontal slide (700) is used for guiding the pick arm in forward and backward position. The horizontal slide 700 starts from the input bin and travels to receiving station. An encoder, which may be built in a motor (e., stepper motor), controls the number of steps for the horizontal slide to travel.

[0083] The vertical slide 710 may be used for picking up, separating, and releasing the PETRIFILM plates. The picker travels through 3 rows of suction cups for separation of PETRIFILM plates if two or more PETRIFILM plates are stuck to each other while picking up from the input bin.

[0084] Photo-micro sensors may be used for detecting home and end position of horizontal and vertical arm. They are also used to stop the picker at each vacuum point substation to facilitate separating stuck plates.

[0085] Coordination of Separation Station and Receiving Station

[0086] In some embodiments, separation station and receiving station (work together to insert a single PETRIFILM plate in reader (610) (see e.g., figures 6A-B).

[0087] Without wishing to be bound by any particular theory, the vacuum separator station with the help of a series of vacuum cups, enables the separation of multiple PETRIFILM plates picked from the bin. In this configuration, separation station includes a series of vacuum point substation that hold the plates with vacuum from bottom side when the picker arm places the PETRIFILM plate on the separation station. If multiple PETRIFILM plates are picked by picker, the separation takes place on successive cups until a single PETRIFILM plate remains on the picker arm which will be delivered to the feeder station.

[0088] As illustrated in figure 7D, in some embodiments, the apparatus disclosed herein includes a picker with multiple suction cups, for example, with five bellows suction cups (740), mounted on a picker arm vacuum manifold (730) to pick a PETRIFILM plate (an exemplary culture device) from an input bin. Picker 720 is configured to pick a PETRIFILM plate without disturbing microbiological colonies and also to easily pick up a tilted PETRIFILM plate from the input bin. When 2 or more PETRIFILM plates are stuck together, one or more arrangements of multiple suctioncups (e.g., 5 bellow cups of picker arm and 3 rows of 5 flat suction cups each row), on separation station may be used to facilitate the separation of PETRIFILM plates such that only a single PETRIFILM plate is transferred to the next station e.g., by creating differential vacuum pressure between suction cups on the picker (740) and the suction cups at the vacuum point substation (e.g. 410, 420, 430).

[0089] During the horizontal arm movement, the sensor plate of picker arm triggers the positional sensor in the path and picker (740) will stop to respective separation station for separation. A minor offset may be maintained between picker arm suction cups and separation station suction cups. Without wishing to be limited to any particular theory, this offset creates shear force for separation to facilitate to separation of the plate on the top of the stack.

[0090] Figure 8 illustrates a configuration of apparatus for the separation of stuck culture device plates. The apparatus disclosed herein may include a separation station involving a use of vacuum and / or sensor. When 2 or more PETRIFILM plates are stuck together, the separation station helps to separate out stuck PETRIFILM plates (e.g., in 3 stages) and allows only one PETRIFILM plate to be fed to the PPRA.

[0091] Without wishing to be limited by any particular theory, separation works via vacuum by creating differential vacuum pressure between suction cups on the picker and vacuum cups on the separation station (410). The term, “separator cups” is used interchangeably with the term “vacuum cups” to refers to vacuum cups on the separation station that may be arranged in a sequential vacuum point substations (see Figure 4) and is used to hold the sheets with vacuum from bottom side when picker places it at the receiving station. The offset of vacuum cup facilitates release of the vacuum developed in between 2 PETRIFILM plates stuck together. If there are morethan 3 PETRIFILM plates stuck together during separation stage, the additional stuck PETRIFILM plate will be placed back in the input bin.

[0092] Figure 9 illustrates how an exemplary automated feed mechanism may be used to feed PETRIFILM plate into an image capture device 900. A configuration for feeding PETRIFILM plate into the entrance PPRA 900 via the receiving station (exemplified by PPRA) includes entry guides 910 and gripper 920. One challenge that is overcome is that sometimes a PETRIFILM plate is inclined while being placed on feed mechanism 920. Feed mechanism 920 has defined entry path which corrects the inclination and feeds PETRIFILM plate in straight line in PPRA 900. Also, the feed mechanism may be configured to hold a separated top plate which is carried and then release at the entrance of PPRA 900 .

[0093] Figures 10A-C illustrate an exemplary configuration of the input bin assembly. Input bin rests on a slider plate that can slide out to facilitate removal and / or stacking of the input bin. In Figure 10A, the input bin sits in its home position. Operation of the apparatus disclosed herein operates only when the input bin is in the home position.

[0094] Once the input bin 1000 is empty, or a run is paused, the lifter elevator will reach its home position and press lock-override plunger 1001 (Figs. 10A and 10B). The lock-override plunger 1001 unlocks the slider plate with the input bin (i.e., “input bin station”) which can be pulled out and the empty input bin can be refilled with a new stack of PETRIFILM plates.

[0095] If power failure occurs during the function, lift assembly elevator (1003) may be manually moved to its home position by rotating knob (1004). The term “lifter assembly elevator” is used interchangeably “lift elevator” to refer to a means of moving the stack of input bin from the bottom of the input bin to the top. In some embodiments,the lifter assembly elevator comprises a motor, vertical slide and a means to engage the lifter plate in the input bin to move plates in the input bin vertically.

[0096] Figures 11A-C illustrates an exemplary input bin station for the mounting of input bin 1100 mounting. Figure 11A shows input bin 1100 mounted on input bin station where sliding plate 1105 is at the home position. The machine only operate when sliding plate 1105 is at its home position. In some embodiments, the input bin station includes an input bin (1100), a magnetic base for holding the input bin in place (1104), telescopic rails (1103) to facilitate the sliding of the input bin station away from the machine into an “open” position, a means for locking the slider plate (e.g., lockoverride plunger (1108). The term “input bin slider assembly” is used interchangeably herein with the term “input bin station”.

[0097] Telescopic rails 1103 may be a push-to-open type. By pushing the front cover of the drawer with the input bin 120 (e.g., as shown in Figure 1), the telescopic rails 1103 will get unlocked, and slider will come out of the apparatus. To avoid the opening of input bin station during the operation, a means is used to lock the telescopic rails (e.g. lock-override plunger). Lock override plunger 1108 will allow slider to move out only when lifter plate 1106 is at home position.

