Patent Application
20180272335
This application is based upon and claims the benefit of priority from Japanese Patent Application No. 2017-059796, filed Mar. 24, 2017, the entire contents of which are incorporated herein by reference.
Embodiments described herein relate generally to a droplet dispensing apparatus.
In biological and pharmaceutical research and development, medical diagnosis/examination, and agricultural testing, analytic devices and testing methods involving dispensing liquids in volumes within a picoliter (pL) to microliter (μL) range are often used.
For improved speed in testing and evaluation, a droplet dispensing apparatus typically ejects droplets of a liquid simultaneously from multiple nozzles into different wells of a microplate (also referred to as a multi-well plate) or the like.
When liquid is being dispensed simultaneously from a plurality of nozzles, there is a possibility that some of the nozzles might not discharge the liquid as intended. In such a case, the intended amount of liquid is not dispensed from a malfunctioning nozzle, which may cause erroneous evaluation results in some testing applications.
In general, according to one embodiment, a droplet dispensing apparatus includes a droplet ejection array having a plurality of nozzles from which droplets can be ejected into a well opening of a microplate plate on a baseplate, a sensor configured to detect a liquid amount in the microplate, and a controller configured to detect that a nozzle in the plurality of nozzles is not discharging during a droplet ejection process based on an initial liquid amount in the microplate as detected by the sensor and a final liquid amount in the microplate as detected by the sensor during a droplet ejection process in which a predetermined number of droplets are to be ejected from the plurality of nozzles into the microplate.
Hereinafter, droplet dispensing apparatuses according to example embodiments will be described with reference to the drawings. It should be noted, that the particular embodiments explained below are some possible examples of a droplet dispensing apparatus according to the present disclosure and do not limit the possible configurations, specifications, or the like of droplet dispensing apparatuses according to the present disclosure.
An example of a droplet dispensing apparatus 1 according to a first embodiment will be described with reference to
The droplet dispensing apparatus 1 includes a main body 1A having a rectangular flat baseplate 3 and a mounting module 5. In the example embodiment explained herein, a microplate 4, which may also be referred to as a receiving unit, a multiwell plate, or a microwell plate in some contexts, has 96 wells into which a solution can be dispensed. Microplates having 96 wells are commonly used in a biochemical research and clinical examination. However, the microplate 4 is not limited to having 96 wells and may have any other number of wells, such as 384 wells, 1536 wells, 3456 wells, or 6144 wells.
The microplate 4 is disposed at the center position of the baseplate 3 and can be secured to and detached from a plate attachment portion 3a of the baseplate 3. There are a pair of X-direction guide rails 6a and 6b extending on the baseplate 3 in a X-direction on both sides of the microplate 4. The ends of each of the X-direction guide rails 6a and 6b are fixed to fixing bases 7a and 7b protruding on the microplate 4.
A Y-direction guide rail 8 extending in a Y-direction is installed between the X-direction guide rails 6a and 6b. Both ends of the Y-direction guide rail 8 are fixed to X-direction moving bases 9 which can slide in the X-direction along the X-direction guide rails 6a and 6b, respectively.
In the Y-direction guide rail 8, a Y-direction moving base 10 is provided, on which the mounting module 5 is movable in the Y-direction along the Y-direction guide rail 8. The mounting module 5 is mounted on the Y-direction moving base 10. The droplet ejecting apparatus 2, which is a droplet ejecting unit, is fixed to the mounting module 5. Thus, the droplet ejecting apparatus 2 can move to any position in X and Y directions, which are orthogonal to each other in this instance, by the combination of a movement of the Y-direction moving base 10 along the Y-direction guide rail 8 in the Y-direction and a movement of the X-direction moving bases 9 along the X-direction guide rails 6a and 6b in the X-direction. In addition, the droplet ejecting apparatus 2 may be detached from and attached to the mounting module 5.
The droplet ejecting apparatus 2 according to the first embodiment has a flat base plate 21. As shown in
As shown in
On the electrical mounting board 23, an electrical mounting board wiring 24 is patterned on the side opposite to the recessed portion 21b. Three wiring patterns 24a, 24b, and 24c respectively connected to a terminal portion 131c of a lower electrode 131 and two terminal portions 133c of an upper electrode 133 are formed in the electrical mounting board wiring 24.
