Induction Heated Micro PCR Chip with Embedded Metal Heater
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Solution Overview
Problem
Conventional PCR systems face challenges in miniaturization due to high costs, complex fabrication, and inefficiencies in heating and temperature control, particularly with silicon substrates and contact heating methods, which hinder the development of cost-effective, disposable, and efficient micro-Polymerase Chain Reaction systems.
Innovation Solution
A non-contact real-time micro-Polymerase Chain Reaction system utilizing an inductively heated polymer chip with an embedded metal heater and infrared temperature sensing, fabricated from materials like PDMS, acrylic, or polycarbonate, which employs an induction heater and infrared radiation for temperature control, eliminating the need for complex thermal management and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If silicon substrates are used for microchip PCR, then thermal conductivity is improved, but manufacturing cost and fabrication complexity increase
Solution Approach 1:
The patent employs disposable polymer chips instead of expensive silicon substrates. The chips are designed for single-use PCR applications, eliminating the need for complex cleaning and sterilization processes while maintaining adequate thermal performance for the intended application lifecycle.
Solution Approach 2:
The patent changes the material parameter from silicon to polymer (PDMS, polycarbonate, or acrylic), accepting lower thermal conductivity in exchange for simplified fabrication, optical transparency, and cost reduction. The thermal conductivity parameter is adjusted to match the requirements of disposable microchip PCR.
2Use of energy by moving object
If contact heating with resistive heaters is used, then heating efficiency is improved, but temperature control complexity and cost increase
Solution Approach 1:
The patent replaces the mechanical contact heating system (resistive heaters requiring electrical connections and thermal coupling) with an electromagnetic induction heating system. The induction heater generates eddy currents in the chip material itself, providing contactless heating with simplified temperature control.
Solution Approach 2:
The patent introduces an intermediate metal layer embedded in the polymer chip that serves as the heating element. This metal layer couples the induction heater's electromagnetic field to the chip, enabling efficient and uniform heating without direct mechanical contact between the heater and chip.
3Reliability
If complex multi-step fabrication is used for reaction chambers, then sealing reliability is improved, but manufacturing cost increases
Solution Approach 1:
The patent uses thin polymer films and simple lamination techniques to create sealed reaction chambers. The flexible nature of polymer materials allows for effective sealing through bonding and adhesion without requiring complex multi-step fabrication processes like those needed for rigid silicon substrates.
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
This system achieves efficient and reliable PCR processes with simplified chip fabrication, reduced costs, and improved disposability, enabling rapid deployment of low-cost, real-time microchip PCR applications by using non-contact heating and temperature sensing, ensuring accurate temperature control and fluorescence detection.
Implementation Method 1
An induction heater mounted in around the chip and is inductively coupled to the metal heater
Implementation Method 2
utilizing an inductively heated polymer chip with an embedded metal heater
Implementation Method 3
An infrared temperature sensor mounted below the chip for measuring a temperature of the metal heater
Data Source
AI summary
The present disclosure provides a non-contact real time micro Polymerase Chain Reaction (PCR) system comprising; a chip having a reaction chamber for holding a sample and an embedded metal heater below the reaction chamber for heating the sample; an optical unit comprising an associated LED driver and a photo detector amplifier placed above the chip to detect fluorescence; an induction heater mounted around the chip and inductively coupled to the metal heater; an infrared temperature sensor mounted below the chip for measuring a temperature of the metal heater, wherein the infrared temperature sensor is interfaced with a signal conditioner; and a controller interfaced with the signal conditioner and the induction heater for regulating the power to the induction heater based on feedback received from the infrared temperature sensor through the signal conditioner.