[0098] Input bin 1100 may be fitted with magnetic catches striker plates at the bottom. Users can un-mount empty bin and mount the filled bin easily by placing the input bin on magnetic base 1104.

[0099] Figures 12A-B illustrate an exemplary lift elevator. In this configuration, the lift elevator consists of a linear gantry 1201 stacked vertically which may be driven by a motor 1204. One lifter plate may be mounted on moving carriage. Once the lift elevator is operational it functions to provide upward movement of PETRIFILM plate stacks in the input bin for ease of picking it by the picker. It may include two or moreIR sensors for detecting when the lifter is at its home position 1203 and end position 1202 at its extreme positions. During the function of lift elevator, the sliding plate 1105 is held in position by lock-override plunger 1101 and will not allow to move out. (Figure 77)

[0100] Once the input bin is empty, or a run is paused, lifter 1205 will reach its home position and press lock-override plunger 1101 (Figure 77). The lock-override plunger 1107 unlocks input bin station which can be pulled out and the empty input bin can be refilled with a new stack of PETRIFILM plates.

[0101] If power failure occurs during the function, lift elevator can be manually moved to its home position by rotating the knob (1004) given in the slider gantry (see Figures 10A-C).

[0102] As shown in Figure 13, in certain embodiments there may be continuous reading of PETRIFILM plates e.g., until the input bin 1300 is emptied. The level of PETRIFILM plates available for the picker to pick up is maintained by the lifter. A reflective sensor 1301 may be used to read the PETRIFILM plate level continuously. It will give feedback to motor (see Fig. 12) controlling motion of lift. Based on feedback received by reflective sensor 1301, the motor will drive the lifter to achieve required level of PETRIFILM plate.

[0103] Firmware function:

[0104] Firmware may be used to control the movement of lifter. A motor and sensors may be used in the assembly. For example, the lifter may be moved using a stepper motor (232). The movement of the stepper motor may be controlled using home position, end position, and level detection sensors. During movement, if the sensor is activated, the motor may be stopped considering the lifter has reached either at home or end position. During device power-up or if the run is stopped / paused, the input lifterwill be moved to its home origin. In some embodiments, the input bin can hold about 1-500 plates, about 100-300, about 200-400, about 200-500, or about 250 PETRIFILM plates. The sensor may be used to notify the apparatus about input bin level status via a software application.

[0105] In some embodiments, the firmware takes at maximum 6 seconds to place PETRIFILM plate at receiving station. Time may be measured from the moment PETRIFILM plate is picked up from the input bin and placed at the receiving station and picks up the next PETRIFILM plate from input bin. If any error occurs during operation, the device goes into error state. The error is notified on the UI and an alarm may be generated.

[0106] Hardware function:

[0107] In certain embodiments, the input bin of the apparatus disclosed herein may be used for stacking the PETRIFILM plates which are required for the enumeration process. In some embodiments, about 250 PETRIFILM plates is stacked in the input bin. A lift attached to a stepper motor may be used to maintain the level of the plates in the input bin to allow picker to lift the PETRIFILM plates.

[0108] Photo micro sensors may be used for detecting the home and end position of the lifter. Reflective sensors may be used to maintain the desired level of PETRIFILM plate inside the input bin.

[0109] An input bin as shown in Figure 14 may be used at input bin assembly to feed the untested PETRIFILM plate to a PPRA. Input bin may include magnetic strike plates 1406 for mounting to the sliding plate. For instance, two or more magnetic strike plates for mounting purposes may be used.

[0110] Input bin may include two spring loaded clips 1401 which pushes the PETRIFILM plates in the input bin into one direction and keep the plates aligned. Thiswill help the picker to pick up the PETRIFILM plate at the correct position. It also ensures that the stacks align along a side of the input bin, especially along rear cover 1403, which aids in maintaining alignment, facilitates the picking of top sheet, and allows for the stack of plates to contain sheets of varying sizes.

[0111] In some embodiments, the input bin may include a lifter plate to support the PETRIFILM plate stack for bottom side. Also, it avoids damage that may happen during lifting.

[0112] Lifter plate 1402 may be movable by a lifter elevator in a vertical direction in order to maintain a necessary height for the picker to engage with and be in communication with the top sheet. Additionally, the lifter plate may adopt an angle within the input bin to accommodate stacks of sheets of varying sizes. Typically, the angles adopted by the support plate assembly may be ascending or descending, when hinged relative to rear cover 1403. The stack of plates may also adopt an ascending or descending angle if the lifter plate is adopted in such a manner.

[0113] In some configurations, bin base 1405 may be made up of acetal, side covers 1403 and rear cover 104 may be made of metal such as aluminum sheet.

[0114] Figure 15A shows an alternate configuration of the input bin. In particular, the ascending and descending angles of the exemplified input bin allows input bin to have declining stack 1500 and cartridges with inclining stack 1501 to readily conform to the desired angle. One or more optional stripper blocks 1502 may be used separate lightly stuck plates, which helps to eliminate drops. In particular, contact of one or more stripper blocks with top sheet, and optionally any other sheets that are stuck to the top sheet causes the stuck sheets to separate and become unstuck. These additional unstuck sheets then drop down vertically and rejoin the stack of plates. Spring loaded plate1503 displays an alternative angle of spring loaded clip 1401. Bin base 1505 displays an alternative angle of base 1401.

[0115] Figure 15B displays an exemplary input bin with posts. An optional component of the input bin is one or more posts, employed between lifter plate and stripper blocks 1502. These posts may serve to substantially flatten the stack of plates, and further top sheet, as it may be raised vertical within the input bin before being picked by picker. There may be issues in engaging top sheet in communication with picker to be picked if stack of plates (“stack”) is at an insufficient angle. More particularly, issues may be found when the stack and subsequently top sheet are employed at a descending angle (see 1501). A declining stack that improperly engages with sensors and may cause issues in engaging in communication with picker, generally more so than a stack adopting an ascending angle. Stack and top sheet, while being raised vertically within the cartridge and before reaching a position available for picker may engage in communication with the one or more posts, which may have the effect of substantially flattening an ascending or descending stack.

