SAMPLE-TO-ANSWER MICROFLUIDIC CARTRIDGE

• US 20130130262A1
• Filed: 01/28/2011
• Published: 05/23/2013
• Est. Priority Date: 01/29/2010
• Status: Active Grant

• Current Assignee: Revvity Health Sciences Incorporated (Revvity, Inc.)
• Original Assignee: Micronics Inc. (Sony Group Corp.)
• Inventors: Battrell, C. Frederick, Sprague, Isaac, Bragd, Matthew Scott, Capodanno, Jason
• Granted Patent: US 9,132,423 B2
• Time in Patent Office: Days
• US Class Current: 435/6.12
• CPC Class Codes: B01L 2200/0684 Venting, avoiding backpressure, avoid gas bubbles
• CPC Class Codes: B01L 2200/14 Process control and prevention of errors
• CPC Class Codes: B01L 2200/16 Reagents, handling or storing thereof
• CPC Class Codes: B01L 2300/044 pierceable, e.g. films, membranes
• CPC Class Codes: B01L 2300/0672 Integrated piercing tool
• CPC Class Codes: B01L 2300/0816 Cards, e.g. flat sample carriers usually with flow in two horizontal directions
• CPC Class Codes: B01L 2300/0864 comprising only one inlet and multiple receiving wells, e.g. for separation, splitting
• CPC Class Codes: B01L 2300/087 Multiple sequential chambers
• CPC Class Codes: B01L 2300/0887 Laminated structure
• CPC Class Codes: B01L 2300/123 Flexible; Elastomeric
• CPC Class Codes: B01L 2400/0481 squeezing of channels or chambers
• CPC Class Codes: B01L 2400/0487 fluid pressure, pneumatics
• CPC Class Codes: B01L 2400/0638 membrane valves, flap valves
• CPC Class Codes: B01L 3/50273 characterised by the means or forces applied to move the fluids micropumps F04B19/006, of the membrane type F04B43/043
• CPC Class Codes: B01L 3/52 Containers specially adapted for storing or dispensing a reagent B01L3/02 takes precedence; containers for medical or pharmaceutical purposes A61J1/00; containers in general B65D; storing or dispensing test elements G01N33/4875; automated reagent dispensing G01N35/1002
• CPC Class Codes: B01L 7/52 with provision for submitting samples to a predetermined sequence of different temperatures, e.g. for treating nucleic acid samples amplification or hybridisation processes per se C12Q1/68; controlling sequential reactions for synthesis B01J19/0046
• CPC Class Codes: B01L 7/525 with physical movement of samples between temperature zones
• CPC Class Codes: G01N 21/03 Cuvette constructions
• CPC Class Codes: G01N 21/0332 with temperature control control of temperature G05D23/00; cryostats F17C3/08
• CPC Class Codes: G01N 21/17 Systems in which incident light is modified in accordance with the properties of the material investigated where the material investigated is optically excited causing a change in wavelength of the incident light G01N21/63
• CPC Class Codes: G01N 21/64 : Fluorescence; Phosphorescence
• CPC Class Codes: G01N 21/6428 : Measuring fluorescence of fluorescent products of reactions or of fluorochrome labelled reactive substances, e.g. measuring quenching effects, using measuring "optrodes" in vivo A61B5/00; immunoassay G01N33/53
• CPC Class Codes: Y10T 137/0318 : Processes

Abstract

A microfluidic cartridge and methods for performing a diagnostic, molecular or biochemical assay thereon, where all dried and/or liquid reagents necessary for the assay are contained in the cartridge and the assay requires only the addition of sample. Pneumohydraulic features, chamber and diaphragm technologies are introduced for overcoming the problems of bubble interference and reagent washout during operation of a microfluidic cartridge. The cartridges are inserted into a host instrument for performance of an assay and the cartridge is supplied as a consumable.

