This invention relates to automated chemical synthesizers and more particularly to improved automated rotary chemical synthesizer.
The production of chemicals and biochemicals and products such as, for example, peptides, proteins, carbohydrates and DNA and genetic material has been simplified with the advent of synthesizers which automatically or semi-automatically carry out the stepwise addition of reagents and carry out reactions, such as the synthesis of peptides, or for carrying out fragment coupling reactions. Conventionally, fully automated synthesizers include a robotic arm that carries a vertically moveable probe for travel between a source of reagents and individual reaction wells in which the reaction occurs.
The automated synthesizers relying on robotic arms to transfer reagents exhibit several deficiencies. One deficiency is that the robotic arm moves slowly and must make a large number of moves, depending on the number of reactants in the finished product, between the source of reagent, wash solution and the reaction wells thus requiring a substantial amount of time for reagent delivery, particularly when carrying out a large number of reactions in a single block. The use of a single probe on the robotic arm can result in contamination as the probe handles more than one reagent. In addition such synthesizers can require a high level of maintenance to insure the correct calibration of the robotic arm to insure precise alignment with each reaction well. Conventional synthesizers rely on an agitator for mixing of the reagents in the reaction wells. This agitation coupled with the conventional configuration of the reaction wells can result in splash out of material and contamination between adjacent wells of the block.
According to the present invention improved automated synthesizers are provided in which reagents are delivered to reaction wells precisely and at a faster rate than for the synthesizers that utilize a robotic arm. The automated synthesizer of the invention is reliable and economical. In addition, cross-contamination is essentially eliminated as the injection nozzle does not travel in horizontal and vertical directions over a reaction well as is the case for synthesizers employing a robotic arm. Reagents are dispensed directly into the reaction well from containers and dispensing nozzles that are dedicated to a single reagent so the fluid path for each reagent does not come into contact with any other reagent, eliminating another area of contamination.
In accordance with the present invention, there is provided an improved automated synthesizer in which the reaction wells are moved into alignment with stationary nozzles that are in communication with the source of reactants and/or washing solutions. By moving the wells rather than moving the nozzles for the delivery of reagents and washing solutions, the amount of time required to introduce reagent is substantially reduced. The number of washing steps required is reduced since a single dispensing nozzle delivers only one reagent so that a washing step is eliminated when a different reagent is to be delivered to a reaction well. The danger of cross-contamination due to the movement of a dispensing nozzle over the reaction block that can give rise to the possibility of small amounts of reagent from the nozzle gaining access into other reaction wells. Also contamination is eliminated since a separate injector nozzle dispenses one reagent only. In addition, the agitation of the reaction block is eliminated and improved mixing of reactants is achieved by the configuration of the reaction wells and by the movement of the reaction wells as they are brought into alignment with a reagent nozzle or a wash fluid nozzle.
More particularly, in one embodiment the automated synthesizer comprises a rotatable carousel having at least one reaction well disposed at the periphery of the rotatable carousel. A reaction well includes a reaction chamber and an injection port. Preferably a reaction well includes an access port for an inert gas and a drain port for emptying the well. Rotation of the carousel brings at least one of the reaction wells into alignment with a dispensing nozzle of a stationary delivery system for delivery of reagent into the reaction chamber of the reaction well. A reversible stepper motor powers the rotatable carousel for rotation in either direction.
In a preferred embodiment the stationary delivery system comprises at least one reagent station comprising a container for reactants and a dispensing nozzle that is in fluid communication with the reactant in the container. In one embodiment a syringe is activated to draw reagent from the container and to dispense a controlled amount of reagent through the dispensing nozzle into the reaction chamber. A stationary wash station and drain system includes a plurality of wash injectors that are in fluid communication with one or more wash fluids. One or more linear activators are provided to lower the wash nozzles into the reaction wells for an essentially pressure tight seal and to raise the nozzle for clearance during rotation of the carousel. A frame member in the housing supports the reactant containers and wash fluid containers. While the invention is described herein in connection with a syringe and plunger it should be understood that other commercially available alternative injection systems can be employed with good results. For example, the confluent pump and valve module distributed by Sapphire Engineering, Pocasset Mass. can be used with equal results.
A control system including a CPU, keyboard and monitor are provided for programming and controlling the sequence of reactions and washing steps carried out by the automated synthesizer. Pulses of nitrogen gas are introduced into the reaction chamber to purge the liquid portion out of the container through the drain port for disposal or for collection. The drain port includes a suitable device to maintain solids such as solid support resins in the reaction chamber. Such a device may include a filter, a mechanical valve (check, duckbill or pinch) with set cracking pressure, an electronically controlled solenoid valve, or a vertical trap.
In one embodiment of the invention, the stationary delivery system includes one or more removable cartridges that contain reactant and other liquids required for the reaction. A dispensing nozzle is also associated with the cartridge so that each cartridge of the delivery system is self-contained. In yet another embodiment of the invention, a suitable sensor is provided to indicate the level of reactant in the cartridge.
The embodiments of the invention described herein have found utility in peptide formation and other solid phase and liquid phase chemical reactions can be performed using the synthesizer of the present invention.