An input signal control terminal 25 for receiving an external control signal is formed at one end of the electrical mounting board wiring 24. An electrode terminal connector 26 is provided at the other end of the electrical mounting board wiring 24. The electrode terminal connector 26 electrically connects the lower electrode terminal portion 131c and the upper electrode terminal portion 133c formed in the droplet ejection array 27 shown in
In the base plate 21, the droplet ejection opening 21d is provided. As shown in
The droplet ejection array 27 shown in
As shown in
As shown in
Furthermore, in the droplet ejection array 27 according to the present example embodiment, twelve nozzles in one nozzle group are disposed at a position corresponding to one opening 22a of one of the eight solution holding containers 22. The twelve nozzles 110 of one nozzle group are disposed only within one well opening 4b of the microplate 4.
The diaphragm 120 is formed integrally with the pressure chamber structure 200, for example. The driving element 130 is formed for each nozzle 110. The driving element 130 has an annular shape surrounding the nozzle 110. The shape of the driving element 130 is not limited, and may be, for example, a C-shape in which a part of a circular ring is cut out.
The diaphragm 120 deforms in the thickness direction by the action of the planar driving element 130. The droplet ejecting apparatus 2 discharges the solution supplied to the nozzle 110 due to the pressure change occurring in the pressure chamber 210 of the pressure chamber structure 200 caused by the deformation of the diaphragm 120.
The main body 1A of the droplet dispensing apparatus 1 includes a non-discharge state detection unit 231 shown in FIG. 7. The non-discharge state detection unit 231 includes a weight measuring device 230, which may be referred to as a scale, weight sensor, or simply a sensor, that measures the weight of the microplate 4, using a crystal oscillator, for example.
The weight measuring device 230 is connected to a controller 232, including a processor (not shown), which controls the operation of the droplet ejecting apparatus 2 or the overall operation of the droplet dispensing apparatus 1. Detection data from the weight measuring device 230 is input to the controller 232. A display unit 233 such as a monitor, for example, is connected to the controller 232, and a D curve detection unit 234 that detects a drying reduction curve D, which corresponds to a drying reduction as a function of time, is built therein.
The controller 232 detects a weight reduction of the droplet due to drying, which corresponds to a correction value in reference to a drying reduction curve D to an initial measured value of the weight (w) of the microplate 4. The weight measuring device 230 measures an initial weight of the microplate 4 at a beginning of a dropping process and a final weight (w) of the microplate 4 after droplets are dropped on the microplate 4 for a predetermined time, and displays the measured initial weight and the final weight (w) on the display unit 233 as necessary. The controller 232 determines that some of the nozzles 110 in the nozzle group are not discharging, when a difference between the measured final weight (w) and the measured initial weight of the microplate 4 is smaller than an expected weight reduction of the droplets due to drying during the droplet dropping process. When it is determined that some of the nozzles 110 are not discharging, the controller 232 displays information of the droplet dispensing apparatus 1 on the display unit 233 such as a monitor, and abort further droplet dropping processing. When the controller 232 does not detect any nozzle 110 that is not discharging, the controller 232 continues further droplet dropping processing until a predetermined number of droplets are dropped into all wells.
In the droplet dispensing apparatus 1 according to the first embodiment, the droplet ejecting apparatus 2 is mounted on the mounting module 5. When the droplet ejecting apparatus 2 is in use, a predetermined amount of solution is supplied to the solution holding container 22 from the top opening 22b of the solution holding container 22 by a pipette or the like (not shown). The solution is held on the inner surface of the solution holding container 22. The opening 22a at the bottom of the solution holding container 22 communicates with the droplet ejection array 27. The solution held in the solution holding container 22 flows into each pressure chamber 210 of the droplet ejection array 27 through the opening 22a.
