Separable Sensor Array Plate for Thermocycler Calibration

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Solution Overview

Problem

Existing temperature measurement systems for thermocyclers are not separable, requiring the entire tool to be replaced upon recalibration or defect, with calibration data stored in control electronics, leading to high manual mounting efforts and limited thermal homogeneity due to complex sensor housing designs.

Innovation Solution

A separable device comprising a sensor array plate with temperature sensors on tongues and a pressure plate with fins for alignment, allowing individual sensor calibration and storage of calibration data on the sensor array, connected to separate control electronics via a flexible cable, enabling easy replacement and optimal thermal contact.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If temperature sensors are integrated into control electronics with non-separable calibration data storage, then calibration accuracy is maintained, but the entire tool must be replaced upon recalibration or defect, increasing downtime and cost

Engineering Contradiction:

Improvetemperature measurement accuracyVSAvoidsensor replacement ease

Core Design Contradiction:

Measurement precisionVSEase of repair

Solution Approach 1:

The measurement system is divided into separable components: the sensor array plate can be independently removed and replaced from the control electronics. Calibration data is stored on the sensor array plate itself rather than in the control electronics, allowing the sensor array to be replaced without affecting the control system or requiring complete tool replacement.

Inventive Principle:

Principle #1Segmentation

2Reliability

If complex sensor housing designs are used to ensure thermal contact, then measurement reliability is improved, but thermal homogeneity deteriorates due to interference with heat distribution

Engineering Contradiction:

Improvemeasurement reliabilityVSAvoidthermal homogeneity

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The sensor array plate features localized thermal contact points through protruding sensor housings that make direct contact with the operating plate at specific measurement locations. This localized approach ensures reliable thermal contact for accurate measurement while minimizing the overall footprint and interference with heat distribution across the entire operating plate surface.

Inventive Principle:

Principle #3Local quality

3Measurement precision

If manual mounting of sensors is performed with high precision requirements, then measurement accuracy is improved, but mounting time and complexity increase

Engineering Contradiction:

Improvetemperature measurement accuracyVSAvoidcalibration time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The sensor array plate is pre-assembled with all temperature sensors mounted in their correct positions and orientations before installation. Alignment features such as guide pins and keyed slots are pre-integrated into the plate design, ensuring that when the pre-assembled sensor array is installed, the sensors automatically align with the operating plate measurement points, eliminating the need for time-consuming on-site alignment and mounting adjustments.

Inventive Principle:

Principle #10Preliminary action

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

Enables accurate and reliable temperature measurement with reduced downtime, allowing for field calibration and improved thermal homogeneity without affecting the tool's thermal behavior, facilitating easy replacement and recalibration of sensor arrays.

Implementation Method 1

at least one temperature sensor arranged on at least one tongue that is surrounded by a cut-out leaving a bridge to the sensor array plate, wherein the at least one temperature sensor has on both sides spacer and a second surface opposite the first surface for contacting at least one operating plate

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

a pressure plate, comprising fins at the side for connection to the sensor array plate that align with the spacer of the sensor array plate when a pressure plate is arranged onto a sensor array plate

Methodology Applied

Scientific EffectMechanical pressure: Mechanical Force

Data Source

PatentUS11953382B2Calibration tool for planar chip applications

Publication Date: 2024.04.09 STRATEC SE

AI summary

A system comprising a device or the device itself for measuring temperatures, comprising a sensor array plate, comprising on a first surface at least one temperature sensor arranged on at least one tongue that is surrounded by a cut-out leaving a bridge to the sensor array plate, wherein the at least one sensor has on both sides' spacer and a second surface opposite the first surface for connection to at least one operating plate of a thermocycler; and a pressure plate, comprising fins at the side for connection to the sensor array plate that align with the spacer of the sensor array plate when a pressure plate is arranged onto a sensor array plate.