Flexible Membrane Cover for Automated Sample Punching
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Solution Overview
Problem
Automated sample processing systems face challenges in preventing punch loss during the cutting and extraction of small discs from porous substrates due to static electricity and air movement, with current solutions inadequately addressing the issue of discs sticking to equipment or being lost during transport.
Innovation Solution
An automated system with a puncher, ejector pin, and flexible thin film cover flaps that allow for z-axis movement and alignment of receptacles with the punching die, ensuring that cut discs are accurately ejected into wells without sticking, using a handling subsystem that moves in x, y, and z directions, and thin film cover flaps that curve inward to form a low resistance opening for easy insertion and retention of the discs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an enclosed system with reduced air movement and anti-static devices is used, then punch loss is reduced, but device complexity increases
Solution Approach 1:
The patent uses a flexible membrane cover with an opening that allows the punch to pass through while preventing punch loss. The membrane acts as a simple yet effective barrier that eliminates the need for complex enclosed systems with anti-static devices and air movement control, thereby reducing device complexity while maintaining punch retention.
2Reliability
If a modified plate cover with teeth is used to keep punch inside well, then punch retention is improved, but ease of operation deteriorates due to difficulty in adding liquids
Solution Approach 1:
The flexible membrane cover with an opening provides a simple solution that allows punches to be retained in wells while maintaining easy access for liquid handling. The membrane's flexibility and the opening design enable standard liquid handling operations without the need for complex modifications or special procedures.
3Reliability
If thin film covers with slits are used to prevent liquid escape, then liquid containment is improved, but punch insertion becomes difficult due to stiffness and sealing
Solution Approach 1:
The patent employs a flexible membrane cover that is specifically designed to be compliant rather than stiff. The membrane with an opening allows punches to pass through easily during insertion while still providing liquid containment when needed. The flexibility of the membrane eliminates the resistance encountered with stiff thin film covers, making punch insertion straightforward without compromising liquid containment capability.
Data Source
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Figure 3A~3C
AI summary
Automated methods and systems for punching out pieces of a porous substrate for biological samples comprising: loading the porous substrate onto a support comprising a die and an opening; moving a receptacle support in at least a z-direction to position a receptacle relative to the support so that an opening in the receptacle is aligned and substantially flush with the opening in the support; actuating a punching head so that the punching head passes through the die, thereby punching a piece out of the porous substrate; and actuating an ejector pin to eject the punched piece from the porous substrate support and into the receptacle aligned with the opening in the support.