Porous Analysis Chip Assembly for Precise Zone Geometry
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Solution Overview
Problem
Existing methods for manufacturing biological analysis chips, such as protein microarrays and multiplex analysis devices, suffer from imprecise control of analysis zone volume and shape, leading to limited precision and sensitivity due to anisotropic material properties and physico-chemical alterations, which affect the quantification limit and reproducibility of biological analyses.
Innovation Solution
A method involving mechanical assembly of a pad of porous analysis material into a solid support matrix through a through hole, using a pressing force normal to the surfaces, without chemical or heat treatments, ensuring uniform deformation and maintaining native material properties, allowing precise control of the analysis zones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a solid ink printing process is used to deposit wax on the matrix to delimit analysis zones, then the analysis zones can be formed, but the volume and shape of the analysis zones cannot be precisely controlled
Solution Approach 1:
The patent replaces the solid ink printing process (thermal/chemical process) with a mechanical insertion process. A pad of analysis material is mechanically inserted into a through-hole in the matrix, allowing precise control of the analysis zone volume and shape through the geometry of the pad and hole, rather than relying on wax deposition control.
Solution Approach 2:
The patent uses a pad of porous analysis material that is inserted into the matrix. The porous structure allows for controlled capillary action and fluid distribution within the analysis zone, enabling precise control of the effective analysis volume while maintaining ease of manufacture through simple insertion.
2Manufacturing precision
If the matrix is heated to melt wax to limit lateral diffusion, then the wax diffuses to delimit analysis zones, but the manufacturing precision of analysis zone geometry is compromised
Solution Approach 1:
The patent eliminates the heating step entirely by using a mechanical insertion process. The pad is inserted into the through-hole at room temperature, and the analysis zone geometry is defined by the physical dimensions of the pad and hole, not by thermal diffusion of wax.
3Manufacturing precision
If lamination is used to insert adsorbent material into holes, then the holes can be filled, but the adsorbent material becomes anisotropic and may diffuse between channels
Solution Approach 1:
The patent divides the analysis material into separate pads that are inserted into individual through-holes. This segmentation prevents the continuous diffusion path that occurs with lamination, as each pad is isolated within its own hole by the matrix material surrounding it.
Solution Approach 2:
The patent replaces the lamination process (which creates anisotropic properties) with a mechanical insertion process. The pad is inserted into the hole and held in place by mechanical means, preserving the isotropic properties of the adsorbent material while preventing inter-channel diffusion through the physical barrier of the matrix.
4Strength
If chemical or heat treatments are used to assemble components, then the assembly is strong, but the native material properties are altered
Solution Approach 1:
The patent uses a mechanical assembly process where components are joined through physical insertion and retention mechanisms rather than chemical bonding or heat treatment. This maintains the native material properties of all components while achieving sufficient assembly strength through the mechanical interface between the pad, matrix, and cover.
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 method enhances the sensitivity and reproducibility of biological sample analysis by maintaining the integrity of material properties, reducing pollution, and enabling precise control of analysis zones, thus improving quantitative analysis and filtration capabilities.
Implementation Method 1
a mechanical assembly is carried out at a temperature below the melting temperatures of the support and analysis materials, during which a pressing force in the direction normal to the lower and upper surfaces of the matrix is exerted on at least a portion of the matrix which adjoins the at least one pad inserted into the matrix
Implementation Method 2
at least one pad is provided, cut from a sheet of solid and porous analysis material
Data Source
AI summary
Disclosed is a method for manufacturing an analysis chip for analysing a biological sample (1), which method comprises providing a matrix (10) formed in a solid support material in which at least one through hole has been formed (11) and at least one pellet (3), cut out of a sheet (6) of solid and porous analysis material; inserting at least one pellet (3) into the at least one through hole (11) of the matrix (10) by translation of the pellet (3) in a direction at right angles to the lower and upper surfaces of the matrix (10); mechanically assembling at a temperature lower than the melting points of the support and analysis materials by means of a pressing force applied at right angles to the upper surface of the matrix.