Process Tube Securement Region for Thermal Cycler Alignment

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Solution Overview

Problem

The handling and transport of process tubes in racks for nucleic acid amplification processes are inefficient and prone to human error due to their conical or cylindrical shape, leading to misalignment and potential loss of samples during thermal cycler processing.

Innovation Solution

The design of process tubes with a securement region featuring an annular ledge, protrusion, and neck that securely fit into a carrier tray, allowing for adjustment and alignment with thermal cycler heaters, which includes a top ring and base for secure positioning and easy handling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If process tubes are placed in a carrier rack with ports larger than the tube diameter to accommodate manufacturing tolerances, then the tubes can be easily inserted and removed, but the tubes may shift and misalign with thermal cycler heaters during handling and transport

Engineering Contradiction:

Improveease of tube insertion and removalVSAvoidalignment precision with thermal cycler heaters

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The process tube is segmented into distinct functional regions: a securement region with an annular ledge and protrusion for carrier rack engagement, a neck region for sealing, and a body region for sample containment. This segmentation allows the securement region to provide precise alignment features while the body region maintains its standard conical shape for sample processing.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The annular ledge and protrusion act as intermediary structures between the process tube and the carrier rack. These features provide a mechanical interface that ensures precise alignment and secure positioning of the tube within the rack, preventing shifts during handling while still allowing for easy insertion and removal.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If process tubes are securely connected to the rack to prevent shifting, then alignment with thermal cycler heaters is improved, but the tubes may become dislodged during marking by stamping apparatus

Engineering Contradiction:

Improvealignment precision with thermal cycler heatersVSAvoidresistance to dislodging during stamping

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

The securement region of the process tube has different mechanical properties than the body region. The annular ledge and protrusion are designed with specific geometric features that provide strong engagement with the carrier rack for alignment purposes, while the overall connection allows for controlled movement during stamping operations without complete dislodgement.

Inventive Principle:

Principle #3Local quality

3Manufacturing precision

If process tubes are individually handled and placed in the thermal cycler, then precise alignment with heaters can be achieved, but the process becomes time-consuming and difficult to automate

Engineering Contradiction:

Improvealignment precision with thermal cycler heatersVSAvoidprocessing speed and automation capability

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

Multiple process tubes are merged into a single carrier rack assembly, allowing multiple tubes to be aligned and positioned simultaneously. The rack serves as a common platform that maintains precise alignment for all tubes, enabling batch processing and automation while achieving the same alignment precision as individual tube placement.

Inventive Principle:

Principle #5Merging (Combining)

4Ease of operation

If process tubes are allowed to move freely in the rack for easy handling, then insertion and removal are simplified, but samples may be lost due to tube tilting and bumping

Engineering Contradiction:

Improveease of tube handlingVSAvoidsample integrity during transport

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The securement region provides a dynamic connection between the process tube and carrier rack. The annular ledge and protrusion allow for controlled movement and adjustment during insertion, while providing sufficient constraint during transport to prevent excessive tilting and bumping that could compromise sample integrity.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS10220392B2Process tube and carrier tray

Publication Date: 2019.03.05 BECTON DICKINSON & CO

AI summary

The disclosure provides a system and method to safely and efficiently store and transport process tubes in a carrier tray comprising prior to and during amplification of nucleotides in the process tubes. The process tube disclosed includes a securement region having an annular ledge, a neck, and a protrusion. The securement region of the process tube can secure the process tube in a port of the carrier tray, but still allows the process tube to adjust or float in order to align the process tube into a rigid heater well of a thermal cycler.