[0116] Plate guide 1507 may be used above the input bin to retain declining plate stacks and retain dropped plates from falling down into the instrument, which would cause a potential error and / or loss of sample.

[0117] Figure 16A displays the back panel of separation station and illustrates an exemplary configuration when picker 1601 picks more than one PETRIFILM plate from input bin and moves over the vacuum point- 1 where the photo micro sensor 1602 is triggered. The placement of PETRIFILM plate over the vacuum point 1 suction cups (410) block the intake air flow and the change in pressure is recorded by the digital pressure switch. The drop in vacuum pressure (in case of PETRIFILM plate absence) on the digital pressure switch triggers a means used to turned off the next cycle (e.g.,the valve 2 / 2 solenoid is turned to the off state) until the next cycle by triggering a photo micro sensor). The same logic may be applied with vacuum point - 2 and vacuum point - 3.

[0118] A filter may be assembled between a digital pressure switch and vacuum suction cup to avoid contamination entering the vacuum system.

[0119] When both cups are symmetrical, with the same contact surface area, different pressure settings may be required for PETRIFILM plate separation.

[0120] The following are some experimental values of pressure which show the successful separation pressure.

[0121] Firmware function:

[0122] The assembly, as illustrated in figure 6 A, may contain multiple vacuum points (for example, 3 vacuum points) to separate the multiple PETRIFILM plates which are stuck together. This assembly may also include a pressure sensor to read atmospheric pressure and two pressure regulators to control the pressure of vacuum points and the suction cups on the picker arm. Pressure regulator vacuum level values are set in firmware during initialization. To get PETRIFILM plate presence status, a digital switch may be used. Whenever a PETRIFILM plate is detected on a vacuum point, suction will turn on to pick and place a PETRIFILM plate accordingly. Once a PETRIFILM plate is placed on receiving station, suction will be turned off. Also, for picking and placing PETRIFILM plates, stability delays are added.

[0123] During initialization firmware checks the insertion of pressure filters used in the assembly with the help of sensor outputs.

[0124] Hardware function:

[0125] Solenoids may be used to control the flow of vacuum. Off the shelf vacuum regulators are used to monitor and regulate the vacuum. Digital vacuum switches may be used to detect a PETRIFILM plate on the vacuum station.

[0126] In the exemplary configuration illustrated in Figure 19, the feed mechanism at the receiving station inserts the PETRIFILM plate in the reader with a gripper (a type of pusher).

[0127] In some embodiments, the receiving station consists of gripper 1604 which may be operated by cam and rollers. Once a PETRIFILM plate is placed on the receiving station, the PETRIFILM plate is then held by the gripper which guides it into the PETRIFILM plate reader. The gripper returns to the home position once it feeds the PETRIFILM plate to the reader to continue feeding incoming plates from the pick and place mechanism.

[0128] Gripper 1604 functions for holding and feeding the PETRIFILM plate into the PPRA. It includes components such as rails, bearing carriage, rollers and springs. As shown, the gripper may have fixed jaw and a moving jaw to hold the PETRIFILM plate.

[0129] Opening and closing of jaw may be controlled by rollers moving over the cam block mounted on the roller path.

[0130] Picker 1601 picks PETRIFILM plates from the input bin and transfers them to the separation station.

[0131] Figure 19 also shows the handling of the PETRIFILM plate by the picker from the separation station. PETRIFILM plates may be fed to PPRA only after separating.As shown, picker 1601 separates PETRIFILM plates on separator station 1608 and transfers to receiving station 1609 at a particular distance that clears the gripper (such as 3mm to 6mm), where the PETRIFILM plate may be sensed by photo micro sensors 1605. Simultaneously firmware provides feedback from the PPRA that it is available to receive the plate. Once the PETRIFILM plate is present on receiving station 1609 and the PPRA is ready, the firmware command triggers gripper 1604 to hold and feed the PETRIFILM plate inside the PPRA. The optical sensor 1605 may continually sense the PETRIFILM plate till it goes to inside of PPRA. The gripper then moves back to its origin for the next cycle.

[0132] During processing, if a PETRIFILM plate drops before the first vacuum point on the separation station, an optical sensor 1602 will detect this condition . The system will try to pick up the dropped plate and continue processing. If unable to so, a notification will be sent to the UI and an alarm is generated.

[0133] Firmware function:

[0134] In this configuration, the firmware controls the movement of receiving station 1609. A stepper motor and sensors are used in the assembly. When the PETRIFILM plate is placed on receiving station 1609, it may be detected using a IR sensor. Then the feeder notifies presence of PETRIFILM plate to PC application software, receives the status of PETRIFILM plate reader before feeding the plate. After receiving this notification, PC application software responds with feed command that the PETRIFILM plate reader is ready to process the PETRIFILM plate. Then the PETRIFILM plate is fed to the PPRA using the gripper. The movement of the stepper motor may be controlled using home position and end position sensors. During movement if a sensor is activated, the motor is stopped considering the motor has reached either at home or end position. If the PPRA does not receive the PETRIFILMplate, then the operation may be re-tried at least 2 times, 3 times, at least 3 times, etc. After the 3rd retry if PPRA does not receive the PETRIFILM plate, device goes into error. The error is notified on UI and an alarm is generated.

[0135] During device power-on, the gripper is moved to its origin. If any error occurs during operation, the device goes into error state. The error is notified on UI and an alarm is generated.

[0136] Hardware function:

[0137] At the receiving station, the gripper holds the PETRIFILM plate, feeds it to PPRA module so that it can be properly taken inside by the PPRA. The gripper may be operated by rollers and cam mechanism.

[0138] Photo-micro sensors 1605 may be used to detect the home and end positions of receiving station 1609 respectively. Sensors 1605 may also be used to detect the PETRIFILM plate presence at the receiving station 1609, and also checks if the PETRIFILM plate is properly fed to PPRA. Misplaced PETRIFILM plates may be detected by sensor 1605.

