Chip Packaging Structure for Bubble-Free dPCR Micropore Filling
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Solution Overview
Problem
Conventional micro-trap dPCR systems face issues with sample not fully filling micropores and the presence of bubbles within these pores, affecting the accuracy and reliability of nucleic acid concentration calculations.
Innovation Solution
A chip packaging structure featuring a sample substrate with through holes, connected by flow channels on cover plates, allowing for complete sample filling and bubble-free operation through a continuous channel design, with hydrophilic and hydrophobic treatments to enhance sample flow and prevent adsorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If blind holes are adopted as micropores in conventional micro-trap dPCR, then the chip structure is simple and easy to manufacture, but the sample cannot fully fill the micropores and bubbles exist in the micropores
Solution Approach 1:
The chip structure is divided into multiple layers: a substrate layer containing through-holes, a first cover plate with first flow channels, and a second cover plate with second flow channels. This segmentation allows the sample to flow through a continuous path from the sample inlet through the through-holes to the sample outlet, ensuring complete filling of micropores while maintaining manufacturing feasibility through modular assembly.
Solution Approach 2:
The invention transitions from a single-plane blind hole structure to a three-dimensional continuous flow channel system. By adding flow channels in the cover plates that connect to the through-holes in the substrate, the sample can access all micropores through a continuous path, eliminating bubbles while maintaining structural simplicity through layered design.
2Measurement precision
If conventional blind hole micropores are used, then the chip structure is simple, but bubbles exist in the micropores affecting measurement accuracy
Solution Approach 1:
The continuous flow channel structure is designed in advance to guide the sample from the inlet through all through-holes to the outlet. This preliminary design ensures that the sample completely fills all micropores before measurement, preventing bubble formation and ensuring accurate nucleic acid concentration calculations without requiring complex post-processing.
3Reliability
If through holes with flow channels are used to ensure complete sample filling, then sample filling completeness improves, but the chip packaging structure becomes more complex
Solution Approach 1:
The invention merges the flow channel function with the cover plates by integrating first flow channels in the first cover plate and second flow channels in the second cover plate. These flow channels connect to the through-holes in the substrate, creating a unified continuous flow path that ensures bubble-free operation while maintaining structural efficiency through functional integration.
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
Ensures complete filling of micropores without bubble formation, enhancing the accuracy and reliability of nucleic acid concentration calculations in digital polymerase chain reaction (dPCR) processes.
Implementation Method 1
a flow path existing between each pair of the sample inlet and the sample outlet, where a first flow channel structure is on a surface of the first cover plate opposite to the sample substrate, a second flow channel structure is on a surface of the second cover plate opposite to the sample substrate, and the first flow channel structure and the second flow channel structure are connected together with the plurality of through holes, to form a continuous channel corresponding to the flow path
Implementation Method 2
with hydrophilic and hydrophobic treatments to enhance sample flow and prevent adsorption
Data Source
AI summary
A chip packaging structure and a chip packaging method, the structure including: a sample substrate with through holes; first and second cover plates on opposite sides of the sample substrate; and at least one pair of a sample inlet and a sample outlet, each pair of the sample inlet and the sample outlet is in one or both of the first cover plate and the second cover plate, a flow path is between each pair of the sample inlet and the sample outlet, a first flow channel structure is on a surface of the first cover plate opposite to the sample substrate, a second flow channel structure is on a surface of the second cover plate opposite to the sample substrate, and the first flow channel structure and the second flow channel structure are connected with the through holes, to form a continuous channel corresponding to the flow path.