Unitary Biochip Integrating Microfluidic Automation
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Solution Overview
Problem
Current microfluidic biochips are limited in their ability to perform complex series of processing steps without operator intervention, are costly to produce, and often require pre-processing of samples, leading to inefficiencies and contamination issues.
Innovation Solution
The development of biochips that integrate microfluidic and macrofluidic features, fabricated using injection molding of plastic materials, which include pneumatic, thermal, and optical subsystems, enabling automated processing of samples from insertion to results generation without operator intervention, and are designed for single-use to minimize contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If current microfluidic biochips are used, then sample processing can be performed, but they require pre-processing of samples and operator intervention, leading to inefficiencies and contamination issues
Solution Approach 1:
The patent merges multiple processing steps (sample pre-processing, nucleic acid extraction, PCR amplification, electrophoresis, and detection) into a single integrated biochip device. This consolidation eliminates the need for separate pre-processing steps and operator interventions between steps, achieving automated sample-in-to-results-out processing while reducing overall system complexity.
Solution Approach 2:
The biochip is designed as a universal platform that performs multiple functions within a single device: it includes sample processing chambers, nucleic acid extraction regions, PCR amplification zones, electrophoresis channels, and detection areas. This multi-functionality eliminates the need for separate specialized devices for each processing step, thereby reducing operator intervention and improving automation.
2Extent of automation
If complex series of processing steps are integrated, then automated processing is achieved, but manufacturing costs increase
Solution Approach 1:
The biochip is segmented into distinct functional regions (sample processing, extraction, amplification, separation, detection) that can be manufactured using standardized microfabrication techniques. This segmentation allows each region to be optimized and manufactured independently using established processes, reducing overall manufacturing complexity and cost despite the integrated functionality.
Solution Approach 2:
The patent employs parameter changes in the fabrication process, including the use of photolithography, soft lithography, and injection molding with specific material selections (PMMA, COC, COP). These parameter optimizations enable cost-effective mass production of the integrated biochip while maintaining the complex automated processing capabilities.
3Adaptability or versatility
If multiple processing steps are performed, then analysis capability is improved, but the risk of contamination increases
Solution Approach 1:
The patent extracts and isolates specific functional regions for each processing step within the biochip, creating physically separated zones that minimize cross-contamination. The sample processing, extraction, amplification, and detection regions are spatially distinct, allowing multiple analyses to be performed while maintaining contamination barriers between steps.
Solution Approach 2:
The biochip is designed as a single-use disposable device that is discarded after one analysis. This eliminates the need for cleaning and sterilization between uses, thereby preventing contamination from previous samples. The low cost of the disposable chip allows this disposal approach to be economically viable, reducing contamination risk while maintaining analysis capability.
4Ease of operation
If pre-processing steps are required, then sample preparation is possible, but operator intervention and contamination risks increase
Solution Approach 1:
The biochip incorporates preliminary action features where reagents and consumables are pre-loaded into sealed chambers and cartridges within the device. Samples are inserted in their original collection containers, and the chip automatically performs all preparation steps including reagent dispensing, mixing, and processing, eliminating the need for operator pre-processing while maintaining ease of operation.
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
These biochips achieve fully integrated, automated sample processing with reduced costs and minimized operator intervention, capable of performing complex analyses such as nucleic acid sequencing and sizing, while eliminating the need for pre-processing and reducing contamination risks.
Implementation Method 1
pneumatic drive lines to pneumatically drive fluids
Implementation Method 2
thermal subsystem
Implementation Method 3
high voltage subsystem
Implementation Method 4
optical subsystem
Data Source
AI summary
A biochip for the integration of all steps in a complex process from the insertion of a sample to the generation of a result, performed without operator intervention includes microfluidic and macrofluidic features that are acted on by instrument subsystems in a series of scripted processing steps. Methods for fabricating these complex biochips of high feature density by injection molding are also provided.