Claims

1. A microfluidic cartridge for assay of a target analyte or analytes in a biological sample, the microfluidic cartridge comprising:

a) a plastic, thermally insulative cartridge body enclosing;

i) a hydraulic works comprising an upstream sample inlet, one or more on-board liquid or dry reagents for an assay, and a wettable downstream microfluidic subcircuit comprising a channels and chamber fluidly connected to said upstream inlet and vented at a downstream vent; and

ii) a pneumatic works comprising an inlet or inlets for receiving pneumatic pressure and a pneumatic subcircuit comprising a channel and chamber for conveying said pneumatic pressure therefrom; and

b) at least one pneumohydraulic diaphragm configured for interfacing a hydraulic chamber of said wettable microfluidic subcircuit with a pneumatic chamber of said pneumatic subcircuit, said pneumohydraulic diaphragm having a first side facing said hydraulic chamber and a second side facing said pneumatic chamber;

wherein

said at least one pneumohydraulic diaphragm is;

A) an elastic, energy-storing pneumohydraulic diaphragm configured for passively storing a liquid volume under a hydraulic pressure and releasing said liquid volume during wetout of a downstream channel or chamber of said wettable microfluidic subcircuit;

B) a duplexedly layered pneumohydraulic diaphragm having a liquid center for storing and releasing a liquid reagent;

C) a pneumohydraulic diaphragm configured for eliminating headspace from a hydraulic chamber during wetout;

or

D) a pair of pneumohydraulic diaphragms comprising a first pneumohydraulic diaphragm interfacing a first hydraulic chamber with valved inlet and a second pneumohydraulic diaphragm interfacing a second hydraulic chamber with valved outlet, wherein said pair of pneumohydraulic diaphragms comprise an elevated intercommunicating channel between said first and second hydraulic chambers, wherein said pair of pneumohydraulic diaphragms is configured for reciprocally exchanging fluid through said channel by applying opposing pressure differentials across said first and second pneumohydraulic diaphragms; and

wherein said hydraulic chambers and diaphragms are configured for preventing or reducing bubble entrainment or reagent washout during wetout, fill, pumping or rehydration steps of the assay.

2. The microfluidic cartridge of claim 1, wherein said hydraulic works is configured for operation when mounted at a tilt angle theta ranging from 10 to 35 degrees relative to the ground plane on a tilted stage of a host instrument and at least one hydraulic chamber is configured with an outlet and intercommunicating channel positioned superiorly relative to said chamber for venting a gas or discharging a bubble from said chamber.

3. The microfluidic cartridge of claim 1, wherein said hydraulic works comprises a plurality of wettable downstream microfluidic subcircuits with channels and chambers fluidly connected to said upstream inlet and vented at one or more downstream vents, wherein said plurality of wettable downstream microfluidic subcircuits are each configured for performing an assay in parallel, and each said wettable downstream microfluidic subcircuit is provided with a separate detection chamber.

4. The microfluidic cartridge of claim 1, wherein a hydraulic pressure and liquid volume of said elastic, energy storing pneumohydraulic diaphragm in a distended state is passively converted by opening a downstream valve to a work of advancing a meniscus in a wettable downstream microfluidic subcircuit fluidly connected thereto and thereby displacing any gas to said downstream vent.

5. The microfluidic cartridge of claim 4, wherein said liquid volume and hydraulic pressure of said elastic, energy storing pneumohydraulic diaphragm is calibrated to fill said downstream microfluidic subcircuit to a mark.

6. The microfluidic cartridge of claim 5, comprising a plurality of said chambers, each chamber configured with an elastic, passively-operated pneumohydraulic diaphragm configured for filling a downstream wettable microfluidic subcircuit equally to a mark, wherein each said subcircuit is configured for performing an assay in parallel, and each said subcircuit is provided with a separate detection chamber.

7. The microfluidic cartridge of claim 1, wherein said pneumohydraulic diaphragm is a polyurethane diaphragm, a polyvinylidene chloride diaphragm, a polyolefin diaphragm, a polyester diaphragm, a polyethylene diaphragm, a polyethylene terephthalate diaphragm, a nylon diaphragm, or a laminated or co-extruded combination thereof.

8. The microfluidic cartridge of claim 1,

wherein the microfluidic cartridge further comprises:

a) a staging manifold having a plurality of chambers, wherein each said chamber of said plurality of chambers is separated into a hydraulic chamber and a pneumatic chamber by an elastic, energy-storing pneumohydraulic diaphragm sealedly mounted therebetween, such that a liquid volume admitted through an inlet into each said hydraulic chamber in series or in parallel distends each said energy-storing pneumohydraulic diaphragm according to an isobaric pressure proportionate to the displacement volume thereof, wherein said inlet is valvedly closeable for equilibrating said hydraulic pressure throughout said staging manifold after filling is complete; and

;

b) a plurality of vented downstream channels in parallel, wherein one said channel of said plurality of channels is in fluidic communication with each said hydraulic chamber of said staging manifold, each said vented downstream channel having a valve for closing during filling and pressurization and for opening during draining and depressurization, whereby said hydraulic pressure of said elastic, pneumohydraulic diaphragm in a distended state is passively converted to the work of advancing a meniscus during initial wetout of said plurality of vented downstream channels in parallel.

