Multi-Chip Nanopore Flow Cell Packaging for Scalable Sequencing
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Solution Overview
Problem
Existing nanopore-based sequencing systems face challenges in scaling to include more cells due to limitations in chip size, well spacing, and analog component scaling, leading to increased costs and design complexity.
Innovation Solution
A multi-chip nanopore-based sequencing system is developed, integrating multiple nanopore-based sequencing chips and flow cells into a single package, with hermetically sealed chip-to-chip boundaries and shared fluidic channels, allowing for scalable and cost-effective expansion without increasing die size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple sequencing chips are integrated into a single package, then cell density and sequencing throughput are improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The system divides the sequencing platform into multiple independent sequencing chips, each containing a subset of sensors and fluidic channels. These chips can be manufactured separately using standard semiconductor processes and then integrated into a single package, allowing parallel processing of multiple DNA samples simultaneously while maintaining manufacturing feasibility
Solution Approach 2:
Multiple sequencing chips are nested within a single flow cell package, with each chip containing smaller-scale sensor arrays and fluidic channels. This nested architecture allows high cell density (improving productivity) while the outer package provides unified fluidic control and electrical connections, managing the overall device complexity
2Reliability
If chip-to-chip boundaries are hermetically sealed, then fluid flow control and signal integrity are improved, but manufacturing precision requirements increase
Solution Approach 1:
A flow cell made of molded pliable material or glass serves as an intermediary component that hermetically seals the chip-to-chip boundaries. This flow cell provides a unified fluidic environment across multiple chips while isolating electrical signals, achieving reliable fluid flow control without requiring direct precision bonding between chip edges
Solution Approach 2:
The flow cell is constructed from molded pliable material that can conform to the chip boundaries and provide hermetic sealing. This flexible sealing approach accommodates manufacturing tolerances better than rigid sealing methods, reducing the precision requirements for chip alignment and bonding
3Quantity of substance
If reticle sizes and well dimensions are reduced to increase cell density, then sequencing capacity is improved, but manufacturing costs and design complexity increase
Solution Approach 1:
Instead of increasing cell density by reducing the size of individual cells in the planar dimension, the system adds a third dimension by stacking multiple sequencing chips vertically within a single flow cell package. This achieves high cell density while maintaining larger, more manufacturable individual chip dimensions
Solution Approach 2:
Multiple sequencing chips are merged into a single integrated package with shared fluidic control systems and electrical connections. This consolidation achieves high sequencing capacity while using standard semiconductor manufacturing processes for each chip, avoiding the need to manufacture ultra-small individual cells
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
The system enables efficient scaling of cell numbers, reduces design cycles, and lowers costs by modular assembly, overcoming limitations of semiconductor reticle sizes and analog component scaling, while maintaining consistent fluid flow across sensors.
Implementation Method 1
the flow cell coupled to the at least one of the plurality of nanopore-based sequencing chips comprises one or more fluidic flow channels that allow a fluid external to the system to flow on top of the nanopore-based sequencing chip
Implementation Method 2
The chip-to-chip boundary may be hermetically sealed, for example by dicing side walls of the at least two of the plurality of nanopore-based sequencing chips to be substantially vertical and flat; placing the side walls of the at least two of the plurality of nanopore-based sequencing chips such that the side walls are butted against each other; and depositing a hermetic sealing material on the side walls
Implementation Method 3
each of the nanopore-based sequencing chips comprising a plurality of nanopore sensors
Data Source
AI summary
A nanopore-based sequencing system includes a plurality of nanopore-based sequencing chips. Each of the nanopore-based sequencing chips comprises a plurality of nanopore sensors. The system comprises at least one flow cell coupled to at least one of the plurality of nanopore-based sequencing chips, wherein the flow cell coupled to the at least one of the plurality of nanopore-based sequencing chips comprises one or more fluidic flow channels that allow a fluid external to the system to flow on top of the nanopore-based sequencing chip and out of the system. The system further comprises a printed circuit board electrically connected to the plurality of nanopore-based sequencing chips.