Modular sample processing kits and modules

• US 7,767,937 B2
• Filed: 10/31/2007
• Issued: 08/03/2010
• Est. Priority Date: 07/05/2005
• Status: Active Grant

• Current Assignee: Diasorin Italia SPA
• Original Assignee: 3M Innovative Properties Company (3M Company)
• Inventors: Bedingham, William, Robole, Barry W.
• Primary Examiner(s): PELHAM, JOSEPH MOORE
• Application Number:
  US11/930,628
• Publication Number:
  US 20080050276A1
• Time in Patent Office: 1,007 Days
• Field of Search: None
• US Class Current: 219/388
• CPC Class Codes: G01N 35/025 having a carousel or turntable for reaction cells or cuvettes

Abstract

Modular sample processing apparatus kits that can provide a user with the flexibility to customize a disk-based assay in view of a variety of factors are disclosed. The sample processing apparatus kits of the present invention include one or more process modules that can be retained within openings in a frame. The frame and process modules of the sample processing apparatus kits are preferably adapted for use in sample processing systems that compress the apparatus. The process modules may contain different reagents to perform different tests on the same sample materials or a variety of sample materials. As a result, a single sample processing apparatus can be used to perform a variety of different tests and may include a quality control module capable of providing feedback to the user as to the accuracy of the processes run using the sample processing apparatus. Methods of using the sample processing apparatus that include deforming the process modules and frame are also disclosed.

Claims

1. A modular sample processing apparatus kit comprising:

a frame comprising a plurality of openings arranged in an annular array around a center of the frame;

one or more process modules adapted to be retained within one opening of the plurality of openings of the frame, wherein adjacent process modules loaded into adjacent openings are separated from each other by a radial strut of the frame, and wherein each process module comprises;

a module body comprising first and second major surfaces;

a fluid structure in the process module, the fluid structure comprising a process chamber,

wherein the process chamber comprises a volume defined by a void formed in the module body;

wherein the process chambers of the one or more process modules define an annular processing ring of the modular sample processing apparatus when the one or more process modules are retained within the plurality of openings of the frame;

and wherein each process module further comprises a z-axis thickness measured in a direction normal to the first and second major surfaces of the module body that is larger than a z-axis thickness of the portion of each radial strut of the frame located within the annular processing ring.

2. A kit according to claim 1 wherein, for each of the process modules, the process chambers occupy 50% or more of the volume of the portion of the module body within the annular processing ring.

3. A kit according to claim 1, wherein each process module comprises a mechanical interlocking structure that mates with a complementary structure in each opening of the plurality of openings of the frame.

4. A kit according to claim 1, wherein each process module is adhesively retained in each opening of the plurality of openings of the frame.

5. A kit according to claim 1, wherein the process chamber in each process module comprises a window that transmits electromagnetic energy of selected wavelengths into or out of the process chamber.

6. A kit according to claim 1, wherein the process chamber in each process module of the one or more process modules contains a reagent, and wherein the reagents in the process chambers of at least two process modules are different.

7. A modular sample processing apparatus kit comprising:

a frame comprising at least one opening;

at least one process module adapted to be retained within the at least one opening of the frame, wherein the at least one process module comprises;

a module body comprising first and second major surfaces;

a fluid structure in the process module, the fluid structure comprising an input well in fluid communication with a process chamber, wherein the input well is located radially inward of the process chamber relative to the center of the frame,

wherein the process chamber comprises a volume defined by a void formed in the module body;

and wherein the at least one process module further comprises a z-axis thickness measured in a direction normal to the first and second major surfaces of the module body that is larger than a z-axis thickness of a portion of the frame.

8. A kit according to claim 7, further comprising at least one blank module adapted to be retained within the at least one opening of the frame, wherein the at least one blank module is substantially free of reagents.

9. A kit according to claim 7, wherein the at least one process module comprises a mechanical interlocking structure that mates with a complementary structure in the at least one opening of the frame.

10. A kit according to claim 7, wherein the at least one process module is adhesively retained in the at least one opening of the frame.

11. A kit according to claim 7, wherein the process chamber in the at least one process module comprises a window that transmits electromagnetic energy of selected wavelengths into or out of the at least one process chamber.

12. A kit according to claim 7, wherein the process chamber in at least one of the at least one process module contains a reagent.

13. A process module adapted for use in a modular sample processing apparatus that includes a frame with at least one opening, wherein the process module comprises:

a module body comprising first and second major surfaces;

a metallic foil layer attached to the second major surface of the module body;

a fluid structure in the process module, the fluid structure comprising a process chamber,

wherein the process chamber comprises a volume defined by a void formed through the first and second major surfaces of the module body and the metallic foil layer attached to the second major surface over the void in the second major surface;

wherein the process module comprises a z-axis thickness measured in a direction normal to the first and second major surfaces of the module body that is larger than a z-axis thickness of a portion of the frame.

