Automated Biopolymer Production Modules for Low-Variation DNA and RNA

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Solution Overview

Problem

The production of DNA or RNA is labor-intensive and prone to quality variation and error due to the need for skilled technicians to operate multiple pieces of equipment and transport materials between them, increasing costs and complexity.

Innovation Solution

An automated modular system that automates the entire production process, including preparation of reaction vessels, synthesis, purification, and packaging, using a robotic transport system to move materials between modules, reducing the need for human intervention and enabling continuous quality control.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If separate equipment is used for each production step with skilled technicians operating them, then each individual step can be performed with specialized equipment, but the overall process becomes labor intensive and requires human intervention at multiple steps

Engineering Contradiction:

Improveindividual step performanceVSAvoidhuman intervention requirement

Core Design Contradiction:

Ease of manufactureVSExtent of automation

Solution Approach 1:

The patent combines multiple separate pieces of equipment into an integrated automated system where synthesis modules, purification modules, and robotic transport systems work together as a unified production line, eliminating the need for separate technician-operated equipment for each step

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The automated system performs material transport and process coordination without human intervention, with robotic arms automatically transferring materials between modules and the control system autonomously managing the production sequence from synthesis to packaging

Inventive Principle:

Principle #25Self-service

2Reliability

If skilled technicians operate and transport materials between individual pieces of equipment, then proper operation and material handling can be ensured, but production costs significantly increase

Engineering Contradiction:

Improveoperation qualityVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent replaces the mechanical system of manual material handling with an automated robotic transport system that uses robotic arms and automated conveyors to transfer materials between modules, eliminating technician labor while maintaining operational reliability through programmed precision

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The automated control system incorporates feedback mechanisms to monitor and adjust operations in real-time, ensuring quality control and proper material handling without requiring skilled technicians, thereby reducing labor costs while maintaining or improving operational reliability

Inventive Principle:

Principle #23Feedback

3Ease of manufacture

If multiple individual pieces of equipment are used in the production process, then each step can be performed with dedicated equipment, but the process complexity and sources of quality variation increase

Engineering Contradiction:

Improvestep-specific equipment capabilityVSAvoidprocess complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent segments the production process into distinct modular units (synthesis modules, purification modules, packaging modules) that can be independently designed and optimized for each step, while the automated control system integrates them into a coordinated whole, reducing overall process complexity through standardization

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The automated system uses universal interfaces and standardized protocols across all modules, allowing the same robotic transport system and control architecture to handle different production steps, thereby reducing complexity despite the presence of multiple specialized equipment functions

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Reliability

If human intervention is required at multiple steps, then quality control can be performed manually, but unnecessary complexity and sources of quality variation and error are introduced

Engineering Contradiction:

Improvequality control capabilityVSAvoidquality variation

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The automated system maintains continuous operation without human intervention interruptions, eliminating the variability introduced by manual operations at different steps, and ensuring consistent quality through uninterrupted automated processes from synthesis to packaging

Inventive Principle:

Principle #20Continuity of useful action

Data Source

PatentUS11439971B2Automated modular system and method for production of biopolymers

Publication Date: 2022.09.13 SYNTHEGO CORP

AI summary

The present invention provides an automated modular system and method for production of biopolymers including DNA and RNA. The system and method automates the complete production process for biopolymers. Modular equipment is provided for performing production steps with the individual modules arrange in a linear array. Each module includes a control system and can be rack mounted. One side of the array of modules provides connections for power, gas, vacuum and reagents and is accessible to technicians. On the other side of the array of modules a robotic transport system is provided for transporting materials between module interfaces. The elimination of the requirement for human intervention at multiple steps in the production process significantly decreases the costs of biopolymer production and reduces unnecessary complexity and sources of quality variation.