Thermocycler Thermal Uniformity via Segmented Peltier Control
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Solution Overview
Problem
Existing thermocycler devices face challenges in maintaining uniform temperature across a sample block, leading to variations in PCR process yields due to temperature gradients and heat transfer delays, particularly in larger formats like 8 by 12 microtiter plates.
Innovation Solution
The implementation of a thermal block assembly with multiple thermoelectric devices, each paired with a unique thermal sensor and controller, allowing independent temperature control to achieve a substantially uniform temperature profile across the sample block.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single heating-cooling unit is used for the sample block, then the device complexity is reduced, but temperature uniformity across the sample block deteriorates
Solution Approach 1:
The sample block is divided into multiple independently controlled heating-cooling zones, each with its own heating-cooling unit. This segmentation allows each zone to be optimized for uniform temperature control, eliminating the temperature gradients that occur with a single large heating unit while maintaining manageable device complexity through modular architecture.
Solution Approach 2:
Each heating-cooling unit is independently controlled to provide localized temperature management for its specific region of the sample block. This local quality approach ensures that temperature uniformity is maintained in each zone without requiring the entire block to be controlled as a single unit, resolving the contradiction between complexity and uniformity.
2Productivity
If the sample block size is increased to accommodate more samples, then productivity is improved, but temperature uniformity deteriorates
Solution Approach 1:
The enlarged sample block is divided into multiple smaller heating-cooling zones, each managed by its own heating-cooling unit. This allows the system to accommodate more samples (increased productivity) while maintaining temperature uniformity within each smaller zone, as heat transfer distances are reduced and control is more localized.
Solution Approach 2:
The sample block is organized into a multi-zone grid structure, adding a spatial dimension to temperature control. Each heating-cooling unit manages a specific region in this multi-dimensional space, allowing the system to scale capacity while maintaining uniform temperature distribution through coordinated control of multiple zones.
3Measurement precision
If thermal sensors are placed in each heating-cooling unit, then temperature measurement precision is improved, but device complexity increases
Solution Approach 1:
The temperature measurement system is segmented into multiple independent sensing units, with each heating-cooling unit having its own thermal sensor. This segmentation provides precise local temperature measurements without requiring a complex centralized sensing system, as each unit independently monitors and reports its zone's temperature.
Solution Approach 2:
Each heating-cooling unit is self-equipped with its own thermal sensor, allowing it to autonomously monitor and regulate its temperature without relying on external sensing infrastructure. This self-service approach improves measurement precision while minimizing overall system complexity by distributing the sensing function across independent modular units.
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 significantly reduces thermal non-uniformity, ensuring consistent PCR process outcomes by minimizing temperature variations and optimizing heat transfer, thereby enhancing the efficiency and reliability of thermal cycling.
Implementation Method 1
The Peltier elements are comprised of a semiconductor material and are sandwiched in between the first and the second thermal conducting layers
Implementation Method 2
a first thermal conducting layer, a second thermal conducting layer, a plurality of Peltier elements and a thermal sensor
Data Source
Figure 1~2
Figure 3A~3C
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AI summary
A thermal block assembly including a sample block and two or more thermoelectric devices, is disclosed. The sample block has a top surface configured to receive a plurality of reaction vessels and an opposing bottom surface. The thermoelectric devices are operably coupled to the sample block, wherein each thermoelectric device includes a housing for a thermal sensor and a thermal control interface with a controller. Each thermoelectric device is further configured to operate independently from each other to provide a substantially uniform temperature profile throughout the sample block.