[0139] Figure 17A shows how an exemplary optical reader in “docked” operational position (namely, an aligned needed for operation where the slot for receiving plates is aligned with the receiving station). The term “optical reader docking station” as used herein refers to a plate with rotation mechanism for the optical reader. During operation the optical reader is orientated so that certain features (e.g., 1702 and 1703) are not easily accessible by the user. The docking station may be opened by engaging pull handle 1705. This engages the docking station which engages 1704 which results in the rotation of the docking station (see Fig. 17B) and PPRA 1700. This results in placement of 1702 and 1703 at the front of the apparatus (see Fig. 17B).

[0140] In some embodiments, the docking station includes a pull handle (e.g. 1705), locator (e.g., 1706), magnetic catcher, magnet (e.g., 1707), rotary plate (e.g., 1708), guide pin assembly (e.g., 1710), telescopic rails, sliding plate (e.g., 1709), and base plate (e.g., 1712).

[0141] The docking station may be locked at the desired position by a means such as a magnetic catcher.

[0142] When the user wants to operate the PPRA system manually, the station can be pulled outside by pull handle 1705 for operation (ref Fig. 17B).

[0143] Sliding plate 1709 may be mounted on telescopic rails which allows the linear movement to the PPRA station (ref Fig. 17B). Rotary plate (1708) may be mounted on bearing assembly which may be mounted on sliding plate (1709). A guide pin assembly (1710) may be used.

[0144] An IR sensor ,may be included on base plate 1712 to ensure that rotary plate 1708 and sliding plate 1709 are in home position. Locator 1706 may be included on rotary plate 1708 to provide fool proofing for PPRA system.

[0145] Figures 18A-B illustrate how shows the sorting of PETRIFILM plates may be done at sorting station based on the results of PPRA system into “positive” and “negative” results based on pre-defined parameters, such as the presence of microbe or a certain enumeration amount (“positive”), or the absence of microbe or a certain enumeration amount (“negative”). As shown, the sorting station includes a sorter block and at least one output bin. Sorter block 1802 moves horizontally along horizontal slider gantry 1806 to sort plates that exit the PPRA based on pre-defined parameters into the respective output bin(s). Figure 18A shows how output bins 1804 may be arranged at the sorter block. Figure 18B shows how reflective sensors 1807 may be used to move the plates exiting PPRA 1800 to output on the left or right. The sortingstation may include locking mechanism 1805 to prevent output bins from sliding during operation.

[0146] As illustrated in Figures 18C-D, once the PETRIFILM plate is read by PPRA1800, PETRIFILM plate will get ejected by PPRA 1800 and falls on plate rest block1801. As shown, rest block 1801 has a tapered top face with an angle of about 10° with respect to horizontal plane. This helps the falling plate to reach the end position of sorter block 1802 so that any plate that falls in a random position also reaches the end position of the sorter block.

[0147] In some embodiments, the apparatus includes a rest block with two slots at top face. Sorter block 1802 may have two projection at bottom. During the function, projections of sorter block 1802 sweeps through slots of rest block 1801. So, this feature will avoid PETRIFILM plates getting stuck in the gap between PETRIFILM plate rest block 1801 and sorter block 1802 (see figures 18B and 18C).

[0148] Rest block 1802 may include reflective sensor 1807 which will sense the presence of PETRIFILM plate on the block and gives a signal to sort the plate based on PPRA data output. Sorter block 1802 then slides the plates from the block into the respective bins 1804.

[0149] The sorting of PETRIFILM plates may be done with the help of slider gantry 1806 stacked horizontally. This slider gantry may include three IR sensors 1807 for its position control.

[0150] Moving connecting bracket 1808 may be fitted with signal cut off brackets which will cut the signal and activates the sensor. So based on sensor feedback, the motor of the sliding gantry drive, the slider block sorts the positive and negative PETRIFILM plate plates.

[0151] Firmware function:

[0152] Firmware may be used to sort the plates to a respective output bin depending on the result received from software application. Stepper motor and sensors may be used in the assembly. When a plate is placed on the sorter block, it may be detected e.g., using a IR sensor. Then PETRIFILM plate sorting slide assembly notifies presence of PETRIFILM plate to software application, to get the sorting information. After receiving this be notification, PC application software responds with sorting command. Then the sorting station will sort the PETRIFILM plate to the respective output bin. The movement of stepper motor may be controlled using home position, center position and end position sensors. During movement if the sensor is activated, the motor is stopped depending on whether the motor has reached either at home, center, or end position.

[0153] Firmware takes e.g., up to 6 seconds to sort PETRIFILM plate at the sorting station, time measured from the moment PETRIFILM plate is discharged from PPRA.

[0154] If any error occurs during operation, the device goes into error. The error is notified on UI and an alarm is generated.

[0155] Hardware function:

[0156] At PETRIFILM plate sorting station, the PETRIFILM plate may be collected in the duct at the exit of the PPRA and then using the horizontal sorter block the PETRIFILM plate is sorted and collected in respective output bins.

[0157] Photo micro sensors may be used for detecting home, middle and end position of horizontal sorter slider motor.

[0158] Figure 19 illustrates using sorter block 1900 to sort scanned PETRIFILM plates as per result received from the PPRA. Sorter block 1900 is part of a sorting station and includes a sorter block with at least one output bin. The sorting station may also include reflective sensors (e.g. 1807) which may be used to move the plates exitingPPRA a predetermined output bin. The sorting station may include also locking mechanism 1805 to prevent output bins from sliding during operation.

[0159] As illustrated, sorter block 1900 works on sliding principle and will sort the top PETRIFILM plate ejected out from the PPRA in either output bin (on the right) or output bin (on the left) depending on whether the scanned plate tests positive or negative for the microorganism being tested and / enumerated.

[0160] As illustrated in Figures 20A-C, the sorting station includes two gantries (2004) which may be used to maintain a consistent falling depth into output bins 2000.

