Acoustic Droplet Dispensing Calibration via Liquid Level Feedback
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Solution Overview
Problem
Acoustic droplet dispensing systems face challenges in precisely controlling droplet volume due to variables such as chemical composition, viscosity, temperature, and liquid level, leading to inconsistent droplet sizes.
Innovation Solution
A method for calibrating the system by measuring the liquid level in the source container before dispensing, using indicators like fluorescent chemicals to calculate average droplet volume, and adjusting dispensing parameters through a burst curve to achieve uniform droplet volumes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If acoustic wave parameters are used to dispense droplets, then droplet dispensing capability is achieved, but droplet volume consistency deteriorates due to liquid level variations
Solution Approach 1:
The system measures the liquid level in the source container and uses this measurement to dynamically adjust the acoustic wave dispensing parameters. This feedback loop ensures that droplet volume remains consistent even as the liquid level changes during the dispensing process, directly resolving the contradiction between maintaining dispensing capability and ensuring volume precision.
Solution Approach 2:
The patent changes the acoustic wave parameters (such as amplitude, duration, or frequency) based on the measured liquid level. By dynamically adjusting these parameters, the system compensates for liquid level variations and maintains consistent droplet volumes, thereby resolving the contradiction between productivity and manufacturing precision.
2Device complexity
If liquid level is not monitored, then dispensing process is simple, but droplet volume control precision deteriorates
Solution Approach 1:
The system incorporates liquid level monitoring with feedback control, where the measured liquid level is used to adjust dispensing parameters in real-time. This feedback mechanism ensures precise droplet volume control while maintaining a relatively simple overall process structure, resolving the contradiction between process simplicity and measurement precision.
Solution Approach 2:
The patent replaces complex mechanical adjustment mechanisms with a simpler system that uses liquid level measurements and computational parameter adjustments. This substitution maintains precision while reducing mechanical complexity, addressing the contradiction between device complexity and measurement precision.
3Productivity
If acoustic wave energy is increased to dispense droplets from lower liquid levels, then dispensing capability is maintained, but energy consumption increases
Solution Approach 1:
Instead of uniformly increasing acoustic wave energy, the system dynamically adjusts the parameters (amplitude, duration, frequency) based on the specific liquid level measurement. This optimized parameter adjustment maintains dispensing capability across varying liquid levels while minimizing unnecessary energy consumption, resolving the contradiction between productivity and energy use.
Solution Approach 2:
The system transitions from static acoustic wave parameters to dynamic parameters that adapt to changing liquid levels. This dynamic adjustment ensures efficient energy use by applying only the necessary acoustic energy required for each dispensing event, resolving the contradiction between maintaining dispensing capability and reducing energy consumption.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method ensures consistent droplet volumes by adjusting dispensing parameters based on liquid level measurements, allowing for precise control and uniformity in droplet dispensing.
Implementation Method 1
an acoustic wave emitter 14 generates an acoustic wave or beam 20 that can be propagated through an optional wave channel 24
Implementation Method 2
The acoustic wave 20 is propagated through the coupling medium 32 after which the wave is transmitted through a source liquid containment structure 44 where the wave comes to focus at or near the surface of the pool of source liquid 40, thereby causing a droplet 60 of the source liquid 40 to be dispensed
Implementation Method 3
The target wellplate is placed in a scanner that reads the quantitative amount of the indicator in each target well
Data Source
AI summary
The present invention comprises a method for calibrating a droplet dispensing apparatus using acoustic energy to dispense a plurality of droplet sets of a liquid from a source container into a plurality of target containers, with each droplet set being comprised of one or more individual droplets of the liquid, and with a liquid level of the liquid in the source container being measured before each of the droplet sets are dispensed. The average droplet volume for the individual droplets in each of the droplet sets is then calculated by detecting the presence of an indicator, such as a fluorescent chemical. Once the average droplet volume has been calculated, it is determined if the average droplet volume for each droplet set is acceptable or not acceptable. Where the average droplet volume is determined to be not acceptable, an existing droplet dispensing parameter is changed to a new droplet dispensing parameter that will cause the average droplet volume for that droplet set to change. A burst curve is then generated that will cause the new droplet dispensing parameter for each droplet set to be used if a subsequent plurality of droplet sets are dispensed.