Micro-well Tape Singulation Using Ridge Deflection and Knife Cutting

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Solution Overview

Problem

Micro-well tape cannot be processed or inserted into existing industry readers without adaptors, as it lacks the necessary mechanisms for singulation and processing.

Innovation Solution

A method and apparatus that uses a tractor drive with a backer plate and sensor to advance and cut the micro-well tape, employing a cutting knife blade and anvil, and upper and lower tape retainers with tapered entries and a groove to deflect the cut tape into a corrugated shape, allowing it to be used as an individual micro-array tray.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of substance

If micro-well tape is used instead of traditional trays, then cost savings are achieved, but the tape cannot be run in existing industry readers without adaptors

Engineering Contradiction:

Improvecost savingsVSAvoidcompatibility with existing readers

Core Design Contradiction:

Loss of substanceVSAdaptability or versatility

Solution Approach 1:

The micro-well tape is segmented into individual micro-array trays through a singulation process. The tape is cut into discrete sections, each containing a specific number of wells (e.g., 96, 384, or 1536 wells), allowing them to be processed individually in existing readers while maintaining the cost benefits of tape-based storage and handling.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

An adaptor mechanism is introduced as an intermediary between the micro-well tape and existing readers. The singulated tape sections are loaded into adaptors that interface with standard reader equipment, enabling compatibility without modifying the readers themselves while preserving the advantages of tape-based micro-well formats.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If micro-well tape is cut into segments, then it can be processed in adaptors, but the cutting process requires precise control to avoid deformation

Engineering Contradiction:

Improvesingulation capabilityVSAvoidcutting precision

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

Perforations are created in the micro-well tape at predetermined intervals before the cutting process. These perforations serve as guide markers that facilitate precise alignment and cutting at the correct locations, ensuring that each singulated section contains the intended number of wells without deformation or misalignment.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The cutting mechanism uses a knife blade that engages with an anvil to sever the tape, replacing complex mechanical cutting systems with a simpler blade-anvil arrangement. This substitution maintains cutting precision while simplifying the overall mechanism and reducing the risk of deformation during the singulation process.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Measurement precision

If the tape is advanced using a tractor drive, then positioning accuracy is improved, but the drive mechanism adds complexity to the apparatus

Engineering Contradiction:

Improvepositioning accuracyVSAvoiddrive mechanism complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The tractor drive mechanism uses a backer plate with ridges that engage with corresponding features on the tape. Rather than using a complex multi-axis positioning system, the drive provides sufficient positioning accuracy through this simplified ridge engagement mechanism, applying just enough complexity to achieve the required precision without unnecessary elaboration.

Inventive Principle:

Principle #16Partial or excessive action

4Ease of operation

If the cut tape is deflected into a corrugated shape, then it can be properly aligned in adaptors, but the deflection requires a complex retainer structure

Engineering Contradiction:

Improvealignment capabilityVSAvoidretainer structure complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The tape retainers are designed with curved or corrugated surfaces that guide the cut tape into a specific deflected shape. This curvature-based design naturally aligns the tape with the adaptor requirements through geometric guidance rather than complex mechanical constraints, achieving proper alignment through the inherent geometry of the retainer surfaces.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The upper and lower tape retainers feature asymmetric tapered entries and raised ridges positioned at specific locations. This asymmetric design creates a unique deflection path for the tape, ensuring proper orientation and alignment in the adaptor while preventing misalignment or incorrect loading. The asymmetric features provide alignment guidance without requiring complex symmetric mechanisms.

Inventive Principle:

Principle #4Asymmetry

Data Source

PatentUS8499669B2Methods and apparatus for singulating micro-well tape

Publication Date: 2013.08.06 LGC GENOMICS LLC

AI summary

An apparatus (10) for singulating micro-well tape includes a tape drive (12) and a cutting assembly (14). The micro-well tape is advanced into and passes between upper and lower tape retainers (44, 45), with the upper tape retainer (44) including a groove (441) into which a raised ridge (451) of a multiplicity of ridges (450) of the bottom tape retainer (45) extends, with the rows of wells moving between adjacent ridges (450) in a movement direction. When a bar code on the micro-well tape is detected by a sensor 24, a knife blade (30) mounted on a slide block (32) is moved vertically to cut the micro-well tape. The new leading edge of the micro-well tape pushes the cut micro-well tape which is deflected by the raised ridge (451).