Pierceable Cap for Pathogen Sample Tubes
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Solution Overview
Problem
Current methods for handling pathogen samples in nucleic acid extraction and PCR thermal cyclers are labor-intensive, prone to human error, leading to contamination and delayed diagnosis, as they require manual uncapping and pipetting, which can result in mistakes and increased risk of pathogen transmission.
Innovation Solution
A cap for pathogen sample tubes featuring pierceable protective film sections that allow automated sample withdrawal, eliminating the need for manual uncapping and reducing the risk of contamination, with a design that includes a plastic body and thin aluminum foil films separated by an air gap for secure sealing and compliance with UN3373 Category B packaging requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual uncapping and pipetting is used, then the process is simple and equipment is basic, but human error increases leading to contamination and failed testing
Solution Approach 1:
The cap is designed to be self-piercing by the automated pipette tip, eliminating the need for manual uncapping. The pierceable protective film section automatically opens when the pipette tip applies force, allowing the automated system to access the sample without human intervention and reducing contamination risk
Solution Approach 2:
The manual mechanical action of uncapping and pipetting is replaced by an automated pipetting system that pierces the protective film and aspirates the sample. This substitution of manual mechanical operations with automated mechanical systems reduces human error while maintaining operational simplicity
2Productivity
If manual handling is used, then equipment requirements are minimal, but labor intensity increases and processing speed decreases
Solution Approach 1:
The cap design enables the automated system to perform the uncapping function automatically through the pierceable protective film section. This self-opening mechanism eliminates the need for separate manual uncapping steps, increasing processing speed while keeping the operation straightforward
Solution Approach 2:
The protective film is pre-configured to be pierceable, preparing the cap for automated access before the sampling process begins. This preliminary preparation allows the automated pipette to immediately pierce and access the sample without requiring additional manual steps, thereby increasing throughput
3Reliability
If conventional caps are used, then manufacturing is simple, but sample spillage risk increases during automated handling
Solution Approach 1:
The protective film section uses a thin, flexible material that can be pierced by the automated pipette tip while maintaining sample containment. This thin film structure provides reliable sealing during storage and transport, yet allows easy penetration by the automated sampling system without causing spillage
Solution Approach 2:
The cap combines a rigid plastic body for structural integrity with a pierceable protective film section made of flexible material. This composite construction maintains sample containment during handling while enabling controlled access through the pierceable film, balancing manufacturing simplicity with reliable containment
4Object-affected harmful factors
If automated piercing is enabled, then contamination risk decreases, but the cap structure becomes more complex
Solution Approach 1:
The sealing function is extracted from the main cap body and implemented as a separate pierceable protective film section. This separation allows the automated piercing action to occur without compromising the overall cap structure, reducing contamination risk while adding minimal complexity to the cap design
Data Source
AI summary
The invention is a cap for a pathogen sample tube, the tube having an open end and the cap being configured to secure the open end of the tube to prevent spillage of any sample stored in the tube. The cap includes a first pierceable protective film section configured to enable an automated pipette or other sample withdrawal system to pierce the protective film section and to aspirate at least some of the sample. The cap also includes a second pierceable protective film section lying underneath the first pierceable protective film section; the film sections are separated by an air gap, that is approximately 2 mm in depth. The film sections are made from a thin aluminium foil that is approximately 25 microns thick, with a thin lacquer coating on its upper side and a co-extrusion coating, such as a polymer coating, on the lower side.