[0161] After sorting is done by sorter block, the PETRIFILM plate will fall into the bin. To get a proper stack into output bin, a maintain proper depth by lifter is needed. If there is falling depth, PETRIFILM plate will fall randomly, and this will stack improperly into the output bin. To avoid this, a reflective sensor 2002 (e.g. two or more sensors) may be used. These sensors will detect the plate level into the bin and gives feedback to sorter lifter assembly. Based on this feedback lifter motors 2005 drive the gantries (2004) downward and maintain the required falling depth into the bin.

[0162] Two different stroke gantries (2004) may be used. A lifter is mounted in the output bins under the lifter plate (e.g. 2201). Lifter plate (2201) may include a signal cut off bracket which will cut the signal of IR sensors (2007 and 2008) mounted at extreme end for home position 2010 and end position 2011. Once lifters 2006 reach their home positions, both lifter will press the plungers of lock-override (e.g., 1805) of the sorting station sliders. During power failure, lifters 2006 can be moved to home position 2010 by rotating knobs (2009) provided on gantry 2004.

[0163] Firmware function:

[0164] Firmware may be used to control the movement of sorter lifter assembly. The stepper motor and sensors may be used in the configuration as illustrated in figure 25. For instance, the lifter may be moved using motor (2005). The movement of the motor may be controlled using home position, end position and level detection sensors. During movement if the sensor is activated, the motor is stopped considering the lifter has reached either at home or end position or level when bin gets full. During device power on or stopped the sorter lifter may be moved to its origin.

[0165] Firmware may be used for repositioning the lifter plate using sorter lifter assembly, whenever the PETRIFILM plate may be placed in the bins. Each output bin can hold multiple PETRIFILM plates (e.g., 1-500, 100-300, or 250 PETRIFILM plates). Also, notifies output bins 2000 level status to the software application.

[0166] If any error occurs during operation, the device goes into error. The error is notified on UI and an alarm is generated.

[0167] Hardware function:

[0168] The sorter block may be used for collecting and levelling the scanned plates in the sorter block. Each output bin has its own motor for collecting and levelling the PETRIFILM plate plates. A lifter plate attached to a motor to maintain the level of plates in output bin .

[0169] Photo-micro sensors may be used for detecting the home and end position of sorter lifter. Reflective sensors (2002) may be used to maintain the desired level of plates inside output bins.

[0170] Figures 21A-B illustrates how a sorting station may be configured for output bin mounting. The sorting station may include output bins 2100, sliding plate 2104, magnetic base for output bin 2103, and telescopic rail 2102. sorting station may also include a means to prevent the output bins from sliding during operation (e.g., 1805).

[0171] The telescopic rail may be pushed to open type. By pushing the drawer with sorter block and output bins 140, the telescopic rail will get unlocked, and sliding plate 2104 will slide forward. To avoid the opening of output bin slider assembly during the function, a lock-override (such as 1805) may be used.

[0172] The lock override may be spring loaded a plunger assembly . During function, a lock-override plunger that may be part of the lock-override assembly will be engaged with notches given in the sorter plate. It will not allow slider to move out unless both sorter lifters reach its home position.

[0173] The output bins may be fitted with striker plate for magnetic catch at the bottom. Users can un-mount filled bin and mount the empty bin easily by picking and placing the sliding plate.

[0174] As shown in figures 22A-B, output bin (700) may be used at sorter slider assembly to collect the PETRIFILM plates sorted by the sorter block. The sorter block may include a means for mounting purpose, for example, two magnetic catchers striker plates 2205 may be used for mounting purpose.

[0175] In some embodiments, the output bin includes a lifter plate to support the stack from the bottom side. Also, it avoids damage that may happen during lifting by the lifter.

[0176] In some embodiments, bin base 2204 may be made up of acetal, top frame 2200, side covers (2203) and rear covers (2202), which may be made of a material such as aluminum.

[0177] Glossary

[0178] Non-Limiting Embodiments

[0179] The description of the invention is meant to be exemplary of certain embodiments of the invention.

[0180] One aspect of the invention pertains to a system which allows for the processing of thin film micro-biological media. These thin film micro-biological media are typically very fragile; furthermore, they often contain living organisms within an inoculation zone, which should not be disturbed or displaced. After inoculation and incubation, these thin film micro-biological media, exemplified here as thin film culture media plates (such as PETRIFILM plates), may become tacky or sticky. They may also warp. These factors make processing these media in an automated environment difficult. Further, these media plates may come in any variety of shape or construction that add additional difficulty to automated processing. The hereto described invention solves these challenges by providing an automated system for processing thin film micro-biological media that successfully avoids these issues.

[0181] Another aspect of the invention pertains to an apparatus for separating a single sheet from a stack of sheets, said apparatus comprising: a stack station configured to retain a stack of sheets having a top sheet on top of the stack; a picker having an attachment portion configured to pick up and release one or more sheets; a separationstation separated from the stack station in a horizontal direction, the separation station comprising one or more substations, each of the one or more substations being configured to reversibly receive one or more sheets from the picker; wherein the picker may be moveable in a horizontal between at least a first location proximal to the stack station and a second location proximal to the separation station; and wherein said picker, when located in the first position, may be moveable in a vertical direction between a first vertical position where the attachment portion engages with the stack and a second vertical position above the top sheet; and wherein said picker, when located in the second position, may be moveable in a vertical direction between a third vertical position where the picker in engages with the separation station and a fourth vertical position that may be above the separation station. In some embodiments, the separation station may comprise two, three, or four substation. In further embodiments, the separation station comprises three substations.

[0182] In some embodiments, the attachment portion of the picker comprises one or more suction devices, particularly wherein the attachment portion comprises one or more suction devices, and more particularly wherein the attachment portion comprises two or more suction devices. In further embodiments, the attachment portion of the picker has a number of suction devices chosen from 1, 3, 5, or 6 suction devices, while in other embodiments, the attachment portion of the picker has 5 suction devices. Examples of the type of suction devices that may be employed are bellows type suction cups.

[0183] In some embodiments, at least one of the substations, and preferably each substation, have sensors that can determine whether a sheet may be located at the substation. The sensors may comprise one or more of an optical sensor, weight sensor, or a pressure sensor.

