U.S. patent application number 15/182187 was filed with the patent office on 2016-10-06 for microfluidic cartridge for processing and detecting nucleic acids.
The applicant listed for this patent is NeuMoDx Molecular, Inc.. Invention is credited to Michael T. Kusner, Jeffrey Williams.
Application Number | 20160288123 15/182187 |
Document ID | / |
Family ID | 48945708 |
Filed Date | 2016-10-06 |
United States Patent
Application |
20160288123 |
Kind Code |
A1 |
Williams; Jeffrey ; et
al. |
October 6, 2016 |
MICROFLUIDIC CARTRIDGE FOR PROCESSING AND DETECTING NUCLEIC
ACIDS
Abstract
A microfluidic cartridge, configured to facilitate processing
and detection of nucleic acids, comprising: a top layer comprising
a set of cartridge-aligning indentations, a set of sample
port-reagent port pairs, a shared fluid port, a vent region, a
heating region, and a set of Detection chambers; an intermediate
substrate, coupled to the top layer comprising a waste chamber; an
elastomeric layer, partially situated on the intermediate
substrate; and a set of fluidic pathways, each formed by at least a
portion of the top layer and a portion of the elastomeric layer,
wherein each fluidic pathway is fluidically coupled to a sample
port-reagent port pair, the shared fluid port, and a Detection
chamber, comprises a turnabout portion passing through the heating
region, and is configured to be occluded upon deformation of the
elastomeric layer, to transfer a waste fluid to the waste chamber,
and to pass through the vent region.
Inventors: |
Williams; Jeffrey; (Chelsea,
MI) ; Kusner; Michael T.; (Ann Arbor, MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
NeuMoDx Molecular, Inc. |
Ann Arbor |
MI |
US |
|
|
Family ID: |
48945708 |
Appl. No.: |
15/182187 |
Filed: |
June 14, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14755821 |
Jun 30, 2015 |
9403165 |
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15182187 |
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13766009 |
Feb 13, 2013 |
9101930 |
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14755821 |
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61598240 |
Feb 13, 2012 |
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61667606 |
Jul 3, 2012 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B01L 2400/0406 20130101;
B01L 2400/0487 20130101; B01L 2300/06 20130101; B01L 2300/0893
20130101; B29L 2031/756 20130101; B01L 3/527 20130101; B01L
3/502723 20130101; B01L 2200/027 20130101; B01L 2300/0609 20130101;
B01L 2300/0681 20130101; B01L 2300/0861 20130101; B29C 65/484
20130101; B01L 3/502738 20130101; B01L 2300/0887 20130101; B01L
2300/14 20130101; B01L 7/525 20130101; B29C 66/8322 20130101; B01L
2300/1827 20130101; C12N 13/00 20130101; B01L 2200/142 20130101;
B01L 3/5025 20130101; B01L 2300/022 20130101; B01L 2400/086
20130101; B01L 2300/0864 20130101; B01L 3/502746 20130101; B29C
66/71 20130101; B01L 2200/0605 20130101; B01L 2400/0694 20130101;
B01L 2400/0481 20130101; B01L 2300/0816 20130101; B01L 2400/0622
20130101; B01L 2300/1805 20130101; C12Q 1/68 20130101; B01L
2300/0809 20130101; B01L 2200/12 20130101; B01L 2300/123 20130101;
C12Q 1/686 20130101; B01L 2400/0478 20130101; B01L 3/50273
20130101; B01L 3/508 20130101; B29K 2021/00 20130101; B01L 2200/10
20130101; C12M 23/42 20130101; B01L 2300/0883 20130101; B01L
2300/16 20130101; B01L 2400/043 20130101; B29C 65/08 20130101; B01L
2300/021 20130101; B01L 3/502 20130101; B01L 2300/0636 20130101;
C12Q 1/6806 20130101; B01L 3/567 20130101; B01L 3/502715 20130101;
B29C 65/606 20130101; B01L 2200/0689 20130101; B01L 2300/0627
20130101; C12N 15/1013 20130101; B01L 7/52 20130101; B01L 3/502761
20130101; B01L 2200/0684 20130101; B01L 2300/0672 20130101; B01L
2300/087 20130101; B29C 66/81423 20130101; B01L 2200/025 20130101;
B29C 66/71 20130101; B01L 2200/0668 20130101; B01L 2200/0615
20130101; B01L 2300/044 20130101; B01L 2300/1822 20130101; B01L
2400/065 20130101; B01L 3/5027 20130101; B01L 2400/0655 20130101;
C12Q 1/6813 20130101; B01L 2300/0867 20130101; B01L 3/502707
20130101 |
International
Class: |
B01L 3/00 20060101
B01L003/00; B01L 7/00 20060101 B01L007/00 |
Claims
1. A cartridge for processing a sample, the cartridge comprising: a
first layer comprising a sample port; an intermediate substrate
that is coupled to the first layer, partially separated from the
first layer by a film layer, and configured to form a sealed waste
chamber and a waste port into the sealed waste chamber, wherein the
sealed waste chamber directly opposes the first layer across the
film layer and defines an external void; and a fluidic pathway,
superior to the intermediate substrate and at least partially
separated from the sealed waste chamber by a deformable layer,
wherein the fluidic pathway is fluidly coupled to the sample port,
and wherein, upon deformation of the deformable layer through the
external void defined by the waste chamber, the fluidic pathway is
occluded and configured to transfer waste fluid of the sample
through the waste port into an interior portion of the sealed waste
chamber.
2. The cartridge of claim 1, wherein the first layer is a unitary
construction comprising a reagent port, the sample port, and a
detection chamber, and wherein the fluidic pathway is coupled to
the reagent port, the sample port, and the detection chamber.
3. The cartridge of claim 1, wherein the fluidic pathway is defined
between the first layer and the film layer.
4. The cartridge of claim 1, wherein the elastomeric layer is
situated between the fluidic pathway and the intermediate
substrate, wherein the intermediate substrate provides access to a
set of occlusion positions of the fluidic pathway through the
external void defined by the sealed waste chamber, such that the
fluidic pathway is configured to be occluded through the deformable
layer at the set of occlusion positions from a direction
perpendicular to the broad surface of the first layer.
5. The cartridge of claim 1, further comprising 1) a heating region
defined as a recessed region of the first layer that is parallel to
the external void, and 2) a vent region, such that the fluidic
pathway is configured to cross the heating region and to pass
through the vent region downstream of the heating region.
6. The cartridge of claim 5, wherein the heating region includes at
least one of a heating element and thermally conductive element
integrated into the first layer.
7. The cartridge of claim 1, wherein the external void includes a
superior surface having a set of openings that provide access to
the deformable layer, thereby defining a set of occlusion positions
of the fluidic pathway.
8. The cartridge of claim 7, wherein the cartridge is operable in
an operation mode wherein the deformable layer is transitioned into
a deformed configuration, through the set of openings, that biases
the deformable layer into the fluidic pathway, with the fluidic
pathway occluded at the set of occlusion positions, thereby
defining a truncated fluidic pathway from the sample port to the
waste port.
9. The cartridge of claim 1, wherein the sealed waste chamber
further defines a second external void parallel to the external
void and configured to receive a magnet, wherein the second
external void provides access to a magnetic capture segment of the
fluidic pathway, wherein the magnetic capture segment is downstream
of the sample port and upstream of the waste port.
10. The cartridge of claim 9, wherein the intermediate substrate
includes a magnet proximal the second external void and the
magnetic capture segment.
11. A cartridge for processing of a set of samples, the cartridge
comprising: a first layer and an intermediate substrate coupled to
the first layer and partially separated from the first layer by a
film layer, wherein the intermediate substrate forms a sealed waste
chamber and a set of waste ports into the sealed waste chamber,
wherein the sealed waste chamber directly opposes the first layer
across the film layer and defines an external void; a first fluidic
pathway, formed by at least a portion of the first layer; and a
second fluidic pathway in parallel with the first fluidic pathway
and formed by at least a portion of the first layer, wherein the
first fluidic pathway and the second fluidic pathway are each at
least partially separated from the sealed waste chamber by a
deformable layer that is deformable through the external void, and
each of the first and the second fluidic pathways is configured to
transfer waste fluid of the set of samples into the sealed waste
chamber through the set of waste ports.
12. The cartridge of claim 11, wherein the deformable layer
includes a set of waste openings aligned with the set of waste
ports, thereby allowing transfer of waste fluid from the set of
samples into the sealed waste chamber.
13. The cartridge of claim 12, wherein the first fluidic pathway
comprises a capture segment, wherein the capture segment is
s-shaped and progressively narrowing in an upstream-to-downstream
direction.
14. The cartridge of claim 13, wherein the sealed waste chamber
further defines a second external void parallel to the external
void and configured to receive a magnet, wherein the second
external void provides access to the capture segment of the first
fluidic pathway.
15. The cartridge of claim 11, wherein the first layer is a unitary
construction comprising a first sample port-reagent port pair
including a first sample port, a second sample port-reagent port
pair including a second sample port, a fluid port, a first
detection chamber, and a second detection chamber, wherein the
first fluidic pathway is coupled to the first sample port-reagent
port pair and the first detection chamber, wherein the second
fluidic pathway is coupled to the second sample port-reagent port
pair and the second detection chamber, and wherein the first
fluidic pathway and the second fluidic pathway are both coupled to
the fluid port.
16. The cartridge of claim 15, wherein the first detection chamber
comprises a first serpentine-shaped fluidic channel, and wherein
the first serpentine-shaped fluidic channel comprises three wide
channels directly interconnected by two narrow channels, wherein
the three wide channels include a first wide channel comprising a
detection chamber inlet into the first detection chamber and a
second wide channel comprising a detection chamber outlet from the
first detection chamber.
17. The cartridge of claim 11, wherein the external void includes a
superior surface having a set of openings that provide access to
the deformable layer, thereby defining a first set of occlusion
positions of the first fluidic pathway and a second set of
occlusion positions of the second fluidic pathway.
18. The cartridge of claim 17, wherein the first set of occlusion
positions has a first arrangement and the second set of occlusion
positions has a second arrangement different from the first
arrangement.
19. The cartridge of claim 17, wherein each of the first fluidic
pathway and the second fluidic pathway is operable between at least
a first operation mode, a second operation mode, wherein in the
first operation mode, the first fluidic pathway is transitioned
into a first truncated fluidic pathway with a first subset of the
first set of occlusion positions occluded, wherein in the second
operation mode, the first fluidic pathway is transitioned into a
second truncated fluidic pathway with a second subset of the first
set of occlusion positions occluded, and wherein in the third
operation mode, the first fluidic pathway is transitioned into a
third truncated fluidic pathway with a third subset of the first
set of occlusion positions occluded.
20. The cartridge of claim 19, further including a heating region
defined at a recessed region of a first side of the first layer and
a magnetic region defined at a second side of the first layer,
wherein the heating region directly opposes at least a portion of
the magnetic region across a thickness of the fluidic pathway.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of co-pending U.S. patent
application Ser. No. 14/755,821, filed 30 Jun. 2015, which is a
continuation of U.S. patent application Ser. No. 13/766,009, filed
13 Feb. 2013, now issued as U.S. Pat. No. 9,101,930, which claims
the benefit of U.S. Provisional Application Ser. No. 61/667,606,
filed on 3 Jul. 2012, and U.S. Provisional Application Ser. No.
61/598,240, filed on 13 Feb. 2012, which are all incorporated in
their entirety by this reference.
TECHNICAL FIELD
[0002] This invention relates generally to the molecular
diagnostics field, and more specifically to an improved
microfluidic cartridge for processing and detecting nucleic
acids.