Referring to
A control system includes a drive motor controller 32 for control of the drive motor 14 and a pump controller 34 for activation of the fluid pump 22. Both of the controllers, 32 and 34, are in communication with a central processing unit (CPU) 36 for receiving protocol commands. A user interface 38 is provided for input of commands to the CPU 36.
Referring to
One embodiment that exemplifies a system for driving the carousel 10 is the offset driving system illustrated in
Preferably, as is shown in
In a preferred embodiment the bottom wall 70 of the reaction well 12 slopes downwardly toward the drain opening 80. The angle of slope may range from between about 1° to about 45°, preferably between about 5° and about 30° from the horizontal. This allows fluids to collect at the drain opening 80 which facilitates their removal from the reaction well. As illustrated, the longitudinal dimension of the reaction well 12 is greater than its transverse dimension. Mixing and agitation of reagents in the reaction well 12 without the necessity of a separate agitator is achieved by the orientation of the wells on the carousel 10. As shown in
As shown in
Another embodiment of the reaction well 12 is shown in
When carrying out solid phase reactions the final step necessary to recover the end product is the step of cleaving the product from the solid phase. This is similar to a washing step except that the liquid from the reaction well 12 must be recovered rather than sent to waste. A recovery vessel can be aligned with the drain opening 80 from a reaction well 12 to recover the product along with the cleavage fluid. In one embodiment, carousel 10 can be adapted for conveniently capturing cleavage fluid and the final product by attachment of a recovery container to the annulus 42. As illustrated in
Reagents are controllably dispensed to the reaction chamber 74 at a delivery station 20. Similarly, the reaction chamber 74 is washed with a suitable washing fluid at a wash station similar to the delivery station 20. The number and arrangement of the delivery and wash stations varies depending on the complexity and the number of steps in the reaction protocol being carried out.
In
As shown in
A fluid port 118 in the bottom wall 108 communicates between the reservoir 112 and a fluid supply line 120 that opens to the rear wall and extends through the bottom wall to a fluid dispensing line 130 that communicates between the syringe 126 and the dispensing nozzle 26. A check valve 122 is disposed in the fluid supply line 122 and a plug 123 normally seals the opening of the fluid supply line at the rear wall 106 of the cartridge 100.
The top wall 110 extends beyond the front wall and a linear motor 132 is mounted thereon. A lead screw 134 operated by the linear motor for bi-directional vertical movement extends through the top wall. The extending end of the lead screw 134 carries a plunger block that, responsive to the vertical movement of the lead screw, slides vertically along the outer surface of the front wall 102. A spaced apart upper and lower pair of fingers 138 extend from the face of the plunger block 136 and the flange of the syringe plunger 128 is received the upper and lower pair for the vertical movement of the plunger responsive to the vertical movement of the plunger block. The linear motor is in electrical communication with the pump controller 34 for control of the vertical movement of the plunger block and resultant operation of the syringe 126 through control of the linear motor.
An inert gas supply line 140 extends through the bottom wall 108 for communication between a source of inert gas (not shown) and the fluid dispensing line 130 for introduction of an inert gas into a reaction well 12. A check valve 142 in the inert gas supply line 140 prevents a back flow from the dispensing line 130 to the source of inert gas.
The cartridge 100 operates in the same fashion as a washing station 88 with the following differences. For washing it is necessary to insure that the wash solution is removed from the reaction well 12. Pressurized inert gas is introduced though the dispensing nozzle 26 to flush the reaction chamber 74. To accomplish flushing the dispensing nozzle 26 is longer than for a regent delivery station in order to form a pressure tight seal with the inlet port 76 of the reaction well 12 during a flushing step. The longer dispensing nozzle 26 will normally interfere with the rotation of the carousel 10 and accordingly a suitable linear actuator for lifting the cartridge 100 is provided to move the dispensing nozzle out of interference to permit rotation of the carousel 10 and to lower the cartridge for a pressure tight seal between the dispensing nozzle 26 and the inlet port 76 of the reaction well 12. The Linear Actuator may comprise any apparatus that will lift the and lower the dispensing nozzle including, but not limited to solenoids, linear motors, motors with cam/lifter, motors with lead screw drive and the like.
Referring to
As shown in the figures a dispensing nozzle 144 extends below the bottom wall 108 for a sealed fit in the inlet port 76 of the reaction well 12. To provide the necessary clearance for the rotation of the carousel 10, solenoids 146 are provided to raise the cartridge 100 so that the extended dispensing nozzle 144 is clear of the carousel 10. The solenoids 146 may be attached to the fixed platform 90 to act against the bottom wall 70 of the cartridge 100 or may be received in sockets 148 formed in the bottom wall. In either case guide pins (not shown) on the fixed platform 90 are received in pin sockets 150 formed in the front wall 101 of the cartridge 100 to provide positioning and to guide vertical motion during the lifting sequence. The pump controller is programmed to activate and deactivate the solenoids 146.