A voltage control signal that is input to the input signal control terminal 25 is transmitted from the electrode terminal connector 26 to the terminal portion 131c of the lower electrode 131 and the terminal portion 133c of the upper electrode 133. In response to the voltage control signal applied to the driving element 130, the diaphragm 120 is deformed to change the volume of the pressure chamber 210, and thus the solution is discharged as solution droplets from the nozzle 110 of the droplet ejection array 27. In the example embodiment described herein, solution droplets are simultaneously dropped from the twelve nozzles 110 to one well opening 4b of the microplate 4. A predetermined amount of liquid is dropped to each well opening 4b of the microplate 4 from the nozzle 110.
An amount of liquid that is dropped is controlled by a number of repetitions of one-droplet dropping from each nozzle 110, and thus it is possible to control dropping of a liquid to each well opening 4b in the order of picoliter (pL) to microliter (μL).
In the present embodiment, the controller 232 performs the control of the non-discharge state detection unit 231 shown in the flowchart of
Thereafter, the controller 232 performs a second dropping operation control at a time t2. In
Thereafter, at a time t3 a predetermined time after time t2, the weight measuring device 230 measures a final weight w2 of the microplate 4, and the controller 232 acquires the measured final weight w2. If w 2=w 1, the controller 232 determines that all nozzles 110 in the nozzle group are discharging as intended. When the final weight measured at time t3 is w3, which is smaller than w1 (w3<w1), the controller 232 determines that some of the nozzles 110 in the nozzle group are not discharging as intended.
Thereafter, the controller 232 detects a liquid reduction caused by drying of the microplate 4, before the second dropping operation starts at a time t2 (Act2). Here, the controller 232 acquires weights w (w01, w02, w03 . . . ) of the microplate 4 at each of a plurality of set times (t11, t12, t13 . . . ) from the initial measurement time t1. Then, the controller 232 calculates a characteristic curve connecting w0, w01, w02, w03 . . . , and defines the characteristic curve as a drying reduction curve D.
In Act2, after detecting the drying reduction curve D, the controller 232 proceeds to the discharge process in Act3. In the discharge process of Act3, the controller 232 performs the second dropping operation control at time t2 in
Thereafter, at time t3 a predetermined time after time t2, the weight measuring device 230 measures a final weight w31 of the microplate 4, and the controller 232 acquires this the measured final weight w31 (Act4). In Act5, the controller 232 determines whether or not w31 is equal to the predicted weight determined by reference to the drying reduction curve D. When the measured final weight w32 is smaller than the predicted weight w31 determined in reference to the drying reduction curve D (w31>w32) at time t3, the controller 232 determines that some of the nozzles 110 in the nozzle group are not discharging as intended (Act6). If the W31 is equal to the predicted weight determined in reference to the drying reduction curve D, the controller 232 determines that all nozzles 110 in the nozzle group are discharging as intended (Act7). After Act6, the controller 232 proceeds to Act8, displays information indicating a non-discharge state, for example, “Error/Stop” on the display unit 233, and aborts further droplet dropping processes. After Act7, the controller 232 proceeds to Act9 and continues further droplet dropping processes until a predetermined number of droplets are dropped to all wells (Act3). When it is confirmed that the predetermined number of droplets has been dropped to all wells (Act10), the controller 232 completes the process.
In the droplet dispensing apparatus 1 according to the first embodiment, a non-discharge state detection unit 231 is driven at the time of a dropping operation. The controller 232, by the non-discharge state detection unit 231, detects weight reduction of droplets due to drying based on an initial weight of the microplate 4 measured by the weight measuring device 230. During a droplet dropping process, when the weight (w) of the microplate 4 measured by the weight measuring device 230 is smaller than a predicted weight of the microplate 4 after an expected weight reduction due to drying of droplets, which corresponds to a correction value in reference to the drying reduction curve D, the controller 232 determines that some of the nozzle 110 in the nozzle group are not charging as intended. Thus, the controller 232 can detect a discharge failure in which some of the nozzles 110 in a nozzle group are not discharging during a dropping process. As a result, liquid is dropped simultaneously from twelve nozzles 110 in one nozzle group into a well opening 4b of the microplate 4, the controller 232 can detect a discharge failure, such as clogging, in which some of the nozzles 110 in the nozzle group are not discharging as intended.