BACKGROUND
[0003] Molecular diagnostics is a laboratory discipline that has
developed rapidly during the last 25 years. It originated from
basic biochemistry and molecular biology research procedures, but
now has become an independent discipline focused on routine
analysis of nucleic acids (NA), including deoxyribonucleic acid
(DNA) and ribonucleic acid (RNA) for diagnostic use in healthcare
and other fields requiring nucleic acid analysis. Molecular
diagnostic analysis of biological samples can include the detection
and/or monitoring of one or more nucleic acid materials present in
the specimen. The particular analysis performed may be either
qualitative and/or quantitative. Methods of analysis may involve
isolation, purification, and amplification of nucleic acid
materials, and polymerase chain reaction (PCR) is a common
technique used to amplify nucleic acids. Often, a nucleic acid
sample to be analyzed is obtained in insufficient quantity,
quality, and/or purity, hindering a robust implementation of a
diagnostic technique. Current sample processing methods and
molecular diagnostic techniques are also labor/time intensive, low
throughput, and expensive, and systems of analysis are
insufficient. Furthermore, methods of isolation, processing, and
amplification are often specific to certain nucleic acid types and
not applicable across multiple acid types. Due to these and other
deficiencies of current molecular diagnostic systems and methods,
there is thus a need for improved devices for processing and
amplifying nucleic acids. Thus, there is a need in the molecular
diagnostics field to create an improved microfluidic cartridge to
facilitate processing and detecting of nucleic acids. This
invention provides such a microfluidic cartridge.
BRIEF DESCRIPTION OF THE FIGURES
[0004] FIGS. 1A-1C depict an embodiment of a microfluidic cartridge
(top and side views) and an embodiment of a microfluidic pathway of
the microfluidic cartridge;
[0005] FIGS. 1D-K depict an example embodiment of subsets of
occlusion positions defining truncated portions of a fluidic
pathway;
[0006] FIG. 2 depicts an alternative embodiment of a microfluidic
cartridge (top view) showing individual waste chambers located on
the top of cartridge and multiple fluid ports;
[0007] FIG. 3 depicts an alternative embodiment of a detection
chamber of the microfluidic cartridge (top view) and a heating
element configured to heat the detection chamber;
[0008] FIG. 4 depicts an embodiment of a waste chamber of the
microfluidic cartridge;
[0009] FIGS. 5A-5D depict embodiments of the elastomeric layer of
the microfluidic cartridge, in open and occluded
configurations;
[0010] FIGS. 6A-6C depict an alternative embodiment of a
microfluidic cartridge (top and side views) and an alternative
embodiment of a microfluidic pathway of the microfluidic
cartridge;
[0011] FIG. 7 depicts another alternative embodiment of a
microfluidic pathway of the microfluidic cartridge;
[0012] FIGS. 8A and 8B depict schematics of microfluidic channel
cross sections;
[0013] FIG. 8C depicts specific embodiments of microfluidic channel
cross sections;
[0014] FIG. 9 depicts an embodiment of the microfluidic cartridge
with twelve fluidic pathways (four of which are shown);
[0015] FIGS. 10A and 10B depict embodiments of occlusion of fluidic
pathways with the elastomeric layer and a valving mechanism;
[0016] FIGS. 11A and 11B depict an embodiment of the microfluidic
cartridge;
[0017] FIGS. 12A-12G depict an example manufacturing method for an
embodiment of the microfluidic cartridge; and
[0018] FIG. 13 depicts an alternative example manufacturing method
for an embodiment of the microfluidic cartridge.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] The following description of preferred embodiments of the
invention is not intended to limit the invention to these preferred
embodiments, but rather to enable any person skilled in the art to
make and use this invention.
1. Microfluidic Cartridge
[0020] As shown in FIGS. 1A-1C, an embodiment of a microfluidic
cartridge 100 for processing and detecting nucleic acids comprises:
a top layer 110 comprising a set of sample port-reagent port pairs
112 and a set of detection chambers 116; an intermediate substrate
120, coupled to the top layer 110 and partially separated from the
top layer by a film layer 125, configured to form a waste chamber
130; an elastomeric layer 140 partially situated on the
intermediate substrate 120; a magnet housing region 150 accessible
by a magnet 152 providing a magnetic field 156; and a set of
fluidic pathways 160, each formed by at least a portion of the top
layer 110, a portion of the film layer 125, and a portion of the
elastomeric layer 140. In other embodiments, the microfluidic
cartridge 100 may further comprise a bottom layer 170 coupled to
the intermediate substrate 120 and configured to seal the waste
chamber 130. Furthermore, the top layer 110 of the microfluidic
cartridge 100 may further comprise a shared fluid port 118, a vent
region 190, and a heating region 195, such that each fluidic
pathway 165 in the set of fluidic pathways 160 is fluidically
coupled to a sample port-reagent port pair 113, the shared fluid
port 118, the waste chamber 130, and a detection chamber 117,
comprises a capture segment 166 configured to pass through the
heating region and the magnetic field, and is configured to pass
through the vent region 190 upstream of the detection chamber 117.
Each fluidic pathway 165 thus functions to receive and facilitate
processing of a sample fluid containing nucleic acids as it passes
through different portions of the fluidic pathway 165. As
configured, the microfluidic cartridge 100 can be used to
facilitate molecular diagnostic processes and techniques, and
preferably conforms to microtiter plate dimensional standards.
Alternatively, the microfluidic cartridge 100 may be any
appropriate size. In a specific application, the microfluidic
cartridge 100 can be used to facilitate a PCR procedure for
analysis of a sample containing nucleic acids.
1.1 Microfluidic Cartridge--Top Layer
[0021] The top layer 110 of an embodiment of the microfluidic
cartridge 100 functions to accommodate elements involved in
performing a molecular diagnostic procedure (e.g. PCR), such that a
sample containing nucleic acids, passing through the cartridge, can
be manipulated by the elements involved in performing the molecular
diagnostic procedure. The top layer 110 is preferably composed of a
structurally rigid/stiff material with low autofluorescence, such
that the top layer 110 does not interfere with sample detection by
fluorescence or chemiluminescence techniques, and an appropriate
glass transition temperature and chemical compatibility for PCR or
other amplification techniques. Preferably, the top layer 110 is
composed of a polypropylene-based polymer, but the top layer 110
may alternatively be composed of any appropriate material (e.g.
cyclic olefin polymer). In a specific embodiment, the top layer 110
is composed of 1.5 mm thick polypropylene produced by injection
molding, with a glass transition temperature between 136 and
163.degree. C. The top layer 110 may alternatively be composed of
any appropriate material, for example, a polypropylene based
polymer. As shown in FIGS. 1B and 1C, the top layer 110 preferably
comprises a set of sample port-reagent port pairs 112, a fluid port
118, a vent region 190, a heating region 195 crossing a capture
segment 166 of a fluidic pathway 165, and a set of detection
chambers 116.
[0022] Each sample-port-reagent port pair 113 of an embodiment of
the top layer 110 comprises a sample port 114 and a reagent port
115. The sample port 114 functions to receive a volume of a sample
fluid potentially containing the nucleic acids of interest for
delivery of the volume of fluid to a portion of a fluidic pathway
165 coupled to the sample port-reagent port pair 113. In a specific
embodiment, the volume of a sample fluid is a biological sample
with magnetic beads for nucleic acid isolation; however, the volume
of fluid comprising a sample fluid may alternatively be any
appropriate fluid containing a sample with nucleic acids.
Preferably, each sample port 114 is isolated from all other sample
ports, in order to prevent cross-contamination between samples of
nucleic acids being analyzed. Additionally, each sample port 114 is
preferably of an appropriate geometric size and shape to
accommodate a standard-size pipette tip used to deliver the volume
of a sample fluid without leaking. Alternatively, all or a portion
of the sample ports 114 are configured to be coupled to fluid
conduits or tubing that deliver the volume of a sample fluid.
[0023] Each sample-port reagent port pair 113 of an embodiment of
the top layer 110 also comprises a reagent port 115, as shown in
FIG. 1A. The reagent port 115 in a sample port-reagent port pair
113 functions to receive a volume of fluid comprising a reagent
used in molecular diagnostics, for delivery of the volume of fluid
comprising a reagent to a portion of a fluidic pathway 165 coupled
to the sample port-reagent port pair 113. In a specific embodiment,
the volume of fluid comprising a reagent used in molecular
diagnostics is a sample of reconstituted molecular diagnostic
reagents mixed with nucleic acids released and isolated using the
microfluidic cartridge 100; however, the volume of fluid comprising
a reagent used in molecular diagnostics may alternatively be any
appropriate fluid comprising reagents used in molecular
diagnostics. Preferably, each reagent port 115 is isolated from all
other reagent ports, in order to prevent cross-contamination
between samples of nucleic acids being analyzed. Additionally, each
reagent port 115 is preferably of an appropriate geometric size to
accommodate a standard-size pipette tip used to deliver the volume
of fluid comprising a reagent used in molecular diagnostics.
Alternatively, all or a portion of the reagent ports 115 are
configured to be coupled to fluid conduits or tubing that deliver
the volume of fluid comprising a reagent used in molecular
diagnostics.
[0024] Preferably, the set of sample port-reagent port pairs 112 is
located near a first edge of the top layer 110, such that the
configuration of the sample port-reagent port pairs 112 functions
to increase accessibility, for instance, by a pipettor delivering
fluids to the microfluidic cartridge 100. In one specific example,
the microfluidic cartridge 100 is configured to be aligned within a
module, with the set of sample port-reagent port pairs 112
accessible outside of the module, such that a multichannel pipette
head can easily access the set of sample port-reagent port pairs
112. Preferably, as shown in FIG. 1A, the set of sample
port-reagent port pairs 112 is configured such that the sample
ports 114 and the reagent ports 115 alternate along the first edge
of the top layer no. In an alternative embodiment, the set of
sample port-reagent port pairs 112 may not be located near an edge
of the top layer 110, and may further not be arranged in an
alternating fashion.
[0025] The fluid port 118 of the top layer 110 of the microfluidic
cartridge functions to receive at least one of a wash fluid, a
release fluid, and a gas used in a molecular diagnostic procedure,
such as PCR. In an embodiment, the wash fluid, the release fluid,
and/or the gas are common to all samples being analyzed during a
run of the diagnostic procedure using the microfluidic cartridge
100; in this embodiment, as shown in FIG. 1A, the fluid port 118 is
preferably a shared fluid port, fluidically coupled to all fluidic
pathways 165 coupled to the sample port-reagent port pairs 112, and
configured to deliver the same wash fluid, release fluid, and/or
gas through the shared fluid port. Alternatively, as shown in FIG.
2, the top layer may comprise more than one fluid port 118,
configured to deliver different wash fluids, release fluids, and/or
gases to individual or multiple fluidic pathways 165 coupled to the
set of sample port-reagent port pairs 112.
[0026] Preferably, the fluid port 118 is located along an edge of
the microfluidic cartridge 100, which functions to increase
accessibility to the fluid port by a system delivering fluids to
the fluid port 118. In a specific embodiment, as shown in FIG. 1A,
the fluid port is located approximately midway along an edge of the
microfluidic cartridge 100, different from the edge along which the
set of sample port-reagent port pairs 112 is located.
Alternatively, the fluid port 118 may not be located along an edge
of the microfluidic cartridge 100. Additionally, the fluid port 118
is preferably configured to be coupled to a syringe pump for fluid
delivery; however, the fluid port 118 may alternatively configured
to couple to any appropriate system for fluid delivery. Preferably,
the wash fluid is a wash buffer for washing bound nucleic acid
samples (i.e. nucleic acids bound to magnetic beads), the release
fluid is a reagent for releasing bound nucleic acids samples from
the magnetic beads, and the gas is pressurized air for moving
fluids and demarcating separate reagents. Alternatively, the wash
fluid, release fluid, and gas may be any appropriate liquids or
gases used to carry out a molecular diagnostic procedure.
[0027] The heating region 195 of the top layer 110 functions to
accommodate and position a heating element relative to elements of
the microfluidic cartridge 100. The heating element preferably
heats a defined volume of fluid and the magnetic beads, which has
traveled through the microfluidic cartridge 100, according to a
specific molecular diagnostic procedure protocol (e.g. PCR
protocol), and is preferably an element external to the
microfluidic cartridge 100; alternatively, the heating element may
be integrated with the microfluidic cartridge and/or comprise a
thermally conductive element integrated into the microfluidic
cartridge 100. The heating region 195 is preferably a recessed
fixed region of the top layer 110, downstream of the sample
port-reagent port pairs 112, as shown in FIGS. 1A and 1B.