9. The microfluidic cartridge of claim 8, wherein each said downstream vented channel is fluidily configured as an inlet to a microfluidic subcircuit, and wherein each said elastic, energy-storing pneumohydraulic diaphragm is configured for splitting a liquid volume equally between each said downstream microfluidic subcircuit.

10. The microfluidic cartridge of claim 9, wherein said each microfluidic subcircuit comprises at least one reaction chamber configured for mixing a liquid reagent, a dry reagent, or a combination thereof, with a liquid sample, and at least one detection chamber configured for interfacing with a detection means for detecting a target analyte or analytes.

11. The microfluidic cartridge of claim 1, wherein said pneumatic chamber is vented to atmosphere.

12. The microfluidic cartridge of claim 1, wherein the microfluidic cartridge comprises an on-board reagent reservoir configured for dispensing a liquid volume into a microfluidic subcircuit of said hydraulic works;

wherein said reagent reservoir comprises;

a) a duplexedly layered diaphragm sealedly separating a pneumatic chamber of said pneumatic works and a hydraulic chamber of said hydraulic works, said duplexedly layered diaphragm having a first side facing said pneumatic works and a second side facing said hydraulic works, a first layer forming said first side thereof, and a second layer forming said second side thereof, said first and second layers enclosing said liquid volume as a liquid center therebetween;

b) a fluid outlet configured for receiving and conveying said liquid volume to said downstream microfluidic subcircuit; and

c) a sharp disposed in said hydraulic chamber, said sharp configured for rupturing said second layer and for releasing said liquid volume into said hydraulic works when said duplexedly layered diaphragm is piercingly urged into contact with the sharp by application of a pressure differential across said diaphragm.

13. The microfluidic cartridge of claim 12, wherein said first layer of said duplexedly layered diaphragm is rupture resistant and said second layer is rupture sensitive.

14. The microfluidic cartridge of claim 13, wherein said first layer is a laminated polymer with an outer nylon base layer configured to be puncture resistant and said second layer is a laminated polymer with an outer polyethylene terephthalate member configured to be puncture susceptible.

15. The microfluidic cartridge of claim 12, wherein said on-board reagent reservoir is configured for releasing serial liquid volumes by the action of serial pulses of pneumatic pressure applied thereto.

16. The microfluidic cartridge of claim 12, wherein said liquid volume comprises a liquid reactant, a buffer, a rehydrating fluid, or a diluent, said liquid volume for an assay step selected from rehydrating a dry reagent disposed in a downstream chamber or channel, for rinsing a solid phase, for eluting a target analyte or analytes from a solid phase substrate, for making a dilution, for performing a chromatographic separation, for actuating or stopping a reaction, or for detecting said target analyte or analytes.

17. The microfluidic cartridge of claim 1, wherein the microfluidic cartridge comprises at least one microfluidic subcircuit with a hydraulic chamber formed as a downstream reaction chamber with an upstream inlet and a downstream vent, said downstream reaction chamber containing a dried reagent spot or spots, and

said pneumohydraulic diaphragm is configured to operate with a first position wherein the diaphragm is distended against the floor of the chamber so as to displace headspace air and form a protective temporary tent around and over the reagent spot or spots during wetout, and a second position wherein the diaphragm is relaxedly positioned or aspirated against the roof of the chamber so as to fill the chamber with the liquid volume and uncover and dissolve the reagent spot at full strength without bubble entrainment or reagent washout.

18. The method of claim 17, wherein said dried reagent spot is a buffer, an enzyme, a co-enzyme, a co-factor, a polymerase, a primer, a molecular beacon, a probe, a fluorophore, a dehydrogenase, an oxidase, a reactant, a chromogen, a substrate, an antibody, an antigen, or a control.

