Piezoelectric Array Lens for Microplate Ultrasound Shearing
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Solution Overview
Problem
Current ultrasound systems for shearing cellular material, such as DNA or chromatin, face limitations in throughput, uniformity, and durability, particularly when processing multiple samples simultaneously in microplates, leading to inefficient processing times and potential sample degradation.
Innovation Solution
A piezoelectric element array assembly with a lens layer that focuses ultrasound energy from a single piezoelectric element into multiple wells of a microplate, using amplified driving pulses and a fluidics system to induce cavitation, while ensuring the durability of transducer elements by distributing stress across a larger area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a large ultrasound transducer processes an entire microplate at once, then throughput is improved, but processing uniformity deteriorates due to hot/cold spots at low kHz frequencies
Solution Approach 1:
The patent divides the microplate processing into multiple independent frequency zones. Each zone operates at a different frequency (e.g., 20 kHz, 40 kHz, 60 kHz) to create multiple cavitation fields simultaneously. This segmentation eliminates hot/cold spots by ensuring uniform energy distribution across the entire microplate while maintaining high throughput.
Solution Approach 2:
The system employs periodic switching between multiple frequencies in a cyclical manner. Each frequency zone is activated in sequence or simultaneously with controlled duty cycles, creating periodic cavitation bursts that ensure uniform processing across all wells. This periodic multi-frequency action prevents localized overheating while maintaining high productivity.
2Productivity
If ultrasonically vibrating pins are used to process microplate wells, then processing speed is improved, but cross contamination occurs between wells requiring extensive cleaning
Solution Approach 1:
The patent extracts the physical contact mechanism (vibrating pins) and replaces it with a contactless ultrasound field generated by a plate-mounted transducer. The ultrasonic energy is coupled through the microplate material itself, eliminating the need for pins that physically penetrate wells. This extraction of the contact element completely prevents cross-contamination while maintaining processing speed.
Solution Approach 2:
The microplate itself serves as an intermediary medium that couples ultrasonic energy from the transducer to the samples in each well. The plate material transmits and distributes acoustic energy uniformly across all wells without requiring physical penetration, thus preventing cross-contamination while enabling simultaneous processing of multiple samples.
3Manufacturing precision
If a single ultrasound transducer focuses energy into one well at a time, then processing precision is improved, but processing time increases causing sample degradation
Solution Approach 1:
The patent segments the ultrasound field into multiple independent frequency zones, each capable of focusing energy into specific wells or groups of wells. By operating multiple frequency zones simultaneously or in rapid sequence, the system processes multiple wells in parallel, dramatically reducing total processing time while maintaining precise energy focusing in each zone to prevent sample degradation.
Solution Approach 2:
The ultrasonic system is designed with multi-functionality to process different well configurations simultaneously. Multiple frequency zones can be independently controlled to focus energy into different patterns (single wells, rows, columns, or entire plates), allowing the same system to adapt to various processing needs without increasing processing time or sacrificing precision.
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
This solution enables efficient and uniform shearing of cellular material across multiple wells of a microplate, reducing processing time and sample degradation, while improving the durability of transducer elements to prevent cracking.
Implementation Method 1
at least one piezoelectric element configured to produce ultrasound energy responsive to amplified driving pulses
Implementation Method 2
a lens layer bonded to the at least one piezoelectric element. The lens layer has a plurality of lenses formed therein that are configured to focus ultrasound energy
Implementation Method 3
The focused ultrasound energy creates cavitation in the sample material that is in the well
Data Source
AI summary
Disclosed embodiments include illustrative piezoelectric element array assemblies, methods of fabricating a piezoelectric element array assembly, and systems and methods for shearing cellular material. Given by way of non-limiting example, an illustrative piezoelectric element array assembly includes at least one piezoelectric element configured to produce ultrasound energy responsive to amplified driving pulses. A lens layer is bonded to the at least one piezoelectric element. The lens layer has a plurality of lenses formed therein that are configured to focus ultrasound energy created by single ones of the at least one piezoelectric element into a plurality of wells of a microplate disposable in ultrasonic communication with the lens layer, wherein more than one of the plurality of lenses overlie single ones of the at least one piezoelectric element.