14. A process module according to claim 13, wherein the metallic foil layer is attached to the second major surface of the process module with a pressure sensitive adhesive.

15. A process module according to claim 13, wherein the process module comprises a mechanical interlocking structure that mates with a complementary structure in the at least one opening of the frame.

16. A process module according to claim 13, wherein the process module is adhesively retained in the at least one opening of the frame.

17. A process module according to claim 13, wherein the process chamber comprises a window that transmits electromagnetic energy of selected wavelengths into or out of the process chamber.

18. A method of processing sample materials, the method comprising:

providing a modular sample processing apparatus comprising a frame that comprises at least one opening and at least one process module adapted to be retained within the at least one opening of the frame, wherein the at least one process module comprises a module body comprising at least one process chamber that comprises a volume defined by a void formed in the module body;

providing sample material in the at least one process chamber of the at least one process module;

deforming the sample processing apparatus on a convex transfer surface of a thermal structure, wherein a portion of the at least one process module and the frame are deflected to conform to the convex transfer surface; and

rotating the sample processing apparatus about an axis of rotation while deforming the sample processing apparatus on the convex transfer surface.

19. A method of processing sample materials, the method comprising:

providing a modular sample processing apparatus comprising a frame that comprises a plurality of openings arranged in an array and one or more process modules adapted to be retained within one opening of the plurality of openings of the frame, wherein adjacent process modules loaded into adjacent openings are separated from each other by a strut of the frame, wherein each process module further comprises a module body comprising first and second major surfaces, a metallic foil layer attached to the second major surface of the module body, at least one process chamber that comprises a volume defined by a void formed through the first and second major surfaces of the module body and the metallic foil layer attached to the second major surface over the void in the second major surface;

providing sample material in the at least one process chamber of the one or more process modules;

deforming the sample processing apparatus on a convex transfer surface of a thermal structure, wherein a portion of the one or more process modules and the frame are deflected to conform to the convex transfer surface; and

rotating the sample processing apparatus about an axis of rotation while deforming the sample processing apparatus on the convex transfer surface.

20. A method of processing sample materials, the method comprising:

providing a modular sample processing apparatus comprising a frame that comprises a plurality of openings arranged in an annular array around a center of the frame and one or more process modules adapted to be retained within one opening of the plurality of openings of the frame, wherein adjacent process modules loaded into adjacent openings are separated from each other by a radial strut of the frame, wherein each process module further comprises a module body comprising at least one process chamber that comprises a volume defined by a void formed in the module body, wherein the process chambers of the one or more process modules define an annular processing ring of the modular sample processing apparatus when the one or more process modules are retained within the plurality of openings of the frame;

providing sample material in the at least one process chamber of the one or more process modules;

deforming the annular processing ring of the sample processing apparatus on a convex transfer surface of a thermal structure, wherein a portion of the one or more process modules and the frame are deflected to conform to the convex transfer surface; and

rotating the sample processing apparatus about an axis of rotation while deforming the annular processing ring on the convex transfer surface.

21. A method of processing sample materials, the method comprising:

providing a modular sample processing apparatus comprising a frame that comprises a plurality of openings arranged in an array and one or more process modules adapted to be retained within one opening of the plurality of openings of the frame, wherein adjacent process modules loaded into adjacent openings are separated from each other by a strut of the frame, wherein each process module further comprises a module body comprising first and second major surfaces, a metallic foil layer attached to the second major surface of the module body, at least one process chamber that comprises a volume defined by a void formed through the first and second major surfaces of the module body and the metallic foil layer attached to the second major surface over the void in the second major surface;

providing sample material in the at least one process chamber of the one or more process modules;

deforming the sample processing apparatus on a transfer surface of a thermal structure, wherein a portion of the one or more process modules and the frame are deflected to conform to the transfer surface; and

rotating the sample processing apparatus about an axis of rotation while deforming the sample processing apparatus on the transfer surface.

22. A method of processing sample materials, the method comprising:

providing a modular sample processing apparatus comprising a frame that comprises at least one opening and at least one process module adapted to be retained within the at least one opening of the frame, wherein the at least one process module comprises a module body comprising at least one process chamber that comprises a volume defined by a void formed in the module body;

providing sample material in the at least one process chamber of the at least one process module;

deforming the sample processing apparatus on a transfer surface of a thermal structure, wherein a portion of the at least one process module and the frame are deflected to conform to the transfer surface; and

rotating the sample processing apparatus about an axis of rotation while deforming the sample processing device on the transfer surface.