19. The microfluidic cartridge of claim 1, wherein the microfluidic cartridge is configured for performing PCR, and said microfluidic cartridge comprises:

a first pneumohydraulic diaphragm overlying a first hydraulic chamber and a second pneumohydraulic diaphragm overlying a second hydraulic chamber, said first and second hydraulic chambers having a fluidically interconnecting channel;

a thermal interface for two-zone PCR thermocycling, with a first thermal interface of said first hydraulic chamber configured for apposing a first heating element and a second thermal interface of said second hydraulic chamber configured for apposing a second heating element; and

wherein said first pneumohydraulic diaphragm is configured with a pneumatic means for driving reciprocal fluid flow between said first and second hydraulic chambers during PCR amplification, and

said interconnecting channel is configured to be operated at a tilt angle theta ranging from 10 to 35 degrees so as to reduce interference from bubbles.

20. The microfluidic cartridge of claim 19, wherein said second pneumohydraulic diaphragms is an elastomeric diaphragm and is configured for working passively by the urging of said first pneumohydraulic diaphragm.

21. The microfluidic cartridge of claim 1, further comprising a detection chamber enclosed on a first opposite side by an optical window and on a second opposite side by a thermo-optical window;

wherein

said detection chamber is configured to be operated at a tilt angle theta ranging from 10 to 35 degrees so as to flush air and bubbles to a vented port superiorly disposed thereon.

22. A kit comprising one or more microfluidic cartridges of claim 1 for use as a consumable in a host instrument, said microfluidic cartridge comprising on-board reagents for performing at least one assay for a nucleic acid, a protein, an antigen, an antibody, a metabolite, or an enzyme.

23. A kit comprising one or more microfluidic cartridges of claim 1 for use as a consumable in a host instrument, said microfluidic cartridge comprising on-board reagents for performing at least one nucleic acid assay, each cartridge packaged in a gas tight sealed pouch, with instructions for use, wherein the user need only place a biological liquid sample to be assayed in a sample inlet port and insert said microfluidic cartridge into said host instrument, said cartridge having all primers, enzyme-cofactors, salts, buffers, polymerase, and detection chemistries for testing said liquid sample for a target nucleic acid associated with a bacterium, a Rickettsia, a fungal agent, an antibiotic resistance gene, a gene associated with virulence or toxigenicity, a molecular marker, a single-nucleotide polymorphism, an insect gene, a bee disease agent gene, a plant gene, a plant disease agent, a molecular marker associated with a cell having a pathogenic or carcinogenic condition, a mitochondrial nucleotide sequence, a plasmid sequence, a messenger RNA, a ribosomal RNA, or a panel of target nucleic acids.

29. The microfluidic cartridge of claim 1, wherein said pneumohydraulic diaphragm comprises a metallized film layer.

30. The microfluidic cartridge of claim 12, wherein said liquid volume is degassed and said duplexedly layered diaphragm is gas impervious.

31. The kit of claim 22, wherein the one or more microfluidic cartridges are provided in a gas-tight package comprising inert atmosphere therein.

32. The kit of claim 23, wherein:

a) the bacterium is Acinetobacter baumannii, Actinobacillus equuli, Bacillus anthracis, Brucella melitensis, Brucella abortus, Bordatella pertussis, Bordatella bronchioseptica, Burkholderia pseudomallei, Corynebacterium diptheriae, Coxiella burnetii, Eikenella corrodens, Escherichia coli, Francisella tularensis, Francisella novicida, Fusobacterium necrophorum, Haemophilus influenzae, Klebsiella oxytoca, Klebsiella pneumoniae, Kingella denitrificans, Legionella pneumophila, Listeria monocytogenes, Moraxella catarrhalis, Mycobacterium tuberculosis, Mycoplasma pneumoniae, Neisseria gonorrhoeae, Neisseria meningitides, Pasteurella multocida, Proteus vulgaris, Proteus mirabilis, Pseudomonas aeruginosa, Pseudomonas putrefaciens, Pseudomonas cepacia, Salmonella typhi, Shigella dysenteriae, Staphylococcus aureus, Streptococcus pyogenes, Streptococcus pneumoniae, Treponema pallidum, Yersinia pestis, or Vibrio cholera;

b) the Rickettsia is Chlamydia pneumoniae, Chlamydia trachomatis, Rickettsia prowazekii, or Rickettsia typhi;

