Micro-plate Grid Inserts for High-Density Sample Storage
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Solution Overview
Problem
Existing sample handling systems face challenges in increasing storage capacity within standardized micro-plates due to limitations in compartment size and manufacturing constraints, leading to inefficient use of space and reliability issues in injection-molding processes.
Innovation Solution
A sample handling system featuring a micro-plate with separate grid inserts that can be attached and detached from a frame, allowing for increased storage capacity by reducing the effective volume required for tube storage, and enabling improved manufacturing through separate production of frame and grid inserts using injection-molding techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the number of storage compartments on micro-plates is increased by reducing compartment dimensions, then storage capacity is improved, but the wall thickness becomes too small to provide mechanical stability
Solution Approach 1:
The micro-plate is divided into a frame structure with multiple separate grid inserts, each containing multiple compartments. This segmentation allows the frame to provide overall structural support while the grid inserts can be optimized for storage capacity, resolving the contradiction between increased compartment density and maintained wall thickness for mechanical stability.
Solution Approach 2:
Multiple grid inserts are nested within the frame structure, with each grid insert containing multiple compartments. This nested arrangement increases storage capacity within the standardized micro-plate dimensions while the frame provides the necessary mechanical support, avoiding the need to reduce wall thickness.
2Quantity of substance
If the number of storage compartments is increased while maintaining standardized outer dimensions, then storage capacity is improved, but manufacturing reliability deteriorates due to injection-molding constraints
Solution Approach 1:
The micro-plate is segmented into a frame and multiple separate grid inserts. This segmentation allows each component to be manufactured using standard injection-molding processes with reliable tolerances, then assembled together to achieve high storage capacity. The separate manufacturing of grid inserts avoids the reliability issues of attempting to mold extremely thin-walled compartments in a single piece.
Solution Approach 2:
The frame and multiple grid inserts are combined through assembly (e.g., ultrasonic welding, snap-fitting, or screw connections) to form the complete micro-plate. This merging approach allows each component to be manufactured reliably using standard processes while achieving the overall high storage capacity design when assembled.
3Quantity of substance
If the outer dimensions of micro-plates are increased to add more storage compartments, then storage capacity is improved, but compatibility with standard equipment deteriorates
Solution Approach 1:
Multiple grid inserts are nested within the frame to increase storage capacity while maintaining the standardized outer dimensions of the micro-plate. This nested arrangement allows high storage capacity without exceeding the size limits of standard equipment, preserving equipment compatibility.
Solution Approach 2:
Instead of increasing the horizontal footprint of the micro-plate, the design utilizes the vertical dimension by stacking multiple grid inserts within the frame. This dimensional change increases storage capacity while maintaining compatibility with standard equipment that expects standardized micro-plate dimensions.
Data Source
Figure 1
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AI summary
Sample handling system for handling samples contained in tubes (4), each tube (4) having a hollow body, a closed bottom and an open top for accessing the sample contained in the tube (4). The system comprises a micro-plate (1) comprising at least one grid insert (2) having a plurality of compartments. Each compartment comprises one or more side walls laterally confining a through-hole for receiving a said tube (4). The through-hole has a top opening and a bottom opening and extends between the top opening and the bottom opening. A frame (3) to which the at least one separate grid insert (2) is to be attached to form the micro-plate (1). The frame (3) laterally confines a through-opening which is dimensioned to allow for accessing each compartment (21) of the attached at least one grid insert (2) from above and from below. This allows for moving such tube (4) into and out of each compartment (21) through each of the top opening (202) and the bottom opening (203) of the through-hole (201).