Alternatively, the heating region may not be fixed and/or recessed,
such that the heating region 195 sweeps across the top layer 110 of
the microfluidic cartridge 100 as the heating element is moved. The
microfluidic cartridge 100 may altogether omit the heating region
195 of the top layer 110, in alternative embodiments using
alternative processes (e.g. chemical methods) for releasing nucleic
acids from nucleic acid-bound magnetic beads.
[0028] The vent region 190 of an embodiment of the top layer 110
functions to remove unwanted gases trapped within a fluidic pathway
165 of the microfluidic cartridge, and may additionally function to
position a defined volume of fluid within a fluidic pathway 165 of
the microfluidic cartridge. The vent region 190 is preferably
located downstream of the heating region 195 in an embodiment where
the heating region 195 is fixed on the top layer 110 of the
microfluidic cartridge 100, but alternatively may be located at
another appropriate position on the top layer 110 such that
unwanted gases are substantially removed from the microfluidic
cartridge 100 during analysis. The top layer 110 may alternatively
comprise more than one vent region 190 located at appropriate
positions in the top layer 110. Preferably, as shown in FIGS. 1A
and 1B, the vent region 190 is a recessed region in the top layer
110, and further comprises a film covering the vent region 190.
Preferably, the film covering the vent region 190 is a
gas-permeable but liquid-impermeable film, such that unwanted gases
may be released from the microfluidic cartridge 100, but fluids
remain within the microfluidic cartridge 100 and flow to the point
of contacting the film. This functions to remove unwanted gases and
position a defined volume of fluid within a fluidic pathway 165 of
the microfluidic cartridge. In a specific embodiment, the film
covering the vent region is a hydrophobic porous
polytetrafluoroethylene-based material, synthesized to be
gas-permeable but liquid-impermeable. Alternatively, the film
covering the vent region may be gas and liquid permeable, such that
unwanted gases and liquids are expelled from the microfluidic
cartridge 100 through the vent region 190. Other alternative
embodiments of the microfluidic cartridge 100 may altogether omit
the vent region.
[0029] The set of detection chambers 116 of an embodiment of the
top layer 110 functions to receive a processed nucleic acid sample,
mixed with molecular diagnostic reagents, for molecular diagnostic
analysis. Preferably, the set of detection chambers 116 is located
along an edge of the top layer 110, opposite the edge along which
the set of sample port-reagent port pairs 112 is located, which
allows sample fluids dispensed into the microfluidic cartridge 100
to be processed and mixed with molecular diagnostic reagents on
their way to a detection chamber 117 of the set of detection
chambers 116 and facilitates access to the detection chambers by
external elements performing portions of a molecular diagnostics
protocol (e.g. heating and optics systems). Alternatively, the set
of detection chambers 116 may not be located along an edge of the
top layer 110. In a first variation, as shown in FIGS. 1A and 11B,
each detection chamber 117 in the set of detection chambers
comprises a serpentine-shaped channel 16 for facilitating analysis
of a solution of nucleic acids mixed with reagents. In the first
variation, three portions of the serpentine-shaped channel 16 are
preferably wide and shallow to facilitate heating, and are
interconnected by two narrow portions, which function to increase
fluid flow resistance and reduce the proportion of nucleic acid not
contained within the detection area. The first variation functions
to facilitate filling of the set of detection chambers in a manner
that reduces the potential for trapped air bubbles, to facilitate
rapid molecular diagnostic techniques, and to comply with current
imaging technologies. In a specific example of the first variation,
each serpentine-shaped channel 16 is injected molded into the top
layer 110 of the microfluidic cartridge 100, and the three
interconnected portions of the serpentine-shaped channel 16 are
each 1600 .mu.m wide by 400 .mu.m deep.
[0030] In a second variation, each detection chamber 117 in the set
of detection chambers has a depth between 0.400 mm and 1.00 mm, and
a diameter between 3.50 mm and 5.70 mm, to provide a volumetric
configuration that facilitates reaction efficiency. In a specific
example of the second variation, each detection chamber 117 in the
set of detection chambers 116 is configured to contain a total
volume of 10 uL, and has a depth of 0.80 mm and a diameter of 3.99
mm; however, in alternative embodiments, each detection chamber 117
in the set of detection chambers 116 may be configured to contain a
total volume less than or greater than 10 uL.
[0031] Preferably, as shown in FIGS. 1A and 1B, the lower regions
of each detection chamber 117 in the set of detection chambers 116
includes a PCR compatible film that is thin, to facilitate
efficient thermocycling, and has low autofluorescence, to
facilitate light-based molecular diagnostic assays performed at the
set of detection chambers 116. The PCR compatible film is
preferably composed of a polypropylene based polymer thermally
bonded to the bottom of the top layer, but may alternatively be
composed of any appropriate PCR-compatible material and bonded in
any fashion. In one specific variation, the PCR compatible film is
a cyclic olefin polymer (COP) film, thermally bonded to the top
layer 110, with a glass transition temperature suitable for a
molecular diagnostic protocol. In one alternative embodiment,
depending on the configuration of imaging, heating, and/or cooling
elements external to the microfluidic cartridge 100, the top and/or
bottom of the detection chambers 117 in the set of detection
chambers 116 may be entirely formed of a clear or transparent
material (e.g. glass or plastic) allowing transmission of light. In
a variation of this alternative embodiment, lensing, other optical
components, or additional structures may also be incorporated into
the detection chambers, to facilitate light transmission and/or
focusing. In the variation of the alternative embodiment, a lens
may be manufactured (e.g. injection molded) directly to form a
surface of a detection chamber 117.
[0032] In the embodiment of the set of detection chambers 116 that
includes a PCR compatible film, the PCR compatible film may further
include a thermally conductive component, which functions to
transfer heat from a heating element to the detection chamber.
Depending on the position of the heating element(s) relative to the
microfluidic cartridge 100 during analysis, the thermally
conductive component of the PCR compatible film may be integrated
with just the upper region of each detection chamber, just the
lower region of each detection chamber, or both the upper and lower
regions of each Detection chamber. The thermally conductive
component of the PCR compatible film may comprise a wire mesh with
a substantially small wire diameter, as shown in FIG. 3, thermally
conductive particles distributed through the PCR compatible film
(in a manner that still allows for optical clarity), or any other
appropriate thermally conductive component (e.g. thermally
conductive beads integrated into the PCR compatible film). The
region laterally around the detection chamber may also further
include one or more heat-transfer elements or air channels speed
heat dissipation. Alternatively, a detection chamber 117 in the set
of detection chambers 116 may not include a PCR compatible film
with a thermally conductive component. Preferably, each detection
chamber 117 is heated using a diced silicon wafer with conductive
channels flip-chip bonded to a detection chamber to provide
resistive heating; however, each detection chamber 117 may
alternatively be heated using any appropriate heating device or
method, and may be assembled using any appropriate method.
[0033] Preferably, each detection chamber 117 in the set of
detection chambers 116 is thermally isolated from all other
detection chambers, in order to prevent contamination of data from
a detection chamber 117 due to heat transfer from other detection
chambers in the set of detection chambers 116. In one embodiment,
each detection chamber 117 of the set of detection chambers 116 is
spaced far from adjacent detection chambers to limit thermal
crosstalk. In another alternative embodiment, the top layer 110 may
comprises slots between adjacent detection chambers to separate the
detection chambers with an air gap. In one variation, thermal
isolation is achieved by surrounding the side walls of each
detection chamber 117 with a thermally insulating material, such as
an insulating epoxy, putty, filler, or sealant. In another
variation, the thermally insulating material has a low density,
which functions to reduce heat transfer from other detection
chambers. In yet another variation, thermal isolation is achieved
by geometrically separating or displacing the detection chambers
relative to each other within the top layer 110 of the microfluidic
cartridge 100, such that heat transfer between detection chambers
is hindered.
[0034] Preferably, each detection chamber 117 in the set of
detection chambers 116 is also optically isolated from all other
detection chambers, in order to prevent contamination of data from
a detection chamber 117 due to light transfer from other detection
chambers in the set of detection chambers 116. Preferably, optical
isolation is achieved with detection chambers having substantially
vertical walls, and separating each detection chamber 117 in the
set of detection chambers from each other. However, in one
variation, the sidewalls of each detection chamber 117 in the set
of detection chambers 116 are either composed of or surrounded by a
material with low autofluorescence and/or poor optical transmission
properties to achieve optical isolation. In another variation, the
sidewalls of each detection chamber 117 are surrounded by an
optically opaque material, thus allowing transmission of light to a
detection chamber 117 through only the top and bottom regions of
the detection chamber 117. Alternatively, the microfluidic
cartridge 100 may not further comprise any provisions for optical
isolation of each detection chamber 117 in the set of detection
chambers 116, aside from constructing the set of detection chambers
116 with a material having low autofluorescence.
[0035] Additionally, each detection chamber 117 in the set of
detection chambers 116 may be further optimized to meet volumetric
capacity requirements, facilitate high thermocycling rates,
facilitate optical detection, and facilitate filling in a manner
that limits bubble generation. Alternatively each detection chamber
117 in the set of detection chambers 116 may not be optimized to
meet volumetric capacity requirements, facilitate high
thermocycling rates, facilitate optical detection, and/or
facilitate filling in a manner that limits bubble generation.
[0036] The top layer 110 of the microfluidic cartridge 100 may
further comprise a set of cartridge-aligning indentations 180,
which function to align the microfluidic cartridge 100 as it moves
through an external module. As shown in FIG. 2 the set of
cartridge-aligning indentations 180 are preferably located such
that they do not interfere with any ports 112, 118, the heating
region, 195, the vent region 190, and/or the set of detection
chambers 116. In an embodiment, the top layer 110 of the
microfluidic cartridge preferably comprises at least four
cartridge-aligning indentations, located at points on the periphery
of the top layer 110, and the cartridge-aligning indentations are
configured to be recessed regions configured to mate with alignment
pins in a system external to the microfluidic cartridge 100.
Alternatively, the cartridge-aligning indentations may be grooves,
such that the microfluidic cartridge 100 accurately slides into
position along the grooves within a system external to the
microfluidic cartridge 100. In yet another alternative embodiment,
the set of cartridge-aligning indentations 180 may be any
appropriate indentations that allow for positioning of the
microfluidic cartridge 100 within an external system. However, the
microfluidic cartridge 100 may altogether omit the set of
cartridge-aligning indentations 180, and rely upon other features
of the microfluidic cartridge 100 to facilitate alignment.
1.2 Microfluidic Cartridge--Intermediate Substrate
[0037] As shown in FIG. 1B, an embodiment of the microfluidic
cartridge also comprises an intermediate substrate 120, coupled to
the top layer 110 and partially separated from the top layer 110 by
a film layer 125, configured to form a waste chamber 130. The
intermediate substrate 120 functions to serve as a substrate to
which layers of the microfluidic cartridge may be bonded, to
provide guides for the valve pins, and to provide a waste chamber
volume into which a waste fluid may be deposited. Preferably, the
depth of the intermediate substrate 120 provides a waste chamber
volume adequate to accommodate the volume of waste fluids generated
within the microfluidic cartridge 100. Additionally, the depth of
the intermediate substrate 120 provides a low profile for the
microfluidic cartridge 100 to facilitate movement throughout a
compact molecular diagnostic system. Preferably, the intermediate
substrate 120 of the microfluidic cartridge 100 is also configured
such that the footprint of microfluidic cartridge 100 adheres to
microtiter plate standards, to facilitate automated handling of the
microfluidic cartridge 100. The intermediate substrate 120 is
preferably composed of a low-cost, structurally stiff material,
such as polypropylene. However, similar to the top layer 120, the
intermediate substrate may be alternatively composed of a
structurally stiff material with low autofluorescence, such that
the intermediate substrate 120 does not interfere with sample
detection by fluorescence techniques, and an appropriate glass
transition temperature for PCR techniques. In one variation of this
alternative embodiment, the intermediate substrate 120 is composed
of a cyclic olefin polymer (COP), produced by injection molding,
with a glass transition temperature between 136 and 163.degree. C.