[0184] In some embodiments, the apparatus comprises two or more substations, and wherein the picker may be moveable between two or more distinct horizontal positions, each distinct horizontal position being above one of the two or more substations, and, when in each distinct horizontal position, may be moveable between a lower vertical position in communication with the substation that it may be above and an upper vertical position that may be not in communication with the substation that it may be above.

[0185] In some embodiments, the apparatus further comprises a cartridge, or an input bin, disposed at the stack station, wherein the cartridge may be configured to retain the stack of sheets. The cartridge may hold a range of sheets within the stack; the stack may comprise at least 10 sheets, at least 25 sheets, at least 50 sheets, at least 75 sheets, at least 100 sheets, at least 150 sheets, at least 200 sheets, or at least 250 sheets. The cartridge may further comprise a pusher plate. The pusher plate may be configured to be in communication with a portion of the stack of plates such that the stack of plates is further in communication with the opposing interior surface of the cartridge. The pusher plate can also be spring-loaded. Further, in other embodiments, the pusher plate may be in communication with the upper portion of the stack. In some embodiments, the stack of sheets comprises a stack of thin film culture plates.

[0186] In some embodiments, the cartridge further comprises one or more posts configured in such a way as to be in communication with the stack only if said stack has a declining angle and wherein the angle of the stack is substantially less declining after being in communication with said one or more posts. In other embodiments, the cartridge comprises two posts.

[0187] In some embodiments, the cartridge further comprises one or more stripping blocks positioned at a height which may be in communication with the top sheet of thestack and which applies slight resistance to the one or more sheets from the top of the stack of sheets after being picked up by the picker. The stripping blocks may be spring- loaded.

[0188] In some embodiments, the apparatus comprises an elevator in communication with the stack station, the elevator being configured to maintain the top sheet of the stack at a predetermined height. The elevator may be configured to reversibly couple with a cartridge at the stack station.

[0189] In some embodiments, the apparatus comprises a horizontal track, wherein the picker may be movably coupled to the horizontal track and can move between different horizontal positions along the horizontal track. The apparatus may also comprise a vertical track, wherein the picker may be movably coupled to the vertical track and can move between different vertical positions along the vertical track.

[0190] In some embodiments, the apparatus comprises a base that supports the separation station. In other embodiments, the apparatus comprises a receiving station for receiving one and only one sheet. The separation station may be disposed between the stack station and the receiving station. In further embodiments, the receiving station comprises a mover configured to move one and only one sheet at a time away from the receiving station in a horizontal direction. The mover may comprise one or more pushers, one or more rollers, one or more springs, or one or more movable trays. In some embodiments, the mover may be configured to load one and only one sheet at a time into the machine.

[0191] In some embodiments, the apparatus comprises a machine station for holding a machine that may be configured to receive and manipulate one and only one sheet at a time. In some embodiments, the machine may be a reader. In some embodiments, thereader may be an optical reader. In some embodiments, the optical reader may be an optical reader for thin film culture plates.

[0192] Another aspect of the invention pertains to a method of separating one and only one sheet from a stack, comprising the steps of: causing the picker of an apparatus of the preceding embodiments to pick up one or more sheets from the top of the stack of sheets, causing the picker to place at least one of the one or more sheets on the separation station, and causing the picker to retrieve one and only one sheet from the separation station.

[0193] In some embodiments, the method further comprises placing one and only one sheet at a receiving station. In other embodiments, after the picker picks up one or more sheets from the stack of sheet, an elevator at the stack station of the apparatus lifts the stack of sheets such that the top sheet of the stack may beat a predetermined height and may be in contact with the one or more stripping blocks disposed in the cartridge.

[0194] In some embodiments, the method comprises the step of causing the picker to place at least one of the one or more sheets on the separation station, which further comprises causing the picker to place one and only one of the one or more sheets on a first substation of the separation station, causing the picker to move to a position that may be in communication with a second substation of the separation station, and causing the picker to pick up the one and only one sheet from the first substation of the separation station. In further embodiments, the step of causing the picker to place at least one of the one or more sheets on the separation station comprises causing the picker to place at least one of the one or more sheets on a first substation of the separation station, which causes the picker to place one and only one of the one or more sheets on a second substation of the separation station, in turn causing the picker to move to a position that may be in communication with a third substation of theseparation station, further causing the picker to pick up the one and only one sheet from the second substation of the separation station.

[0195] In some embodiments, the method further comprises causing the picker to move pick up one or more sheets from the first substation of the separation station; causing the picker to move to a position that may be in communication with the second substation of the separation station; and causing the picker to pick up one and only one sheet from the first substation of the separation station. In other embodiments, the step of causing the picker to place at least one of the one or more sheets on the separation station comprises causing the picker to place at least one of the one or more sheets on a first substation of the separation station; causing the picker to place at least one of the one or more sheets on a second substation of the separation station; causing the picker to place one and only one of the one or more sheets on a third substation of the separation station; and causing the picker to pick up one and only one sheet from the third substation of the separation station.

[0196] In some embodiments, the method further comprises placing one and only one sheet on a receiving station. In other embodiments, after placing one and only one sheet on the receiving station, the method comprises picking up one and only one sheet from the separation station or and placing the one and only one sheet on the receiving station. In further embodiments, the method further comprises placing one and only one sheet on the receiving station; and causing the mover to move the one and only one sheet from the receiving station. The mover may move the one and only sheet from the receiving station to a machine. Further, the mover may move the one and only sheet from the receiving station to an optical reader at a machine station.

[0197] Another aspect of the invention pertains to a non-transient computer readable storage medium containing executable software that, when executed, causes anapparatus to carry out the previous described method. Yet another aspect of the invention pertains to a computing device containing the non-transient computer readable storage medium.

[0198] In some embodiments, the stack station may be configured to stabilize the stack of said sheets and keep said sheets at an angle so that the picker can pick up the top sheet.

