Ultra-Thin Walled PCR Vessels via Gas-Assisted Injection Molding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional thermal cycling vessels have thick walls that limit heat transfer efficiency and are not compatible with advanced thermal cycling instrumentation, leading to longer PCR cycle times and potential sample loss due to poor sealing and structural integrity issues.
Innovation Solution
A novel injection moulding process and design that allows for the production of ultra-thin walled thermal cycling vessels with consistent wall thicknesses of 0.0025 to 0.0065 inches, using a unique mould arrangement and high-pressure, high-speed injection moulding machines to achieve precise and uniform wall thickness, enhancing thermal transfer and sealing capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional thick-walled vessels are used, then structural integrity is maintained, but heat transfer efficiency deteriorates
Solution Approach 1:
The patent applies thin-walled vessel design (wall thickness 0.0025 to 0.0065 inches) to maximize thermal transfer efficiency while maintaining sufficient structural integrity for thermal cycling applications. The thin walls act as thermal conduits rather than thermal barriers, enabling faster heating and cooling rates during PCR cycles.
Solution Approach 2:
The patent changes the wall thickness parameter from conventional thick walls to ultra-thin walls (0.0025-0.0065 inches), fundamentally altering the thermal properties of the vessel while maintaining structural adequacy through optimized material selection and design.
2Temperature
If wall thickness is reduced to improve heat transfer, then thermal transfer efficiency improves, but manufacturing precision deteriorates
Solution Approach 1:
The patent replaces conventional injection molding with gas-assisted injection molding, where gas pressure is used to plasticize and distribute the thermoplastic material uniformly throughout the mold cavity. This mechanical substitution enables precise control of ultra-thin wall thickness (0.0025-0.0065 inches) that cannot be achieved with traditional mechanical injection alone.
Solution Approach 2:
The patent utilizes gas pressure (pneumatics) as the primary mechanism to plasticize and distribute the thermoplastic resin during molding. The gas assists in filling the mold cavity uniformly and maintaining pressure during cooling, ensuring consistent ultra-thin wall thickness throughout the vessel.
3Loss of time
If ultra-thin walled vessels are manufactured, then heat transfer time is reduced, but device complexity increases
Solution Approach 1:
The patent incorporates gas channels and core pins directly into the mold design during the preliminary molding setup. The gas-assisted injection molding apparatus is pre-configured with gas injection points and distribution channels that automatically plasticize and distribute the thermoplastic material during each molding cycle, eliminating the need for post-manufacturing wall thickness adjustment.
Solution Approach 2:
The gas-assisted injection molding process serves multiple functions simultaneously: it plasticizes the thermoplastic material, distributes it uniformly through the mold cavity, maintains pressure during cooling, and ensures consistent ultra-thin wall thickness. This multi-functional approach reduces overall process complexity despite the sophisticated mold arrangement.
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 ultra-thin walled vessels significantly reduce heat transfer time, improve sealing integrity, and maintain structural robustness, enabling faster PCR cycles and more efficient DNA amplification while being compatible with industry-standard equipment.
Implementation Method 1
evenly displacing a portion of that resin within the cavity by compressing the resin by the walls of the cavity to form the desired wall thickness
Implementation Method 2
The resin is then allowed to cool in the pressurized cavity thereby forming an ultra thin-walled vessel
Data Source
AI summary
The invention concerns a novel sample tube and a method of manufacturing a such a sample tube. According to the method an oversized mold cavity is formed with an opposing pair of mold members of an injection molding machine, the mold members being movable relative to each other and between which mold members the sample tube is formed. A volume of resin exceeding the prescribed volume of the sample tube is injected into the cavity and force is applied to said mold members in order to reduce the volume of said mold cavity for displacing molten polymer in the cavity and for compressing the polymer to form said sample tube. By means of the invention, sample tubes and vessels having ultra thin walls can be manufactured.