In yet another alternative embodiment, the intermediate substrate
120 may be composed of any appropriate material, for example, a
polycarbonate based polymer.
[0038] Preferably, the intermediate substrate 120 of the
microfluidic cartridge 100 is coupled to the top layer 110 and
partially separated from the top layer 110 by a film layer 125. The
film layer 125 functions to isolate individual fluidic pathways 165
of the microfluidic cartridge, to prevent leakage, to provide an
appropriate environment for sample processing and conducting a
molecular diagnostic protocol, and to provide access between a
microfluidic channel (of a fluidic pathway 165) above the film
layer 125 and elements below the film layer 125 (e.g. waste chamber
and/or fluidic pathway occluder). Preferably, the film layer is a
polypropylene (PP) with an appropriate glass transition
temperature, such that it is PCR compatible and thermally bondable
to the top layer 110; however, the film layer may alternatively be
any appropriate material. In a specific embodiment, the film layer
125 is a polypropylene film between 30 and 100 microns thick and
die cut to produce openings at a set of occlusion positions, to
provide access between a microfluidic channel of a fluidic pathway
165 above the film layer 125 and elements below the film layer 125.
In this specific embodiment, the openings are slightly oversized
prior to assembly, in order to allow for constriction during
assembly (due to thermal and pressure effects) and to provide
higher tolerance during assembly of microfluidic cartridge layers.
Alternatively, the film layer is any appropriate material such that
it substantially isolates individual fluidic pathways, and is
easily processable to provide access between a microfluidic channel
of a fluidic pathway 165 above the film layer and elements below
the film layer 125.
[0039] Preferably, the top layer 110, the film layer 125, and the
intermediate substrate are bonded together, such that the top layer
110, film layer, 125, and intermediate substrate form a bonded unit
with a hermetic seal to prevent fluid leakage. A hermetic seal is
preferably formed using a silicone rubber layer coupled to the film
layer 125, but may alternatively be formed using an alternative
material or method. In a specific embodiment, a hermetic seal
formed using a silicone rubber layer is only required at locations
of openings within the film layer (e.g., at locations where an
external occluder interacts with the microfluidic cartridge).
Preferably, in an embodiment where the top layer 110, the film
layer 125, and the intermediate substrate 120 are substantially
identical materials (e.g. polypropylene), at least one of thermal
bonding, adhesives, and ultrasonic welding are used to coupled the
layers 110, 125, 120 together. In an embodiment where the top layer
110, the film layer 125, and the intermediate substrate 120 are
substantially different materials--a combination of thermal bonding
methods and adhesives may be used to bond the top layer 110, the
film layer 125, and the intermediate substrate 120 of the
microfluidic cartridge 100 together. In an alternative embodiment,
the top layer 110, the film layer 125, and the intermediate
substrate 120 of the microfluidic cartridge 100 may be thermally
bonded together in a single step. In yet another alternative
embodiment, the top layer 110, the film layer 125, and the
intermediate substrate 120 may alternatively be modular, in
applications where a portion of the microfluidic cartridge 100 is
partially reusable (e.g. in an application where the waste chamber
may be discarded after use, but the top layer and film may be
reused). In yet another alternative embodiment, the top layer 110,
the film layer 125, and the intermediate substrate 120 may only be
partially bonded, such that a molecular diagnostic system, into
which the microfluidic cartridge 100 is loaded, is configured to
compress the top layer 110, the film layer 125, and the
intermediate substrate 120 together, preventing any fluid
leakage.
[0040] As shown in FIG. 1B, the intermediate substrate 120 of an
embodiment of the microfluidic cartridge 100 is configured to form
a waste chamber 130, which functions to receive and isolate waste
fluids generated within the microfluidic cartridge 100. The waste
chamber 130 is preferably continuous and accessible by each fluidic
pathway 165 of the microfluidic cartridge 100, such that all waste
fluids generated within the microfluidic cartridge 100 are
deposited into a common waste chamber; however, each fluidic
pathway 165 of the microfluidic cartridge 100 may alternatively
have its own corresponding waste chamber 130, such that waste
fluids generated within a fluidic pathway 165 of the microfluidic
cartridge 100 are isolated from waste fluids generated within other
fluidic pathways 165 of the microfluidic cartridge 100. In a
specific embodiment of the microfluidic cartridge 100 with a
continuous waste chamber, the waste chamber has a volumetric
capacity of approximately 25 mL; however, the waste chamber 130 of
another embodiment may have a different volumetric capacity. The
intermediate substrate 120 further comprises a waste vent 135,
which provides access between a microfluidic channel of a fluidic
pathway 165 above the film layer 125 and the waste chamber 130.
Preferably, the intermediate substrate 130 comprises more than one
waste inlet 136, such that the waste chamber is accessible at more
than one location along a fluidic pathway 165 through the waste
inlets 136. Alternatively, the intermediate substrate 120 may
include a single waste inlet 136, such that all waste fluids
generated within the microfluidic cartridge 100 are configured to
travel through the single waste inlet 136 into the waste chamber
130. Also, as shown in FIG. 1B, the intermediate substrate 120 may
comprise a waste vent 131, such that the waste chamber 130 is
vented to prevent pressure build up in the waste chamber as waste
fluid is added.
[0041] As shown in FIGS. 1B and 4, the waste chamber 130 formed by
the intermediate substrate 120 preferably has a corrugated surface
137, such that the waste chamber 130 is not only configured to
receive and isolate a waste fluid, but also functions to 1) provide
structural stability for the microfluidic cartridge 100 and 2)
allow elements external to the microfluidic cartridge 100 to enter
spaces formed by the corrugated surface 137, for greater
accessibility to elements of the microfluidic cartridge 100. Also
shown in FIGS. 1B and 4, each of the ridges in the corrugated
surface 137 may not have the same dimensions, as a result of the
locations of elements within and external to the microfluidic
cartridge 100. In an embodiment of the waste chamber 130 with a
corrugated surface 137, at least two ridges of the corrugated
surface 137 are preferably the same height, such that the
microfluidic cartridge 100 sits substantially level on a flat base.
In an alternative embodiment, all ridges of the corrugated surface
137 of the waste chamber 130 are identical, for structural
symmetry, and in yet another embodiment, the waste chamber 130 may
not have a corrugated surface 137.
[0042] In one preferred embodiment, the intermediate substrate 120
of the microfluidic cartridge 100 further comprises a set of valve
guides, which function to direct a series of external pins or other
indenters through the valve guides at a set of occlusion positions
141, thus affecting flow through a microfluidic channel of a
fluidic pathway 165 at the set of occlusion positions 141. The set
of valve guides 127 may also function to facilitate alignment of
the microfluidic cartridge 100 within an external molecular
diagnostic module. In a first embodiment, as shown in FIG. 1B, the
set of valve guides 127 comprises holes within the intermediate
substrate 120 at the set of occlusion positions 141, with sloped
edges configured to direct a pin or indenter through the holes. In
the first embodiment, the set of valve guides 127 may be produced
in the intermediate substrate 120 by injection molding, or may
alternatively be produced by drilling, countersinking, chamfering,
and/or beveling. In another embodiment, the set of valve guides 127
comprises grooves with holes, such that a pin or indenter is
configured to travel along a groove and through a hole that defines
the valve guide. In a simplified alternative variation, the set of
valve guides 127 may comprise holes through the intermediate
substrate 120, wherein the holes do not have sloped edges. In yet
another simplified alternative variation, the set of valve guides
127 may comprise a slot configured to provide access to the
elastomeric layer 140 by a group of occluding objects (e.g. pins or
indenters), rather than a single occluding object.
1.3 Microfluidic Cartridge--Elastomeric and Bottom Layers
[0043] As shown in FIGS. 1B and 5A-5D, an embodiment of the
microfluidic cartridge 100 also comprises an elastomeric layer 140
partially situated on the intermediate substrate 120, which
functions to provide a deformable substrate that, upon deformation,
occludes a microfluidic channel of a fluidic pathway 165 contacting
the elastomeric layer 140 at an occlusion position of a set of
occlusion positions 141. Preferably, the elastomeric layer 140
comprises an inert, liquid impermeable material, of an appropriate
thickness, that can be heated to temperatures encountered during
manufacturing and/or specified in a molecular diagnostic protocol,
without substantial damage (i.e. compromised surface and/or loss of
mechanical robustness) and is chemically compatible with a PCR
assay. Preferably, the elastomeric layer 140 is non-continuous,
such that portions of the elastomeric layer 140 are positioned
relative to the intermediate substrate 120 in a manner that
directly covers holes provided by the set of valve guides 127.
Alternatively, the elastomeric layer 140 is a continuous layer,
spanning a majority of the footprint of the microfluidic cartridge
100 while covering holes provided by the set of valve guides 127.
In a specific embodiment, the elastomeric layer 140 comprises 500
micron thick strips of a low-durometer silicone that can be heated
to at least 120.degree. C. without substantial damage, which are
bonded to a portion of the intermediate substrate 120 using a
silicone-based adhesive and slightly compressed between the film
layer 125 and the intermediate substrate 120. In a variation of the
specific embodiment, the elastomeric layer 140 may alternatively be
held in place solely by pressure between the intermediate layer 120
and the top layer 110. Preferably, the elastomeric layer 140 is
reversibly deformable over the usage lifetime of the microfluidic
cartridge 100, such that any occlusion of a microfluidic channel of
a fluidic pathway 165 contacting the elastomeric layer 140 is
reversible over the usage lifetime of the microfluidic cartridge.
Alternatively, the elastomeric layer 140 may not be reversibly
deformable, such that an occlusion of a microfluidic channel of a
fluidic pathway 165 contacting the elastomeric layer 140 is not
reversible.
[0044] The set of occlusion positions 141 preferably comprises at
least two types of occlusion positions, as shown in FIG. 1C,
including a normally open position 42 and a normally closed
position 43. As shown in FIGS. 5A-5D, the elastomeric layer 140 at
a normally open position 42 of the set of occlusion positions 141
may be closed upon occlusion by an occluding object (FIGS. 5B and
5D). Preferably, a normally open position 42 is configured to
withstand pressures that can be generated by a fluid delivery
system (e.g. a syringe pump) without leaking, upon occlusion by an
occluding object at the normally open position 42. In one specific
example, a 1/2 barrel-shaped pin head may be used to fully occlude
a normally open position 42 having an arched cross section, as in
FIG. 5C, with near constant pressure on the portion of the
elastomeric layer compressed between the occluding object and
occluding position.
[0045] The normally closed position 43 of the set of occlusion
positions 141, functions to be normally closed, but to be forced
open in response to fluid delivery by a fluid delivery system. In
one variation, the normally closed position 43 may be formed by
manufacturing (e.g. injection molding) the top layer 100, such that
the top layer material at a normally closed position 43 extends
down to the elastomeric layer 140. If an occluding object is held
away from the normally closed position 43, the occlusion position
is closed, but can be forced open due to fluid pressure applied by
a fluid delivery system (e.g. syringe pump). When not in operation,
however, the normally closed position 43 is configured to prevent
leakage and/or fluid bypass. The normally closed position may also
be held closed by an occluding object, to prevent leakage even
under pressure provided by a fluid delivery system, or under
pressure experienced during a high temperature step (e.g.,
thermocycling) to prevent evaporation of a sample undergoing
thermocycling.