[0199] LIST OF EMBODIMENTS1. An apparatus for separating a single sheet from a stack of sheets, said apparatus comprising: a stack station configured to retain a stack of sheets having a top sheet on top of the stack; a picker having an attachment portion configured to pick up and release one or more sheets; a separation station separated from the stack station in a horizontal direction, the separation station comprising one or more substations, each of the one or more substations being configured to reversibly receive one or more sheets from the picker; wherein the picker may be moveable in a horizontal between at least a first location proximal to the stack station and a second location proximal to the separation station; and wherein said picker, when located in the first position, may be moveable in a vertical direction between a first vertical position where the attachment portion engages with the stack and a second vertical position above the top sheet; and wherein said picker, when located in the second position, may be moveable in a vertical direction between a third vertical position where the picker in engages with the separation station and a fourth vertical position that may be above the separation station.2. The apparatus of embodiment 1, wherein the separation station comprises two substations, three substations, or four substations.3. The apparatus of embodiments 1 , wherein the separation station comprises three substations.The apparatus of any of the preceding embodiments, wherein the attachment portion of the picker comprises one or more suction devices, particularly wherein the attachment portion comprises one or more suction devices, and more particularly wherein the attachment portion comprises two or more suction devices. The apparatus of any of the preceding embodiments, wherein the attachment portion of the picker has a number of suction devices chosen from 1, 3, 5, or 6 suction devices. The apparatus of the preceding embodiments, wherein the attachment portion of the picker has 5 suction devices. The apparatus of any of the preceding embodiments, wherein said suction devices are bellows type suction cups. The apparatus of any of the preceding embodiments, wherein at least one of the substations, and preferably each substation, have sensors that can determine whether a sheet is located at the substation. The apparatus of embodiment 8, wherein said sensor comprises one or more of an optical sensor, weight sensor, or a pressure sensor. The apparatus of any of the preceding embodiments, comprising two or more substations, and wherein the picker may be moveable between two or more distinct horizontal positions, each distinct horizontal position being above one of the two or more substations,And, when in each distinct horizontal position, may be moveable between a lower vertical position in communication with the substation that it may be above and an upper vertical position that may be not in communication with the substation that it may be above. The apparatus of any of the preceding embodiments, further comprising a cartridge disposed at the stack station, wherein the cartridge may be configured to retain the stack of sheets. The apparatus of embodiment 11, wherein the cartridge may be configured to retain at least 10 sheets, at least 25 sheets, at least 50 sheets, at least 75 sheets, at least 100 sheets, at least 150 sheets, at least 200 sheets, or at least 250 sheets. The apparatus of embodiment 11, wherein the cartridge further comprises a pusher plate, said pusher plate being configured to be in communication with aportion of the stack of plates such that the stack of plates is further in communication with the opposing interior surface of the cartridge.14. The apparatus of embodiment 13, wherein the pusher plate is spring-loaded.15. The apparatus of embodiment 13, wherein the pusher plate may be in communication with the upper portion of the stack.16. The apparatus of embodiment 11, wherein the cartridge further comprises one or more posts configured in such a way as to be in communication with the stack only if said stack has a declining angle and wherein the angle of the stack is substantially less declining after being in communication with said one or more posts.17. The apparatus of embodiment 16, wherein the cartridge comprises two posts.18. The apparatus of embodiment 11, wherein the cartridge further comprises one or more stripping blocks positioned at a height which may be in communication with the top sheet of the stack and which applies slight resistance to the one or more sheets from the top of the stack of sheets after being picked up by the picker.19. The apparatus of embodiment 18, wherein said one or more stripping blocks are spring-loaded.20. The apparatus of the preceding embodiments, further comprising an elevator in communication with the stack station, the elevator being configured to maintain the top sheet of the stack at a predetermined height.21. The apparatus of embodiment 20, wherein the elevator may be configured to reversibly couple with a cartridge at the stack station.22. The apparatus of the preceding embodiments, further comprising a horizontal track, wherein the picker may be movably coupled to the horizontal track and can move between different horizontal positions along the horizontal track.23. The apparatus of the preceding embodiments, further comprising a vertical track, wherein the picker may be movably coupled to the vertical track and can move between different vertical positions along the vertical track.24. The apparatus of the preceding embodiments, further comprising a base that supports the separation station.25. The apparatus of the preceding embodiments, further comprising a receiving station for receiving one and only one sheet.The apparatus of embodiment 21, wherein the separation station is disposed between the stack station and the receiving station. The apparatus of any of embodiments 25-26 wherein the receiving station comprises a mover configured to move one and only one sheet at a time away from the receiving station in a horizontal direction. The apparatus of embodiment 26, wherein said mover comprises one or more pushers, one or more rollers, one or more springs, or one or more movable trays. The apparatus of the preceding embodiments, further comprising a machine station for holding a machine that may be configured to receive and manipulate one and only one sheet at a time. The apparatus of embodiment 29, wherein the machine may be a reader. The apparatus of embodiment 30, wherein said reader may be an optical reader. The apparatus of embodiment 31, wherein said optical reader may be an optical reader for thin film culture plates. The apparatus of embodiments 27-32, wherein the mover may be configured to load one and only one sheet at a time into the machine. The apparatus of embodiment 1, wherein the stack of sheets comprises a stack of thin film culture plates. A method of separating one and only one sheet from a stack, comprising the steps of: causing the picker of an apparatus of the preceding embodiments to pick up one or more sheets from the top of the stack of sheets, causing the picker to place at least one of the one or more sheets on the separation station, and causing the picker to retrieve one and only one sheet from the separation station. The method of embodiment 35, further comprising placing one and only one sheet at a receiving station. The method of any of embodiments 35-36, wherein after the picker picks up one or more sheets from the stack of sheet, an elevator of embodiment 20 lifts the stack of sheets such that the top sheet of the stack may beat a predetermined height and may be in contact with the one or more stripping blocks of embodiment 18.38. The method of any of embodiments 35-37, wherein the step of causing the picker to place at least one of the one or more sheets on the separation station comprises causing the picker to place one and only one of the one or more sheets on a first substation of the separation station; causing the picker to move to a position that may be in communication with a second substation of the separation station; and causing the picker to pick up the one and only one sheet from the first substation of the separation station.39. The method of any of embodiments 35-37, wherein the step of causing the picker to place at least one of the one or more sheets on the separation station comprises causing the picker to place at least one of the one or more sheets on a first substation of the separation station; causing the picker to place one and only one of the one or more sheets on a second substation of the separation station; causing the picker to move to a position that may be in communication with a third substation of the separation station; and causing the picker to pick up the one and only one sheet from the second substation of the separation station.40. The method of embodiment 39, further comprising causing the picker to move pick up one or more sheets from the first substation of the separation station; causing the picker to move to a position that may be in communication with the second substation of the separation station; and causing the picker to pick up one and only one sheet from the first substation of the separation station.41. The method of any of embodiments 35-37, wherein the step of causing the picker to place at least one of the one or more sheets on the separation station comprises causing the picker to place at least one of the one or more sheets on a first substation of the separation station;causing the picker to place at least one of the one or more sheets on a second substation of the separation station; causing the picker to place one and only one of the one or more sheets on a third substation of the separation station; and causing the picker to pick up one and only one sheet from the third substation of the separation station. The method of any of embodiments 35-41, further comprising placing one and only one sheet on a receiving station. The method of embodiment 42, further comprising, after the step of placing one and only one sheet on the receiving station, picking up one and only one sheet from the separation station or and placing the one and only one sheet on the receiving station. The method of any of embodiments 35-43, further comprising placing one and only one sheet on the receiving station; and causing the mover to move the one and only one sheet from the receiving station. The method of embodiment 44, wherein the mover moves the one and only sheet from the receiving station to a machine. The method of embodiment 45, wherein the mover moves the one and only sheet from the receiving station to an optical reader at a machine station. A non-transient computer readable storage medium containing executable software that, when executed, causes an apparatus to carry out the method of any of embodiments 35-46. A computing device containing the non-transient computer readable storage medium of embodiment 47. The apparatus of any of the preceding embodiments, wherein the stack station may be configured to stabilize the stack of said sheets and keep said sheets at an angle so that the picker can pick up the top sheet.