In operation a protocol consisting of a series of sequential steps for synthesizing a compound is input to the CPU 36 from the user interface 38 or is programmed in the CPU. Instructions from the CPU 36 are sent to the drive motor controller 32 which controls the rotation of the carousel 10. Depending on the particular protocol a reaction well 12 is rotated into alignment with a reagent delivery station 20. The pump controller 34 causes the linear motor 132 and plunger block 136 of the cartridge 100 of the reagent delivery station to fully depress and fully retract the syringe plunger 128 which produces a vacuum in the syringe 126 to draw the desired reagent from the reservoir 112 through the fluid port 118 and fluid supply line 120 into the syringe. The pump controller 34 reverses the vertical movement of the plunger block 136 and syringe plunger 128 to dispense the reagent through the dispensing nozzle 26 into the reaction chamber 74 of the reaction well 12. The sequence of rotation and dispensing steps are repeated until all of the reagents have been dispensed into the reaction chamber 74 of the reaction well 12. The need for an agitator to mix the reactants in the reaction well 12 is unnecessary. The elongated shape of the reaction chamber 74 coupled with rotation of the carousel 10, which rotates in either direction, agitates the fluids in the reaction wells to thoroughly mix the reactants. In addition to rotation during the sequence of steps called for by the protocol, the carousel can be programmed to use the drive motor 14 to agitate the reaction wells 12 with small cyclic motion at a user defined amplitude, duration and frequency.
As required during the reaction, the carousel 10 is rotated to align the reaction well 12 containing the reaction product with a cartridge 100 at a wash station 88. The cartridge 100 is normally in the raised position by the lifting action of the solenoids 146. The pump controller 146 deactivates the solenoids lowering the cartridge 100 which is guided by the guide pins in the pin sockets to bring the extended dispensing nozzle 144 into a tight fit in the inlet port 76 of the reaction well 12. In the case of a liquid reaction, high-pressure nitrogen, or suitable inert gas, is directed into the extended dispensing nozzle 144 to force the contents of the reaction well through the drain opening 80 for recovery of the contents. In the case of solid phase reactions, the pump controller 146 signals the linear motor 132 to cause the syringe plunger 128 to fully depress and retract to create a vacuum to draw wash fluid from the reservoir 112 of the cartridge 100. The linear motor 132 is then commanded to depress the syringe plunger 128 to force the wash fluid into the chamber 74 of the reaction well 12. Following this the flow of pressurized inert gas pressurizes the chamber 74 causing the valve 86 to open to flush the wash fluid from the reaction chamber through the drain opening 80 to the collection drain. The filter 84 in the filter housing 82 retains the solid phase products in the reaction chamber 74 for subsequent cleavage steps.
If a cleavage step is required the recovery container 94 may be attached to the reaction well 12 as described above. In the alternative, a separate vessel may be placed beneath the carousel 10 in alignment with the drain opening 80 of the reaction well 12 undergoing cleavage. Cleavage is carried out in accordance with well-understood procedures and in the same manner as the washing steps except that the cleavage fluid and finished product are recovered for subsequent separation steps.
While the cartridge 100 has been described herein as generally rectangular in shape, the particular shape of the cartridge is not critical. For example the cartridge 100 can be cylindrical with equally good results. The cartridges can be removably attached to the fixed platform 90 to provide flexibility in operation. Thus, simply replacing a cartridge containing one reagent for a cartridge containing a different reagent facilitates switching reagents according to different protocols. Removable cartridges also reduce waste of reagent and washing fluid since a cartridge can be returned to the synthesizer the next time a protocol calling for that reagent is carried out.
As described above the removable segments 48 allow for flexibility in the number of reaction wells 12 on the carousel 10. Depending on the diameter of the carousel 10 and the size of the reaction wells 12 there may conveniently be as many as 108 reaction wells and as few as one.
A scanner may be employed to identify the function, location and contents of each station. For example, a scanner may read an identifying bar code, a two dimensional pixel code, a color code and the like. Fluid level monitors such as Hall effect sensors, optical sensors or other conventionally available fluid sensors may be employed to determine fluid levels in the cartridge reservoirs 24. Means for heating or cooling the contents of the reaction well 12 can be provided, such as, for example, a thermoelectric peltier effect chiller, a resistive heating element or conductive fluid lines that circulate hot or cold fluid around the reaction wells 12 and the reservoir 112 of the cartridges 100. In addition to the delivery stations 20 and wash stations 88, one or more monitoring stations can be carried on the carousel for monitoring temperature, performing spectroscopic analysis of the contents of a reaction well 12, pH, purity of the product and the like.
From time to time it may be desired to carry out certain steps of a protocol on fewer than all of the reaction wells 12 on the carousel 10 or to perform certain procedures manually or on another synthesizer. In those situations the reaction wells 12 will define self contained reaction vessels that can be manipulated separately of the apparatus described herein.
As will be understood by those skilled in the art, various arrangements which lie within the spirit and scope of the invention other than those described in detail in the specification will occur to those persons skilled in the art. It is therefor to be understood that the invention is to be limited only by the claims appended hereto.
This application claims the benefit of the filing date of provisional application Ser. No. 60/735,276, entitled AUTOMATED ROTARY SYNTHESIZER which application is incorporated by reference herein.
Number | Date | Country | |
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60735276 | Nov 2005 | US |