[0046] The microfluidic cartridge 100 may further comprise a bottom
layer 170 configured to couple to the intermediate substrate, which
functions to allow waste to be contained within the microfluidic
cartridge 100, and allow microfluidic cartridges to be stacked. The
bottom layer thus facilitates reception, isolation, and containment
of a waste fluid within the waste chamber. Preferably, the bottom
layer 170 is composed of the same material as the intermediate
substrate 120 for cost and manufacturing considerations, and bonded
to the intermediate substrate 120 in a manner that provides a
hermetic seal, such that a liquid within the waste chamber 130 does
not leak out of the waste chamber 130. In a specific embodiment,
the bottom layer 170 and the intermediate substrate 120 are both
composed of a polypropylene-based material, and bonded together
using an adhesive. In an embodiment of the microfluidic cartridge
100 where the waste chamber 130 has a corrugated surface, the
bottom layer 170 preferably only seals voids defining the waste
chamber 130, such that non-waste chamber regions (i.e. non-waste
housing regions) are not covered by the bottom layer 170.
Alternatively, the microfluidic cartridge 100 may omit the bottom
layer 170, such that any waste fluid that enters the waste chamber
130 completely leaves the microfluidic cartridge 100 and is
collected off-cartridge by a waste-collecting subsystem of an
external molecular diagnostic system. In this alternative
embodiment, the intermediate substrate 120 is configured to
fluidically couple to the waste-collecting subsystem.
1.4 Microfluidic Cartridge--Magnet Housing
[0047] The magnet housing region 150 of the microfluidic cartridge
100 functions to provide access to and/or house at least one magnet
152 providing a magnetic field 156 for purification and isolation
of nucleic acids. Preferably, the magnet housing region 150 is
defined by the film layer and the intermediate substrate, such that
the film layer and the intermediate substrate form the boundaries
of the magnet housing region 150. In an embodiment of the
microfluidic cartridge 100 comprising a bottom layer 170, the
magnet housing region 150 may further be defined by the bottom
layer 170, such that the bottom layer partially forms a boundary of
the magnet housing region 150. The magnet housing region 150 is
preferably a rectangular prism-shaped void in the microfluidic
cartridge 150, and accessible only through one side of the
microfluidic cartridge 100, as shown in FIG. 1B. Preferably, the
magnet housing region 150 can be reversibly passed over a magnet
152 to house the magnet 152, and retracted to remove the magnet 152
from the magnet housing region 150; however, the magnet 152 may
alternatively be irreversibly fixed within the magnet housing
region 150 once the magnet 152 enters the magnet housing region
150.
[0048] Preferably, the magnet housing region 150 is bounded on at
least two sides by the waste chamber 130, and positioned near the
middle of the microfluidic cartridge 100, such that a fluidic
pathway 165 passing through the magnetic field 156 passes through
the magnetic field 156 at least at one point along an intermediate
portion of the fluidic pathway 165. Preferably, the magnet housing
region 150 also substantially spans at least one dimension of the
microfluidic cartridge, such that multiple fluidic pathways 165 of
the microfluidic cartridge 100 cross the same magnet housing region
150, magnet 152, and/or magnetic field 156. Alternatively, the
magnet housing region 150 may be configured such that a magnet
within the magnet housing region 150 provides a magnetic field
spanning all fluidic pathways 165 of the microfluidic cartridge in
their entirety. In alternative embodiments, the microfluidic
cartridge may comprise more than one magnet housing region 150, a
magnet housing region 150 may be configured to receive and/or house
more than one magnet 152, and/or may not be positioned near the
middle of the microfluidic cartridge 100. In yet another
alternative embodiment, the magnet housing region 150 may
permanently house a magnet 152, such that microfluidic cartridge
comprises a magnet 152, integrated with the intermediate substrate
120. In embodiments where the magnet 152 is retractable from the
microfluidic cartridge 100, the magnet 152 may be a permanent
magnet or an electromagnet. In embodiments where the magnet 152 is
configured to be integrated with the microfluidic cartridge 100,
the magnet 152 is preferably a permanent magnet, which provides a
stronger magnetic field per unit volume.
1.5 Microfluidic Cartridge--Fluidic Pathways
[0049] The set of fluidic pathways 160 of the microfluidic
cartridge 100 functions to provide a fluid network into which
volumes of sample fluids, reagents, buffers and/or gases used in a
molecular diagnostics protocol may be delivered, out of which waste
fluids may be eliminated, and by which processed nucleic acid
samples may be delivered to a detection chamber for analysis, which
may include amplification and/or detection. Preferably, each
fluidic pathway 165 in the set of fluidic pathways 160 is formed by
at least a portion of the top layer, a portion of the film layer,
and a portion of the elastomeric layer 140, such that each fluidic
pathway 165 may be occluded upon deformation of the elastomeric
layer 140 at a set of occlusion positions 141. Additionally, at
least one fluidic pathway 165 in the set of fluidic pathways 160 is
preferably fluidically coupled to a sample port-reagent port pair
113 of the set of sample port-reagent port pairs 112, a fluid port
118, a waste chamber 130, and a detection chamber 117 of the set of
detection chambers 116. Furthermore, at least one fluidic pathway
165 in the set of fluidic pathways 160 is preferably configured to
be occluded upon deformation of the elastomeric layer 140,
configured to transfer a waste fluid to the waste chamber 30,
comprises a capture segment 166 passing through the heating region
195 and a magnetic field 156, and is configured to pass through the
vent region 190 upstream of a detection chamber 117. Alternative
embodiments may omit preferred elements of the embodiment of the
fluidic pathway 165 described above, such as a vent region 190 or a
heating region 195, or add additional elements to the embodiment of
the fluidic pathway 165 described above.
[0050] A fluidic pathway 165 of the set of fluidic pathways 160 may
comprise portions (i.e. microfluidic channels) that are located on
both sides of the top layer 110, but is preferably located
primarily on the bottom side of the top layer (in the orientation
shown in FIG. 1B). In the orientation of the microfluidic cartridge
100 shown in FIG. 1B, a microfluidic channel on top of the top
layer 110 may be further covered by second film layer 168 that
seals the microfluidic channel on top of the top layer 110. The
second film layer 168 may be comprise a cyclic olefin polymer (COP)
film, thermally or adhesively bonded to the top layer 110, or
alternatively may comprise another material that is bonded to the
top layer 110. The use of film layers 125, 168 to cover
microfluidic channels on either side of the top layer 110
facilitates manufacturing, such that long stretches of a fluidic
pathway 165 do not need to be produced within the interior of the
top layer 110. Preferably, microfluidic channels may be etched,
formed, molded, cut, or otherwise shaped into the rigid structure
of the top layer 110, and either remain on one side of the top
layer 110, or pass through the thickness of the top layer 110.
[0051] In one variation, in the orientation of the microfluidic
cartridge 100 shown in FIG. 11B, a fluidic pathway 165 is
preferably located primarily on the bottom side of the top layer
110, comprising a segment running to a vent region 190 on the top
side of the top layer 110. All other segments of the fluidic
pathway 165 are preferably located on the bottom side of the top
layer 110, allowing the fluidic pathway 165 to be sealed by the
film layer 125 without requiring a separate film layer to seal
channels located on the top of the top layer 110.
[0052] In another variation, in the orientation of the microfluidic
cartridge 100 shown in FIG. 1B, a fluidic pathway 165 is preferably
located primarily on the bottom side of the top layer 110,
comprising a segment running to a detection chamber 163 on the top
side of the top layer 110 and a segment running away from the
detection chamber 164 on the top side of the top layer 110. In this
variation, the fluidic pathway 165 thus crosses the thickness of
the top layer 110 upstream of the first segment running to the
detection chamber 163, and crosses the thickness of the top layer
110 downstream of the segment running away from the detection
chamber 164, and crosses the thickness of the top layer 110 to
couple to a sample port 114 and a reagent port 115 on the top side
of the top layer 110. In another variation, as shown in FIG. 6C, a
fluidic pathway 165 is preferably located primarily on the bottom
side of the top layer 110, comprising only a segment running away
from the detection chamber 164 on the top side of the top layer
110. In this other variation, the fluidic pathway 165 thus crosses
the thickness of the top layer 110 downstream of the second
portion, and crosses the thickness of the top layer 110 to couple
to a sample port 114 and a reagent port 115 on the top side of the
top layer 110. Alternatively, other embodiments may comprise a
fluidic pathway 165 with a different configuration of portions on
the top side of the top layer 110 and/or portions on the bottom
side of the top layer 110.
[0053] As shown in FIGS. 1C, 6C, 7 and 9, a fluidic pathway 165 of
the set of fluidic pathways 160 is branched and preferably
comprises an initial segment 174 fluidically coupled to a fluid
channel 119 coupled to a fluid port 118, a sample segment 175
coupled to a sample port 114, a reagent segment 176 coupled to a
reagent port 115, a capture segment 166 passing through at least
one of the heating region 195 and a magnetic field 156, a vent
segment 177 configured to pass through the vent region 190, a
segment running to a detection chamber 163, a segment running away
from the detection chamber 164, and at least one waste segment 178,
179 configured to transfer a waste fluid to a waste chamber 130.
Individual segments of the fluidic pathway 165 are preferably
configured to pass through at least one occlusion position of the
set of occlusion positions 141, to controllably direct fluid flow
through portions of the fluidic pathway 165. A fluidic pathway 165
may also further comprise an end vent 199, which functions to
prevent any fluid from escaping the microfluidic channel.
[0054] The initial segment 174 of the fluidic pathway 165 functions
to deliver common liquids and/or gases from a fluid port 118
through at least a portion of the fluidic pathway 165, the sample
segment 175 functions to deliver a volume of a sample fluid (e.g.
sample comprising nucleic acids bound to magnetic beads) to a
portion of the fluidic pathway 165, and the reagent segment 176
functions to deliver a volume of fluid comprising a reagent to a
portion of the fluidic pathway 165. The capture segment 166
functions to facilitate isolation and purification of nucleic acids
from the volume of the sample fluid, and may be s-shaped and/or
progressively narrowing, to increase the efficiency and/or
effectiveness of isolation and purification. Alternatively, the
capture segment 166 may altogether be replaced by a substantially
straight portion 166 or any other geometric shape or configuration
that functions to facilitate isolation and purification of nucleic
acids from the volume of the sample fluid. The capture segment 166
of the fluidic pathway 165 preferably has an aspect ratio less than
one, which functions to facilitate capture of magnetic particles,
but may alternatively have an aspect ratio that is not less than
one.
[0055] The vent segment 177 functions to deliver a processed sample
fluid through the vent region 190 for gas removal. The segment
running to a detection chamber 163 functions to deliver a processed
sample fluid to the detection chamber 117 with a reduced quantity
of gas bubbles, and the segment running away from the detection
chamber 164 functions to deliver a fluid away from the detection
chamber 117. The segments may be arranged in at least one of
several configurations to facilitate isolation, processing, and
amplification of a nucleic acid sample, as described in three
exemplary embodiments below:
[0056] A first embodiment, as shown in FIG. 1C, of a fluidic
pathway 165 preferably comprises an initial segment 174 fluidically
coupled to a fluid channel 119 coupled to a shared fluid port 118,
a sample segment 175 coupled to a sample port 114 and to the
initial segment 174, and an s-shaped capture segment 166,
configured to pass through the heating region 195 and a magnetic
field 156, coupled to the initial segment 174 and the sample
segment 175. In a variation of the first embodiment, the s-shaped
capture segment 166 may comprise an initial wide arc 166 to provide
a greater surface area for magnetic bead capture. In another
variation of the first embodiment, the capture segment 166 may
alternatively be a progressively narrowing s-shaped capture segment
166. The first embodiment of the fluidic pathway 165 also comprises
a reagent segment 176 coupled to a reagent port 115 and to the
capture segment 166, a vent segment 177 coupled to the reagent
segment 176 and configured to pass through the vent region 190, a
segment running to a detection chamber 163 from the vent region
190, a winding segment running away from the detection chamber 164,
and an end vent 199 coupled to the segment running away from the
detection chamber 164. The first embodiment of the fluidic pathway
165 also comprises a first waste segment 178 configured to couple
the initial segment 174 to the waste chamber 130, and a second
waste segment 179 configured to couple the capture segment 166 to
the waste chamber 130. The first waste segment 178 preferably
functions to allow evacuation of excess release fluids from a
fluidic pathway 165, for precise metering of the amount of release
reagents used in a molecular diagnostic procedure using a low
volume of sample.
