Thermal Cycler Orientation and Sealing for Compact PCR Systems
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Solution Overview
Problem
Existing PCR instruments are large in size due to bulky components, prone to moisture-induced corrosion, and require significant electrical current, making them less scalable, reliable, and space-efficient for laboratory use.
Innovation Solution
A thermal cycler system with a sample block and thermoelectric devices, where the thermal control unit is oriented differently from the sample block and thermoelectric cooler, and a hermetically sealed drip pan and heat sink configuration to isolate thermoelectric devices from ambient moisture, reducing the overall size and improving reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional PCB-based thermal control systems are used, then thermal cycling function is achieved, but instrument footprint becomes large
Solution Approach 1:
The patent divides the thermal control system into modular heating zones, each with independent thermoelectric devices and control circuits. This segmentation allows the system to achieve comprehensive thermal control while reducing the overall footprint by eliminating the need for large perimeter-based PCB structures.
Solution Approach 2:
The patent transitions from a two-dimensional PCB layout to a three-dimensional integrated structure where thermal control elements are embedded within the sample block itself. This dimensional change allows thermal control functionality to be achieved without the large horizontal footprint required by traditional PCB arrangements.
2Ease of operation
If thermoelectric devices are exposed to ambient environment, then device accessibility is maintained, but moisture-induced corrosion occurs
Solution Approach 1:
The patent creates a sealed, moisture-barrier environment around the thermoelectric devices using conformal coating and encapsulation techniques. This inert environmental approach protects the devices from moisture-induced corrosion while maintaining thermal efficiency, thereby improving reliability without compromising operational accessibility.
3Productivity
If high electrical current is provided to thermoelectric devices, then thermal cycling performance is improved, but electrical component size increases
Solution Approach 1:
The patent replaces traditional mechanical relay-based current control with solid-state electronic switching and pulse-width modulation (PWM) techniques. This substitution enables high current delivery to thermoelectric devices while using compact electronic components instead of large inductors and mechanical switches, thereby improving thermal cycling performance without increasing component volume.
4Measurement precision
If multiple PCBs are used for thermal control, then control precision is achieved, but device complexity increases
Solution Approach 1:
The patent merges multiple separate PCB control functions into a single integrated control circuit board that manages all thermoelectric devices and temperature sensors. This consolidation maintains the precision of individual zone control while reducing system complexity by eliminating the need for multiple separate PCB assemblies and their associated connection interfaces.
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 solution enables a smaller, more reliable, and scalable thermal cycler with reduced moisture exposure to thermoelectric devices, enhancing performance and space efficiency in laboratories.
Implementation Method 1
Thermoelectric devices utilize the Peltier effect to pump heat from one side of the device to another
Implementation Method 2
a hermetically sealed drip pan and heat sink configuration to isolate thermoelectric devices from ambient moisture
Data Source
AI summary
In one aspect, a thermal cycler system including a sample block and a thermoelectric device is disclosed. In various embodiments, the sample block has a first surface configured to receive a plurality of reaction vessels and an opposing second surface. In various embodiments the thermoelectric device is operably coupled to the second surface of the sample block. In various embodiments a thermal control unit is provided. In various embodiments the thermal control unit includes a computer processing unit. In various embodiments the thermal control unit includes an electrical current source. In various embodiments the thermal control unit also includes an electrical interface portion configured to connect the thermoelectric device with the electrical current source by way of an electrical cable. In various embodiments the thermal control unit is oriented in a different plane than the sample block and thermoelectric cooler.