Additively Manufactured PCR Thermoblock for Uniform Edge Heating
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Solution Overview
Problem
Existing thermoblocks in PCR thermocyclers face challenges with temperature homogeneity, particularly at the lateral edges due to exposure to ambient temperature, leading to inefficiencies and increased energy consumption, and require complex manufacturing processes that compromise mechanical strength and optimization possibilities.
Innovation Solution
The use of additive manufacturing, specifically Selective Laser Melting (SLM), to create a thermoblock with integrally connected sample container receptacles and base portions, optimizing the structure for homogeneous temperature distribution and mechanical strength, while minimizing parasitic heat capacity and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If solid metal thermoblocks with chip-removing manufacturing processes are used, then temperature homogeneity is improved, but process time increases and energy consumption rises
Solution Approach 1:
The thermoblock is segmented into a modular structure with a base plate and multiple receptacles that are integrally connected through additive manufacturing. This segmentation allows optimization of heat transfer paths while reducing overall thermal mass compared to solid metal blocks, thereby decreasing process time while maintaining temperature homogeneity.
Solution Approach 2:
The invention changes the manufacturing parameter from chip-removing processes to additive manufacturing, and modifies the material parameter by using materials with optimized thermal conductivity. This allows creation of structures with tailored thermal properties that achieve homogeneity faster than traditional solid metal blocks.
2Temperature
If solid metal thermoblocks are used, then temperature homogeneity is improved, but energy consumption increases
Solution Approach 1:
The modular segmented structure reduces unnecessary thermal mass while maintaining heat distribution efficiency. By eliminating excess material present in solid metal blocks, the system consumes less energy to achieve and maintain temperature homogeneity across all receptacles.
Solution Approach 2:
The invention optimizes thermal conductivity parameters through material selection and structural design, enabling more efficient heat transfer with lower energy input. The additive manufacturing process allows precise control of thermal properties to minimize energy waste while ensuring uniform temperature distribution.
3Temperature
If additional temperature control devices are arranged in edge regions, then temperature inhomogeneity is compensated, but device complexity and production cost increase
Solution Approach 1:
The base plate is designed with locally optimized thermal conductivity, particularly enhanced in edge regions through the additive manufacturing process. This local quality enhancement compensates for edge effects and ambient temperature influences without requiring additional control devices, thereby maintaining temperature homogeneity while reducing device complexity.
4Strength
If additive manufacturing with integral design is used, then mechanical strength and material efficiency are improved, but manufacturing complexity increases
Solution Approach 1:
The base plate and multiple receptacles are merged into a single integrally connected component through additive manufacturing. This merging eliminates the need for separate manufacturing and assembly steps, reducing overall manufacturing complexity while maintaining mechanical strength through the continuous material structure characteristic of additive manufacturing.
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
Achieves rapid temperature changes with improved temperature homogeneity and reduced energy consumption, enhancing the efficiency and mechanical robustness of thermocyclers.
Implementation Method 1
The thermoblock (1) is manufactured by means of an additive manufacturing process, in particular by means of Selective Laser Melting (SLM)
Implementation Method 2
Peltier elements that are thermally coupled to the underside of the block are generally used for temperature regulation
Data Source
AI summary
The invention relates to a thermoblock for receiving and regulating the temperature of at least one laboratory specimen vessel in a laboratory temperature regulation device, more particularly in a PCR thermocycler, wherein the thermoblock has been produced by means of an additive manufacturing method using a material containing metal. The invention further relates to a method for producing the thermoblock and a computer-implemented method for the simulation of physical characteristics of the thermoblock to be produced in accordance with the invention.