[0057] In the first embodiment, the set of occlusion positions 141
comprises a first occlusion position 142 located along the initial
segment 174 between points at which the initial segment couples to
the fluid channel 119 and to the capture segment 166. The set of
occlusion positions 141 also comprises a second occlusion position
143 located along the sample segment 175, a third occlusion
position 144 located along the reagent segment 176, a fourth
occlusion position 145 located along the first waste segment 178,
and a fifth occlusion position 146 located along the second waste
segment 179. In the first embodiment, the set of occlusion
positions 141 also comprises a sixth occlusion position 147 located
along the vent segment 177 upstream of the vent region 190, a
seventh occlusion position 148 located along the segment running to
the detection chamber 163, and an eighth occlusion position 149
located along the segment running away from the detection chamber
164. In the first embodiment, the first, second, third, fifth, and
sixth occlusion positions 142, 143, 144, 146, 147 are normally open
positions 42 and the fourth, seventh, and eighth occlusions
positions 145, 148, 149 are normally closed positions 43, as shown
in FIG. 1C.
[0058] The occlusion positions of the set of occlusion positions
141 of the first embodiment are preferably located such that
occluding subsets of the set of occlusion positions 141 defines
unique truncated fluidic pathways to controllably direct fluid
flow. For example, as shown in FIG. 1D, occluding the fluidic
pathway 165 at the first, third, fourth, and sixth occlusion
positions 142, 144, 145, 147 forms a truncated pathway by which a
volume of a sample fluid, comprising nucleic acids bound to
magnetic beads and delivered into the sample port 114, may flow
past the second occlusion positions 143 into the capture segment
166 for isolation and purification of nucleic acids using the
heating region 195 and the magnetic field 156. Nucleic acids bound
to magnetic beads may thus be trapped within the capture segment
166 by the magnetic field 156, while other substances in the volume
of sample fluid may pass into the waste chamber 130 by passing the
fifth occlusion position 146. Following this subset of occlusion
positions, the occlusion at the first occlusion position 142 may be
reversed, as shown in FIG. 1E, and the fluidic pathway 165 may be
occluded at the second occlusion position 143 to form a second
truncated pathway by which a wash fluid may be delivered through
the fluid port 118, into the capture segment 166 (thus washing the
trapped magnetic beads), and into the waste chamber 130 by passing
the fifth occlusion position 146. The occlusion at the second
occlusion position 143 may then be reversed, and the first
occlusion position 142 may be occluded (as shown in FIG. 1D), so
that other fluidic pathways in the set of fluidic pathways 160 may
be washed. After all fluidic pathways have been washed, a volume of
air may be transferred through the fluid port 118 to prevent
mixture of a wash solution with a release solution.
[0059] Thereafter in the first embodiment, as shown in FIG. 1E, the
fluidic pathway 165 may be occluded at the second occlusion
position 143 and the occlusion at the first occlusion 142 may be
reversed, thus creating a third truncated pathway as shown in FIG.
1D. A release solution may then be delivered through the fluid port
118, into the capture segment 166, and to the waste chamber 130 by
passing the fifth occlusion position 146. The release solution may
then be sealed within a fourth truncated pathway (including the
capture segment 166) of the fluidic pathway 165 by occluding the
fluidic pathway at the fifth occlusion position 146, as shown in
FIG. 1F. A release solution may then be delivered to other fluidic
pathways of the set of fluidic pathways 160.
[0060] Thereafter, as shown in FIG. 1G, the occlusion at the fourth
occlusion position 145 may be reversed, creating a fifth truncated
pathway, and release solution within the fluidic pathway 165 may be
metered by pumping air through the fluid port 118, which functions
to push a portion of the release solution into the waste chamber
130. A volume of release solution will still be maintained within
the capture segment 166 at this stage. As shown in FIG. 1H, the
first and the fourth occlusion positions 142, 145 may then be
occluded to form a sixth truncated pathway sealing the volume of
release solution, with the captured magnetic beads bound to nucleic
acids, within the capture segment 166. The volume of the remaining
release solution is therefore substantially defined by the
microchannel volume between junctions in the fluidic pathway 165
near the fourth and sixth occlusion positions 145, 147, and may be
any small volume but in a specific variation is precisely metered
to be 23+/-1 microliters. Release solution may be sealed within
capture segments of other fluidic pathways using a similar process.
A heater may then be provided at the sixth truncated pathway,
inducing a pH shift within the sixth truncated pathway to unbind
nucleic acids from the magnetic beads.
[0061] Thereafter in the first embodiment, as shown in FIG. 1I, the
occlusions at the first and third occlusion positions 142, 144 may
be reversed, defining a seventh truncated pathway, and the entire
released nucleic acid sample (e.g. .about.20 microliters) may be
aspirated out of the microfluidic cartridge through the reagent
port 115. This released nucleic acid sample is then used to
reconstitute a molecular diagnostic reagent stored off of the
microfluidic cartridge 100. During the reconstitution, the
occlusion at the sixth occlusion position 147 may be reversed, and
the fluidic pathway 165 may be occluded at the first occlusion
position 142 to form an eighth truncated pathway, as shown in FIG.
1J. Once reconstitution of the molecular diagnostic reagent with
the released nucleic acid sample is complete and well mixed, the
reconstituted mixture may then be dispensed through the reagent
port 115, through the eighth truncated pathway, and to the
detection chamber 117, by using a fluid handling system to push the
seventh occlusion position (normally closed) open. The detection
chamber 117 is completely filled with the mixed reagent-nucleic
acid sample, after which the fluidic pathway 165 is occluded at the
third, sixth, seventh and eighth occlusion positions 144, 147, 148,
149, defining ninth truncated pathway, as shown in FIG. 1K. Other
pathways of the set of fluidic pathways 165 may be similarly
configured to receive a reagent-nucleic acid mixture. An external
molecular diagnostic system and/or module may then perform
additional processes, such as thermocycling and detection, on the
volume of fluid within the detection chamber 117.
[0062] An alternative variation of the first embodiment may further
comprise additional occlusion positions or alternative variations
of the set of occlusion positions 141, such that occlusion at the
additional occlusion positions permanently seals the waste chamber
from the fluidic pathway 165. Other alternative variations of the
first embodiment may also comprise configurations of the set of
occlusion positions 141 that are different than that described
above. The variations may be configured, such that the a fluidic
pathway 165 facilitates meter release, does not allow meter
release, facilitates addition of other reagents (e.g.
neutralization or DNase reagents), facilitates additional washing
steps, and/or facilitates other operations without changing the
layout of the fluidic pathway 165 of a microfluidic cartridge
embodiment. Thus, multiple unique operations may be performed using
the same microfluidic cartridge, by occluding fluidic pathways 160
at varied subsets of a set of occlusion positions 141.
[0063] A second embodiment, as shown in FIG. 6C, of a fluidic
pathway 165' preferably comprises an initial segment 174'
fluidically coupled to a fluid channel 119' coupled to a shared
fluid port 118', a sample segment 175' coupled to a sample port
114' and to the initial segment 174', and a capture segment 166',
configured to pass through the heating region 195 and a magnetic
field 156, coupled to the initial segment 174'. The second
embodiment of the fluidic pathway 165' also comprises a reagent
segment 176' coupled to a reagent port 115' and to the turnabout
portion 176', a vent segment 177' coupled to the reagent segment
176' and to the capture segment 166' and configured to pass through
the vent region 190, a segment running to a detection chamber 163'
from the vent region 190, a segment running away from the detection
chamber 164', and an end vent 199 coupled to the segment running
away from the detection chamber 164'. The second embodiment of the
fluidic pathway 165' also comprises a first waste segment 178',
coupled to the initial segment 174' at a point between points
connecting the initial segment 174' to the sample segment 175' and
to the capture segment 166'. The first waste segment 178' is
configured to couple the initial segment 174' to the waste chamber
130. The second embodiment of the fluidic pathway 165' also
comprises a second waste segment 179' configured to couple the
capture segment 166' to the waste chamber 130', and an end vent
segment 197' coupled to the capture segment 166' downstream of the
point of connection to the second waste segment 179', and coupled
to an end vent 199. The end vent segment 197' functions to provide
fine metering of a fluid flowing through the fluidic pathway
165'.
[0064] In the second embodiment, the set of occlusion positions
141' comprises a first occlusion position 142' located along the
initial segment 174' between points at which the initial segment
couples to the fluid channel 119' and to the sample segment 175'.
The set of occlusion positions 141' also comprises a second
occlusion position 143' located along the sample segment 175', a
third occlusion position 144' located along the reagent segment
176', a fourth occlusion position 145' located along the first
waste segment 178', and a fifth occlusion position 146' located
along the second waste segment 179'. In the second embodiment, the
set of occlusion positions 141' also comprises a sixth occlusion
position 147' located along the vent segment 177' upstream of the
vent region 190, a seventh occlusion position 148' located along
the segment running to the detection chamber 163', and an eighth
occlusion position 149' located along the segment running away from
the detection chamber 164'. Additionally, in the second embodiment,
the set of occlusion positions 141 comprises a ninth occlusion
position 157' located along the sample segment 175' between the
sample port 114 and the second occlusion position 143, a tenth
occlusion position 158' located along the end vent segment 197',
and an eleventh occlusion position 159' located along the capture
segment 166' between points at which the capture segment 166'
couples to the end vent segment 197' and to the vent segment
177'.
[0065] The occlusion positions of the set of occlusion positions
141' of the second embodiment are preferably located such that
occluding of subsets of the set of occlusion positions 141' defines
unique truncated fluidic pathways to controllably direct fluid
flow. For example, occluding the fluidic pathway 165' at the first,
fourth, sixth, tenth, and eleventh occlusion positions 142', 145',
147', 158', 159' forms a truncated pathway by which a volume of a
sample fluid, comprising nucleic acids bound to magnetic beads and
delivered into the sample port 114, may flow into the capture
segment 166' for isolation and purification of nucleic acids using
the heating region 195 and the magnetic field 156. Nucleic acids
bound to magnetic beads may thus be trapped within the capture
segment 166' by the magnetic field 156, while other substances in
the volume of sample fluid may pass into the waste chamber 130 by
passing the fifth occlusion position 146'. Following this subset of
occlusion positions, the occlusion at the first occlusion position
142' may be reversed, and the fluidic pathway 165' may be occluded
at the second occlusion position 143' to form a second truncated
pathway by which a wash fluid may be delivered through the fluid
port 118, into the capture segment 166' (thus washing the trapped
magnetic beads), and into the waste chamber 130 by passing the
fifth occlusion position 146'. A volume of air may then be pumped
through the fluid port 118 to flush any remaining wash solution
into the waste chamber 130.
[0066] Thereafter, in the second embodiment, the fluidic pathway
165' may be occluded at the fifth occlusion position 146' and the
occlusion at the tenth occlusion position 158' may be reversed,
closing access to the waste chamber 130 and opening access to the
end vent segment 197'. A release solution may then be delivered
through the fluid port 118, into the capture segment 166', and to
the end vent segment 197'. The volume of the release solution is
therefore defined by the microchannel volume between the fourth and
tenth occlusion positions 145', 158', and may be any small volume
but in a specific variation is precisely metered to be 15
microliters. Thereafter, occluding the fluidic pathway 165' at the
tenth occlusion position 158', reversing the occlusion at the
fourth occlusion position 145' (defining a fourth truncated
pathway), and delivering air through the fluid port 118 pushes any
remaining release buffer from the fluidic pathway 118 into the
waste chamber 130, thereby ensuring that excess release buffer is
not later exposed to nucleic acids bound to the magnetic beads (at
this point, the nucleic acids are not substantially released from
the magnetic beads because heat has not been added). Thereafter,
the fluidic pathway 165' is occluded at the first and fourth
occlusion positions 142', 145', defining a fifth truncated pathway
comprising the capture segment 166', and the magnetic beads are
heated to an appropriate temperature and time (e.g., 60 degrees for
5 minutes) within the heating region 195 to release the nucleic
acids from the magnetic beads and into the release buffer.