c) the virus is Measles virus, HIV virus, Hepatitis C virus, Hepatitis B virus, Dengue Virus, Western Equine Encephalitis virus, Eastern Equine Encephalitis virus, Venezuelan Equine Encephalitis virus, Enteroviruses, Influenza virus, bird flu, Coronavirus, SARS Coronavirus, Polio virus, Adenovirus, Parainfluenza virus, Hanta virus, Rabies virus, Argentine Hemorrhagic Fever virus, Machupo virus, Sabia virus, Guanarito virus, Congo-Crimean Hemorrhagic Fever virus, Lassa Hemorrhagic Fever virus, Marburg virus, Ebola virus, Rift Valley Fever virus, Kyasanur Forest Disease virus, Omsk Hemorrhagic Fever, Yellow Fever virus, Smallpox virus, a retrovirus, Monkeypox virus, or foot and mouth disease virus;

d) the fungal agent is Coccidiodes immitis, Candida albicans, Cryptococcus neoformans, Histoplasma capsulatum, Blastomyces dermatitidis, Sporotrhix schenki, or Aspergillus fumigates;

or

e) the parasitic agent is Plasmodium falciparum, Plasmodium vivax, Plasmodium ovale, Plasmodium malariae, Toxoplasma gondii, Plasmodium bergeri, Schistosoma mansoni, Schistosoma hematobium, Schistosoma japonicum, Entamoeba histolytica, Babesia, Toxoplasma gondii, Trypanosoma cruzi, Leishmania ssp, Trypanosoma brucei, Trichinella spiralis, Toxocara canis, Necator americanus, Trichuris trichura, Enterobius vermicularis, Dipylidium caninum, Entamoeba histolytica, Dracunculus medinensis, Wuchereria bancrofti, Brugia malai, Brugia timori, Strongyloides stercoralis, Ascaris lumbricoides, Onchocerca volvulus, Naegleria fowleri, Clonorchis sinensis, Cryptosporidium parvum, or Leishmania spp.

24. A method for wetout of a microfluidic cartridge while limiting bubble entrainment therein, the method comprising:

a) pumping a liquid volume through an inlet and into a plurality of hydraulic chambers of a microfluidic card so that an elastic pneumohydraulic diaphragm overlying said liquid volume in each said hydraulic chamber is stretchedly distended, thereby isobarically pressurizing said liquid volume in said plurality of hydraulic chambers;

b) valvedly opening an outlet from each said hydraulic chamber, each said outlet with fluidic connection to a vented downstream microfluidic subcircuit; and

c) splitting said liquid volume substantially in equal measure into a plurality of wettable downstream microfluidic subcircuits.

25. A method for wetout of a microfluidic cartridge comprising reagent spots, while limiting bubble entrainment therein, the method comprising:

a) pumping a liquid volume through an inlet and into a plurality of hydraulic chambers of the microfluidic card so that an elastic pneumohydraulic diaphragm overlying the liquid volume in each said hydraulic chamber is distended, thereby isobarically pressurizing said liquid volume;

b) pressurizing a second diaphragm in a plurality of downstream reaction chambers, each said downstream reaction chamber containing a dried reagent spot, the second diaphragm forming a protective temporary tent for sealing around and over the reagent spot and for displacing headspace air from the downstream reaction chamber;

c) valvedly opening an outlet from each said hydraulic chamber, each said outlet with fluidic connection to one of said plurality of downstream reaction chambers;

d) wetting the downstream reaction chamber around said temporary tent and displacing any residual air from the reaction chamber by allowing the distended elastic pneumohydraulic diaphragm to relax, the liquid volume forming an advancing meniscus;

e) optionally closing a valve downstream from the downstream reaction chamber; and

f) lifting said temporary tent and conveying a remaining part of the liquid volume into each reaction chamber, thereby dissolving the reagent spot at full strength without bubble entrainment or reagent washout.

26. The method of claim 25, wherein said dried reagent spot is a buffer, an enzyme, a co-enzyme, a co-factor, a polymerase, a primer, a molecular beacon, a probe, a fluorophore, a dehydrogenase, a reactant, a chromogen, a substrate, an antibody, an antigen, or a control.

27. A method for assaying a target analyte or analytes, the method comprising supplying a microfluidic cartridge having an on-board liquid reagent sealedly enclosed in a compartment that is substantially gas impervious, wherein said liquid reagent is substantially degassed, said cartridge having means for dispensing said liquid reagent into a microfluidic works therein, said degassed liquid reagent preventing or reducing bubble formation associated with mixing, pumping or heating.

28. (canceled)