Claims

ClaimsWe claim:

1. An apparatus for separating a single sheet from a stack of sheets, said apparatus comprising: a stack station configured to retain a stack of sheets having a top sheet on top of the stack; a picker having an attachment portion configured to pick up and release one or more sheets; a separation station separated from the stack station in a horizontal direction, the separation station comprising one or more substations, each of the one or more substations being configured to reversibly receive one or more sheets from the picker; wherein the picker may be moveable in a horizontal between at least a first location proximal to the stack station and a second location proximal to the separation station; and wherein said picker, when located in the first position, may be moveable in a vertical direction between a first vertical position where the attachment portion engages with the stack and a second vertical position above the top sheet; and wherein said picker, when located in the second position, may be moveable in a vertical direction between a third vertical position where the picker in engages with the separation station and a fourth vertical position that may be above the separation station.

2. The apparatus of claim 1, wherein the separation station comprises two substations, three substations, or four substations.

3. The apparatus of claim 1, wherein the attachment portion of the picker has a number of suction devices chosen from 1, 3, 5, or 6 suction devices.

4. The apparatus of claim 1, wherein at least one of the substations, and preferably each substation, have sensors that can determine whether a sheet is located at the substation.

5. The apparatus of claim 1, comprising two or more substations, and wherein the picker may be moveable between two or more distinct horizontal positions, each distinct horizontal position being above one of the two or more substations, and, when in each distinct horizontal position, may be moveable between a lower vertical position in communication with the substation that it may be above and an upper vertical position that may be not in communication with the substation that it may be above.

6. The apparatus of claim 1, further comprising a cartridge disposed at the stack station, wherein the cartridge may be configured to retain the stack of sheets.

7. The apparatus of claim 6, wherein the cartridge may be configured to retain a number of sheets in the range of about 10 to about 250.

8. The apparatus of claim 6, wherein the cartridge further comprises a pusher plate, said pusher plate being configured to be in communication with a portion of the stack of plates such that the stack of plates is in communication with the opposing interior surface of the cartridge.

9. The apparatus of claim 6, wherein the cartridge further comprises one or more posts configured in such a way as to be in communication with the stack only if said stack has a declining angle and wherein the angle of the stack is substantially less declining after being in communication with said one or more posts.

10. The apparatus of claim 6, wherein the cartridge further comprises one or more stripping blocks positioned at a height which may be in communication with thetop sheet of the stack and which applies slight resistance to the one or more sheets from the top of the stack of sheets after being picked up by the picker.

11. The apparatus of claim 1, further comprising a horizontal track, wherein the picker may be movably coupled to the horizontal track and can move between different horizontal positions along the horizontal track; and a vertical track, wherein the picker may be movably coupled to the vertical track and can move between different vertical positions along the vertical track.

12. The apparatus of claim 1, further comprising a receiving station for receiving one and only one sheet.

13. The apparatus of any of claim 12, wherein said receiving station comprises a mover configured to move one and only one sheet at a time away from the receiving station in a horizontal direction.

14. The apparatus of claim 1, further comprising a machine station for holding a machine that may be configured to receive and manipulate one and only one sheet at a time.

15. A method of separating one and only one sheet from a stack, comprising the steps of: causing the picker of an apparatus of the preceding embodiments to pick up one or more sheets from the top of the stack of sheets; causing the picker to place at least one of the one or more sheets on the separation station, and; causing the picker to retrieve one and only one sheet from the separation station.

16. The method of claim 15, wherein the step of causing the picker to place at least one of the one or more sheets on the separation station comprises:causing the picker to place one and only one of the one or more sheets on a first substation of the separation station; causing the picker to move to a position that may be in communication with a second substation of the separation station; and causing the picker to pick up the one and only one sheet from the first substation of the separation station.

17. The method of claim 15, further comprising placing one and only one sheet on a receiving station.

18. The method of claim 15, wherein the mover moves the one and only sheet from the receiving station to a machine.

19. A non-transient computer readable storage medium containing executable software that, when executed, causes an apparatus to carry out the method of claim 15.

20. A computing device containing the non-transient computer readable storage medium of claim 19.

21. The apparatus of embodiment 1, wherein the stack station may be configured to stabilize the stack of said sheets and keep said sheets at an angle so that the picker can pick up the top sheet.

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