[0067] Thereafter, in the second embodiment, the occlusions at the
first and eleventh occlusion positions 142', 159' are reversed,
defining a sixth truncated pathway, the entire released nucleic
acid sample (e.g. .about.15 microliters) may be aspirated out of
the microfluidic cartridge through the reagent port 115. This
released nucleic acid sample is then used to reconstitute a
molecular diagnostic reagent mixture stored off of the microfluidic
cartridge 100. During the reconstitution process, the occlusion at
the sixth occlusion position 147' may be reversed, thus defining a
seventh truncated pathway. Once reconstitution of the molecular
diagnostic reagent mixture with the released nucleic acid sample is
complete and well mixed, the reconstituted mixture may then be
aspirated through the reagent port 115 through the seventh
truncated pathway to the detection chamber 117, completely filling
the detection chamber 117, after which the fluidic pathway 165' is
be occluded at third, seventh, eighth, and ninth occlusion
positions 144', 148', 149', 157' defining an eighth truncated
pathway. An external molecular diagnostic system and/or module may
then perform additional processes on the volume of fluid within the
detection chamber 117.
[0068] An alternative variation of the second embodiment may
further comprise additional occlusion positions or alternative
variations of the set of occlusion positions 141', such that
occlusion at the additional occlusion positions permanently seals
the waste chamber from the fluidic pathway 165'. Other alternative
variations of the second embodiment may also comprise
configurations of the set of occlusion positions 141' that are
different than that described above.
[0069] A third embodiment, as shown in FIG. 7, of a fluidic pathway
165'' preferably comprises an initial segment 174'' fluidically
coupled to a fluid channel 119'' coupled to a shared fluid port
118, a sample segment 175'' coupled to a sample port 114 and to the
initial segment 174'', and a capture segment 166'' coupled to the
initial segment 174''. The third embodiment of the fluidic pathway
165'' also comprises a reagent segment 176'' coupled to a reagent
port 115, a vent segment 177'' coupled to the reagent segment 176''
and to the capture segment 166'', and configured to pass through
the vent region 190, a segment running to a detection chamber 163''
from the vent region 190, a segment running away from the detection
chamber 164'', and an end vent 199 coupled to the segment running
away from the detection chamber 164''. The third embodiment of the
fluidic pathway 165'' also comprises a first waste segment 178''
configured to couple the initial segment 174'' to the waste chamber
130, and a second waste segment 179'' configured to couple the
capture segment 166'' to the waste chamber 130.
[0070] In the third embodiment, the set of occlusion positions
141'' comprises a first occlusion position 142'' located along the
initial segment 174'' between points at which the initial segment
174'' couples to the fluid channel 119'' and to the sample segment
175''. The set of occlusion positions 141'' also comprises a second
occlusion position 143'' located along the sample segment 175'', a
third occlusion position 144'' located along the reagent segment
176'', a fourth occlusion position 145'' located along the first
waste segment 178'', and a fifth occlusion position 146'' located
along the second waste segment 179''. In the third embodiment, the
set of occlusion positions 141'' also comprises a sixth occlusion
position 147'' located along the vent segment 177'' upstream of the
vent region 190, a seventh occlusion position 148'' located along
the segment running to the detection chamber 163'', an eighth
occlusion position 149'' located along the segment running away
from the detection chamber 164'', and a ninth occlusion position
157' located along the vent segment 177'' between the point at
which the vent segment 177'' couples to the second waste segment
179'' and the sixth occlusion point 147''.
[0071] Similar to the first and the second embodiments, the
occlusion positions of the set of occlusion positions 141'' of the
third embodiment are preferably located such that an occlusion of
subsets of the set of occlusion positions 141'' defines unique
truncated fluidic pathways to controllably direct fluid flow.
Example truncated fluidic pathways, defined by occluding the
fluidic pathway 165'' using subsets of the set of occlusion
positions 141'', are shown in FIG. 7.
[0072] Preferably, a fluidic pathway 165 of the set of fluidic
pathways 160 comprises at least one of a first channel type 171, a
second channel type 172 with a reduced cross sectional area, and a
third channel type 173 with an curved surface as shown in FIG. 8A.
A variation of the first channel type 171 has an approximately
rectangular cross section with slightly sloping walls, such that at
least two walls of the first channel type 171 slope toward each
other to facilitate manufacturing of the first channel type 171;
however, alternative variations of the first channel type 171 may
have non-sloping walls or walls that slope away from each other. In
specific embodiments of the first channel type 171, the walls of
the first channel type 171 slope at 6.degree. from vertical, to
facilitate extraction of injection molded parts, and are between
300 and 1600 microns wide and between 100 and 475 microns tall. In
a first specific embodiment of the second channel type 172, the
cross section of the second channel type 172 is a 250 micron wide
equilateral triangle with the top truncated to be 200 microns deep.
In a second specific embodiment of the second channel type 172, the
cross section of the second channel type is a truncated triangle
that is 160 microns wide and 160 microns deep. In a specific
embodiment of the third channel type 173, the surface of the third
channel type is defined by Gaussian function, and is 800 microns
wide and 320 microns deep. Alternative embodiments of the third
channel type 173 may comprise a surface defined by any appropriate
curved function.
[0073] The first channel type 171 is preferably used over a
majority of a fluidic pathway 165, and preferably in portions near
a vent region 190, in a capture segment 166 configured to pass
through a magnetic field 156, and in a segment leading to a
Detection chamber 163. Preferably, an embodiment of the first
channel type 171, comprising a wide channel with little depth is
used in regions configured to pass through a magnetic field 156,
such that particles in the regions are driven closer to the
magnetic field source. The second channel type 172 is preferably
used near a vent region 190 of a fluidic pathway 165, and
preferably in portions of a fluidic pathway 165 leading to and away
from a detection chamber 163, 164 (to constrict fluid flow into the
Detection chamber 117). The third channel type 173 is preferably
used in a portion of a fluidic pathway 165 near a normally open
position 42 of the set of occlusion positions 141. Transitions
between different channel types 171, 172, 173 may be abrupt, or
alternatively, may be gradual, as shown in FIG. 8B. The first,
second, and third channel types 171, 172, 173 may also
alternatively be used in any appropriate portion of a fluidic
pathway 165. Example embodiments of channel types for segments of a
fluidic pathway are shown in FIG. 8C.
[0074] Multiple fluidic pathways may be configured to pass through
a single heating region 195 of the microfluidic cartridge 100, a
single vent region 190 of the microfluidic cartridge 100, and/or a
magnetic field 156 produced by a magnet 152 housed within a single
magnet housing region 150. Preferably all fluidic pathways of the
set of fluidic pathways 160 are configured to pass through a single
heating region 195 of the microfluidic cartridge 100, a single vent
region 190 of the microfluidic cartridge 100, and a magnetic field
156 produced by a magnet 152 housed within a single magnet housing
region 150; however, alternative embodiments of the set of fluidic
pathways 160 of the microfluidic cartridge may comprise different
configurations wherein fluidic pathways of the set of fluidic
pathways 160 do not share a single heating region 195, a single
vent region 190, and/or a magnetic field 156.
[0075] Additionally, the set of fluidic pathways 160 of the
microfluidic cartridge 100 may comprise virtually any number of
fluidic pathway 165 and/or the set of Detection chambers 116 may
comprise virtually any number of Detection chambers 116 as can
practically be integrated into the microfluidic cartridge 100. In
one specific embodiment, the set of fluidic pathways 160 may
comprise twelve fluidic pathways 165, four of which are shown in
FIG. 9.
1.6 Microfluidic Cartridge--Additional Microfluidic Cartridge
Elements
[0076] The microfluidic cartridge 100 is preferably configured such
that actual valving members are not integrated into the
microfluidic cartridge 100; thus, opening and/or occluding portions
of a fluidic pathway 165 are performed by systems located external
to the microfluidic cartridge. As an example, portions of a fluidic
pathway 165 may be opened or occluded at occlusion positions, as
described above, by the action of a valving member or mechanism
held beneath the card that applies a biasing force to deform the
elastomeric layer 140 and occlude a fluidic pathway 165. The force
may be applied by a mechanical member (e.g., a pin, post, etc.), an
electromechanical member (e.g. a solenoid), a pneumatic or
hydraulic member (e.g., air, water, etc.) or any other appropriate
means, as shown in FIGS. 10A and 10B. In some variations, the
cartridge may include one or more registration regions that allow
the card to be aligned with respect to the valving member or
mechanism. In alternative embodiments, the elastomeric layer 140,
the set of valve guides 127, and the set of occlusion positions 141
may be omitted and replaced with valves integrated within the
microfluidic cartridge 100, that are configured to controllably
occlude and open portions of a fluidic pathway 165.
[0077] Other embodiments of the microfluidic cartridge 100 may
further comprise a tag 198 that functions to encode and provide
identifying information related to the microfluidic cartridge 100.
The tag 198 may comprise a barcode, QR code, or other optical
machine-readable tag, or may alternatively be an electronic tag,
such as an RFID chip. The identifying information preferably
comprises at least information relating to the position of a
microfluidic cartridge 100 within a molecular diagnostic system,
and information relating to samples analyzed using the microfluidic
cartridge 100 (e.g. how many positions remain available for
conducting tests). In alternative variations, the tag may relate
other information about samples (e.g. sample type, sample volume,
sample concentration, date) processed using the microfluidic
cartridge 100. Preferably, the tag does not interfere with
procedures being performed using the microfluidic cartridge, and is
located in an unobtrusive position on the microfluidic cartridge
100, such as a side panel of the microfluidic cartridge 100.
Alternatively, the microfluidic cartridge 100 may not comprise a
tag 198, and a user or other entity may relate identifying
information to the microfluidic cartridge 100 using any appropriate
element.
[0078] As a person skilled in the art will recognize from the
previous detailed description and from the FIGURES and claims,
modifications and changes can be made to the preferred embodiments
of the microfluidic cartridge 100 without departing from the scope
of this invention, as is shown in the example embodiment shown in
FIGS. 11A and 11B, and in the alternative example embodiment of
FIGS. 6A-6C, wherein in the orientation of FIG. 6B, the
intermediate substrate 120 comprising a waste chamber 130 is
coupled to the top layer 110, and the elastomeric layer 140 is
located on the bottom of the microfluidic cartridge 100.
2. Specific Embodiment of a Microfluidic Cartridge
[0079] The following description a specific embodiment of the
microfluidic cartridge 100 is for illustrative purposes only, and
should not be construed as definitive or limiting of the scope of
the claimed invention.
[0080] The specific embodiment of the microfluidic cartridge 100,
as shown in FIGS. 11A and 11B, meets SLAS ANSI guidelines for a
microtiter plate footprint, governing the dimensions of the
specific embodiment of the microfluidic cartridge 100. The specific
embodiment of the microfluidic cartridge 100 is thus 127.76 mm long
and 85.48 mm wide.
[0081] The specific embodiment of the microfluidic cartridge 100
comprises a top layer 110 including a set of twelve sample
port-reagent port pairs 112, a set of twelve Detection chambers
116, a shared fluid port 118, a heating region 195, and a vent
region 190; an intermediate substrate 120, coupled to the top layer
110 and partially separated from the top layer 110 by a film layer
125, configured to form a waste chamber 130; an elastomeric layer
140 partially situated on the intermediate substrate 120; a magnet
housing region 150 accessible by a magnet 152 providing a magnetic
field 156; a bottom layer 170 coupled to the intermediate substrate
120 and configured to seal the waste chamber, and a set of fluidic
pathways 160, formed by at least a portion of the top layer 110, a
portion of the film layer 125, and a portion of the elastomeric
layer 140.
