Resistive heaters and anisotropic thermal transfer
Inventors
Jones, David E. • Bills, Michael • Wernerehl, Aaron D. • Chamberlain, Anson Cole
Assignees
Publication Number
US-11786906-B2
Publication Date
2023-10-17
Expiration Date
2036-04-15
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Abstract
System, heaters, and heat transfer devices are disclosed. For example, a system for performing polymerase chain reaction includes a support member configured to receive a sample vessel and a heater that is positioned to affect a temperature of the sample vessel. The system additionally includes a heat transfer device disposed between the heater and the sample vessel. The heat transfer device illustratively includes anisotropic fibers axially aligned parallel to one another and positioned to conduct heat from the at least one heater toward the sample vessel in the axial direction of the anisotropic fibers. An exemplary heater includes a body defining one or more channels, a heating element positioned in the one or more channels, and retention members adjacent the one or more channels. At least a portion of the heating element is mechanically interlocked with the channel by deforming the retention members into a closed position.
Core Innovation
The invention provides a system for performing polymerase chain reaction (PCR) comprising a support member configured to receive a sample vessel, a heater assembly with at least two resistive heaters each maintained at constant but different temperatures, and an anisotropic heat transfer device situated between the heater and the sample vessel. The heat transfer device consists of axially aligned anisotropic fibers that conduct heat efficiently in the axial direction and restrict lateral heat transfer, enabling precise temperature control of the sample during thermal cycling.
The heater assembly further includes Peltier devices in thermal communication with each resistive heater, with the resistive heaters disposed between their respective Peltier device and the heat transfer device. The assembly is movable relative to the support member so either heating member can be selectively aligned with the sample vessel, allowing selective transfer of heat at different temperatures by alternating the position of the heaters. This arrangement enables rapid temperature cycling necessary for PCR and other thermo-cycling processes.
The background identifies problems such as the inefficiency of traditional heaters in PCR applications, including slow, imprecise or non-uniform heating that can disturb or contaminate samples. There is a need for systems delivering rapid, efficient, and controlled thermal cycling, minimizing sample disturbance while maximizing heat transfer efficiency—especially for multiplex PCR and sensitive diagnostic applications.
Claims Coverage
The independent claims detail four main inventive features associated with systems for precise thermal cycling using heaters and anisotropic heat transfer devices.
System with moveable heater assembly and anisotropic fiber heat transfer device
A system comprising: - A support member designed to hold a sample vessel. - A heater assembly including at least a first and second heating member, both resistive heaters, spaced apart and each maintained at a constant temperature but at different values (e.g., denaturation and annealing). - A heat transfer device between the heater and sample vessel, made of anisotropic fibers axially aligned parallel to one another, capable of independent axial heat conduction and lateral heat retardation. - A moveable heater assembly enabling selective alignment of either heating member with the sample vessel for alternate temperature transfer through the heat transfer device. - Each resistive heater is in thermal communication with a Peltier device, positioned so the resistive heater is disposed between the Peltier device and the heat transfer device.
Heater with resistive element mechanically interlocked within a channel
Each resistive heater includes: - A body defining one or more channels. - A resistive heating element positioned within the channels, and an electrically insulating layer at least between the resistive heating element and the body. - The resistive heating element is mechanically interlocked in the channel (not adhesive bonded).
System for heating with multiple heaters and anisotropic heat transfer device
A system comprising: - A heating target area. - A heater assembly with multiple heating members (each a resistive heater), each heated to and maintained at a different temperature. - A heat transfer device disposed between the heater assembly and the target area, comprising a plurality of anisotropic fibers axially aligned and configured for independent axial heat conduction and lateral heat retardation, and a retaining mechanism holding the fibers together. - The heater assembly is spaced so each heating member is in thermal communication with the heat transfer device simultaneously, and is selectively movable to alternate alignment with different target areas.
System with movable mount for heater assembly and anisotropic heat transfer device
A system featuring: - A heater assembly with a mount (circular or polygonal) holding multiple resistive heating members, each kept at a different temperature and spaced apart. - The heater assembly is moveable relative to the target area, allowing selective alignment of heating members with the target. - A heat transfer device positioned adjacent the heater assembly and target area, composed of axially aligned anisotropic fibers for axial heat transfer and lateral heat retardation. - Peltier devices in thermal communication with each resistive heater, with each resistive heater disposed between the respective Peltier and the heat transfer device.
The claims collectively protect systems and methods combining mechanical, electrical, and thermally anisotropic devices for precise sample heating, especially for PCR and other rapid thermal cycling processes.
Stated Advantages
Efficient heat transfer from the heater to the sample with minimal disturbance to the sample, reducing the risk of contamination or sample loss.
Rapid and precise thermal cycling is enabled by the highly anisotropic heat transfer device and moveable/multiple constant-temperature heating elements.
The system achieves uniform and independently controlled temperature zones using axially aligned anisotropic fibers, minimizing radial heat loss and cross-talk.
Lower energy requirements for heating by combining Peltier devices with resistive heaters, resulting in faster temperature changes and improved efficiency.
Reduced thermal mass and increased thermal conductivity of the heater, allowing more efficient and faster cycling for PCR applications.
Mechanical interlocking of the heating element without adhesive enhances heat transfer and decreases thermal resistance.
Documented Applications
The system is used for performing polymerase chain reaction (PCR), including multiplex PCR for rapid and sensitive infectious disease diagnostics.
The heater and heat transfer technologies are applicable to closed biological analysis systems, such as the FilmArray® instrument and self-contained sample handling pouches.
The system may be used in any application where improved thermal cycling rates are desirable, including laboratory analysis beyond PCR.
The system can be used for channel or vessel sealing by applying heat to specific locations of a sample handling pouch or container.
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