[0082] The top layer 110 of the specific embodiment of the
microfluidic cartridge 100 functions preferably as described in
Section 1.1, and is composed of polypropylene with low
autofluorescence and a glass transition temperature suitable for
PCR. The majority of the top layer 110 of the specific embodiment
is 1.5 mm thick (aside from regions defining ports, the vent, the
heating region 195 or fluidic pathways 165), and is produced by
injection molding without the use of a mold release. The
polypropylene is clear to allow transmission of light in the
detection chambers. The injection molding process defines the set
of 12 sample port-reagent port pairs, which are located along one
long edge of the top layer 110, and also defines the set of 12
detection chambers 116, which are located along the opposite long
edge of the top layer 110. The Detection chambers 117 do not
completely transect the top layer 110, as shown in FIGS. 11A and
11B. Each detection chamber 117 of the specific embodiment is
identical and comprised of three interconnected channels,
configured in a circular arrangement, with each of the
interconnected channels approximately 0.4 mm deep and 1.6 mm wide
at its widest point, resulting in a total volume of .about.10 mL
for each detection chamber 117. The dimensions of the detection
chambers 117 of the specific embodiment are such that the detection
chambers 117 facilitate heating from one side (resulting in simpler
heater design yet fast cycling given the small depth of the
channels), and also facilitate the injection molding process. The
bottoms of the detection chambers 117 are formed by the film layer
125, which is polypropylene film compatible with PCR (100 microns
thick or less) that offers low autofluorescence. The film layer 125
can withstand temperatures up to 120.degree. C. or more.
[0083] The injection molding process also defines the shared fluid
port 118 of the top layer 110, and the vent region 190, which is
recessed 0.5 mm into the top surface of the top layer 110 (in the
orientation shown in FIG. 11B), and is covered with a
polytetrafluoroethylene membrane, which is hydrophobic, gas
permeable, and liquid impermeable. A paper label is bonded with
adhesive to the top layer 110 over the vent region 190, which
serves to identify the cartridge and protect the vent region 190,
as shown in FIGS. 11A and 11B. The injection molding process also
defines the heating region 195, which is recessed and spans the
long dimension of the top layer 110, slightly offset from a midline
of the top layer 110. The top layer 110 of the specific embodiment
requires approximately 15 grams of polypropylene, and all draft
angles for the top layer 110 are a minimum of 4 degrees, as defined
by the injection molding process.
[0084] In the specific embodiment, the intermediate substrate 120
is composed of a polypropylene material to minimize cost and
simplify assembly, and in the orientation shown in FIG. 11B, the
top of the intermediate substrate 120 is 1.5 mm thick. The film
layer 125, partially separating the intermediate substrate 120 from
the top layer 110 is a polypropylene film with a nominal thickness
of 50 microns. The film layer 125 is able to withstand temperatures
of up to 95.degree. C. encountered during fabrication and during an
intended PCR procedure, while being thermally bondable to the top
layer 110. The top layer 110 and the film layer 125 are bonded
using thermal fusion bonding, and this subassembly is bonded to the
intermediate substrate 120 using a polymer adhesive. Additionally,
for aligning layers 110, 120, 125 and bonding the top layer 110 to
the intermediate substrate 120, plastic studs are configured to
extend from the top of the intermediate substrate 120 through
die-cut holes in the film layer 125 and injection molded holes in
the bottom of the top layer 110. The intermediate substrate also
comprises a set of valve guides 127, at a set of occlusion
positions 141, which are holes with chamfered edges through the
intermediate substrate 127. Each valve guide in the set of valve
guides 127 is 2.1 mm.times.2.1 mm square, and configured to
accommodate an occluder with a 2 mm.times.2 mm square head for
normally open positions 42 or 2.1 mm diameter circle to accommodate
a 2 mm diameter round pin for normally closed positions 43.
[0085] The elastomeric layer 140 of the specific embodiment is
composed of a low durometer silicone, and comprises strips that are
500 microns thick and that can withstand temperatures of
120.degree. C. at a minimum. The strips of the elastomeric layer
are arranged over the set of valve guides 127, and bonded to the
top of the intermediate substrate 120 using a silicone adhesive.
Additionally, the elastomeric layer 140 is slightly compressed
between the film layer 125 and the top of the intermediate
substrate (in the orientation shown in FIG. 11B).
[0086] The bottom layer 170 of the specific embodiment of the
microfluidic cartridge 100 is composed of polypropylene, identical
to that of the intermediate substrate 120. The bottom layer is 1.5
mm thick, and is contiguous in the area of the set of Detection
chambers 116, such that an outer perimeter of the entire bottom
layer 170 substantially spans the footprint of the microfluidic
cartridge 100. The bottom layer 170 of the specific embodiment is
bonded to the intermediate substrate 120 using polymer adhesive,
providing a hermetic seal that ensures that a waste fluid within
the waste chamber 130 of the intermediate substrate 120 does not
leak out of the waste chamber 130.
[0087] The specific embodiment of the microfluidic cartridge 100
comprises twelve fluidic pathways 165 in the set of fluidic
pathways 160, such that the microfluidic cartridge 100 is capable
of testing up to twelve samples using twelve distinct fluidic
pathways 165. Each of the twelve fluidic pathways 165 is coupled to
one of the twelve sample port-reagent port pairs 113 on one end of
the microfluidic cartridge 100, and coupled to one of the twelve
detection chambers 117 on the other end of the microfluidic
cartridge, as shown in FIGS. 11A and 11B. Each fluidic pathway 165
is substantially identical (aside from portions connecting to an
initial segment 174 fluidically coupled to a fluid channel 119
coupled to a fluid port 118) and identical to the first embodiment
of a fluidic pathway described in Section 1.5 and shown in FIG. 1C.
Additionally, the microfluidic channels comprising each fluidic
pathway 165 are of the first channel type 171 and 500 microns wide
by 475 microns deep, aside from the microfluidic channels of the
segments leading to and away from the detection chambers 163, 164,
the turnabout portions 166, and the vent segments 177. Also,
parallel microfluidic channels of the fluidic pathways 165 of the
specific embodiment are typically evenly spaced at 2.25 mm
(center-to-center).
[0088] The fluidic pathways 165 of the specific embodiment are, in
their default condition, open at all occlusion positions, aside
from the fourth, seventh, and eighth, occlusion positions 145, 148,
149, as shown in FIG. 1C. Furthermore, the s-shaped capture segment
166 of a fluidic pathway of the specific embodiment is configured
to have a volume capacity of 22 .mu.L, have a width of 5.5 mm, and
weave back and forth over a magnetic field 156, by crossing the
magnet housing region 150. The depth of the s-shaped capture
segment 166 is 0.4 mm for the 1.6 mm wide channels and 0.475 for
the 0.5 mm narrower channel.
[0089] The specific embodiment also comprises a barcode tag 198
located on a vertical edge of the microfluidic cartridge 100, as
shown in FIG. 11A. Additional features of the specific embodiment
of the microfluidic cartridge 100 are shown in FIGS. 11A and
11B.
3. Assembly Method for an Embodiment of the Microfluidic
[0090] An embodiment of an assembly method 200 for an embodiment of
the microfluidic cartridge 100 is shown in FIGS. 12A-12G. The
assembly method 200 preferably comprises aligning the top layer to
the film layer and thermally bonding the two, using silicone
adhesive to bond the elastomeric layer to the intermediate
substrate of the microfluidic cartridge S210; compressing the top
layer, the film layer, the elastomeric layer, and the intermediate
substrate and bonding the top/film layers to the elastomeric
layer/intermediate substrate S220; bonding the intermediate
substrate to the bottom layer S230; installing the vents of the
vent region S250; and applying labels and packaging S260.
[0091] Step S210 recites aligning the top layer to the film layer
and thermally bonding the two, using silicone adhesive to bond the
elastomeric layer to the intermediate substrate of the microfluidic
cartridge, and functions to create a first subassembly comprising
the top layer, the film layer, the elastomeric layer, and the
intermediate substrate. Preferably, the elastomeric layer is glued
with silicone to the intermediate substrate; however, the
elastomeric layer may alternatively be solely compressed between
the top layer/film layer and the intermediate substrate, without
any adhesive. Preferably, a first jig is used to align the top
layer and the film layer using pins in the jig and holes in the
layers, and in an example embodiment of S210, the top layer is
first placed face down in the first jig, and the film layer is
placed onto the top layer in preparation for thermal bonding using
a lamination machine or hot press. In the example embodiment of
S210, the elastomeric layer is then fit over ultrasonic welding
tabs in of the top layer, as shown in FIGS. 12D and 12F, however,
processes other than ultrasonic welding may be used. An adhesive
may also be applied around the border of the elastomeric layer, to
prevent leakage between the elastomeric layer and the intermediate
substrate. Protrusions molded into the top of the intermediate
substrate are then passed through alignment holes in the top layer,
thus aligning the top layer, the elastomeric layer, and the
intermediate substrate of the microfluidic cartridge. In
alternative embodiments of S210, any appropriate alignment
mechanism may be used to align the top layer, the elastomeric
layer, and the intermediate substrate, using for example, a
combination of adhesives, frames, and alignment pins/recesses.
[0092] Step S220 recites compressing the top layer, the film layer,
the elastomeric layer, and the intermediate substrate and bonding
the top/film layers to the elastomeric layer/intermediate
substrate, and functions to seal the layers in order to prevent
leakage between the layers. Preferably, S220 forms hermetic seals
between the top layer and the elastomeric layer, and the
elastomeric layer and the intermediate substrate, in embodiments of
S210 where an adhesive application is involved. In an example
embodiment of S220, the first jig with the top layer, the
elastomeric layer, and the intermediate substrate is placed within
an ultrasonic welder to be compressed and ultrasonically
welded.
[0093] Step S230 recites bonding the intermediate substrate to the
bottom layer S230, which functions to form a second subassembly
comprising the top layer, the elastomeric layer, the intermediate
substrate, and the bottom layer. Preferably, the bottom layer
self-aligns with the intermediate substrate as a result of the
bottom layer fitting completely inside a recessed flange on the
lower portion of the intermediate layer. The bottom layer is
preferably thermally bonded to the intermediate layer.
Alternatively, the bottom layer may be bonded to the intermediate
layer using adhesive or ultrasonic welding, as shown in FIG.
12G.
[0094] Step S250 recites installing the vents of the vent region
S250, which functions to permanently form the vents of the vent
region. Step S250 is preferably performed by heat staking the vents
in place, but may alternatively be performed using adhesive or
solvent bonding process. Following step S250, the assembly method
200 may further comprise certain quality control measures,
including pressure testing the microfluidic cartridge S252 by
blocking all sample and reagent ports, and injecting air into the
fluid port, and removing the finished microfluidic cartridge from
the second jig S254. Step S260 recites applying labels and
packaging, and functions to prepare the microfluidic cartridge with
identifying information using at least a barcode label, and
preparing the microfluidic cartridge for commercial sale.
[0095] An alternative embodiment of an assembly method 300, as
shown in FIG. 13, comprises thermally bonding the film layer to the
top layer to form a first subassembly S310; adding a vent to the
first subassembly and applying a label to create a second
subassembly S320; applying an adhesive inside a bottom flange of
the intermediate substrate and bonding the bottom layer to the
intermediate substrate S330; applying a tag to the intermediate
substrate to create a third subassembly S340; positioning the
elastomeric layer on the third subassembly to create a fourth
subassembly S350; applying adhesive to the fourth subassembly S360;
and coupling the second subassembly to the fourth subassembly
S370.
[0096] The FIGURES illustrate the architecture, functionality and
operation of possible implementations of methods according to
preferred embodiments, example configurations, and variations
thereof. It should also be noted that, in some alternative
implementations, the functions noted in the block can occur out of
the order noted in the FIGURES. For example, two blocks shown in
succession may, in fact, be executed substantially concurrently, or
the blocks may sometimes be executed in the reverse order,
depending upon the functionality involved. It will also be noted
that each block of the block diagrams and/or flowchart
illustration, and combinations of blocks in the block diagrams
and/or flowchart illustration, can be implemented by special
purpose systems that perform the specified functions or acts.
[0097] As a person skilled in the art will recognize from the
previous detailed description and from the figures and claims,
modifications and changes can be made to the preferred embodiments
of the invention without departing from the scope of this invention
defined in the following claims.
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