When a discharge failure is detected, and thus a predetermined amount of liquid cannot be dropped from the droplet ejection array 27 into the well openings 4b of the microplate 4, the controller 232 can quickly stop further solution dropping from the nozzle 110. Thus, the controller 232 can stop the dropping of liquid at an early stage when a discharge failure occurs, which contributes to reduction of waste in a dose-response or the like, and early error detection in an evaluation results of drug performance. As a result, it is possible to provide a droplet dispensing apparatus which can provide more accurate evaluation results of drug performance or the like.
A piezoelectric element may be made of a lead-free material that has lower piezoelectric characteristics than a piezoelectric element including a lead component, for example, PZT (Pb(Zr,Ti)O3: lead titanate zirconate). Therefore, in the case of the piezoelectric element made of a lead-free material, the amount of displacement of the diaphragm 120 during driving is smaller than that of the piezoelectric element made of PZT, so that the amount of liquid per drop is small.
In the example embodiment described herein, a plurality of nozzles 110 (12 nozzles arranged in 3×4 rows and columns) in one nozzle group for one well opening 4b is provided. Thus, even with a lead-free piezoelectric element having low piezoelectric characteristics, it is possible to speed-up the dropping of the required amount of liquid. Therefore, it is possible to complete the dropping of the necessary amount of the liquid in a short time to all the well openings 4b of the microplate 4.
In this example embodiment, the non-discharge state detection unit 231 of the droplet dispensing apparatus 1 according to the first embodiment is modified as follows. The same reference numerals are used for the components that are substantially the same as those of the first embodiment, and the detailed description of repeated components may be omitted.
In the first embodiment, the non-discharge state detection unit 231 detects a discharge failure by measuring of a microplate 4 by the weight measuring device 230. In the second embodiment, a non-discharge state detection unit 241 includes a scanner 240, which may be referred to as a transparency sensor or simply a sensor, that detects the presence or absence of droplets discharged from the nozzles 110 in the nozzle group based on the measured or otherwise detected transparency of the microplate 4. The scanner 240 is formed of, for example, a CMOS sensor.
The scanner 240 is connected to a controller 242 which controls the operation of the droplet ejecting apparatus 2 or the overall operation of the droplet dispensing apparatus 1. The detection data from the scanner 240 is input to the controller 242. A display unit 243 such as a monitor is connected to the controller 242, and a transparency detection unit 244 that measures the transparency of the microplate 4 is built therein.
The controller 242 detects a decrease or otherwise a change in transparency (v) of droplets due to drying from the initial transparency (v) of the microplate 4. The scanner 240 measures initial transparency of the microplate 4 at a beginning of a dropping process and a final transparency (v) of the microplate 4 after droplets are dropped on the microplate 4 and the measured transparency (v) of the microplate 4 for a predetermined time, and displays the measured initial transparency and the final transparency (v) on the display unit 243 as necessary. The controller 242 determines that some of the nozzles 110 in the nozzle group are not discharging, when a difference between the measured final transparency (v) and the measured initial transparency of the microplate 4 is smaller than an expected transparency reduction of the droplets due to drying during the droplet dropping process. When it is determined that some of the nozzle 110 are not discharging, the controller 242 displays information of the droplet dispensing apparatus 1 on the display unit 233 such as a monitor, and abort further droplet dropping processing. When the controller 242 does not detect any nozzle 110 that is not discharging, the controller 242 continues further droplet dropping processing.
In the present embodiment, the controller 242 performs the control of the non-discharge state detection unit 241 shown in the flowchart of
Thereafter, the controller 242 performs a second dropping operation control at a time t2. In
Thereafter, at a time t3 a predetermined time after time t2, the controller 242 acquires transparency v2 of the microplate 4 measured by the scanner 240. If v2=v1, the controller 242 determines that the nozzle 110 of the nozzle group is in a successful state where there is no non-discharge. In addition, at the time point t3, in a case where the measured transparency v3 is smaller than v1 (v3<v1), the controller 242 determines that any one of the nozzles 110 in the nozzle group is in a non-discharge state. In addition,
On the other hand, the actual curve in consideration of the liquid reduction amount due to the dry state of the microplate 4 after a lapse of a predetermined time from the above initial measurement time shows characteristics similar to those in the first embodiment. That is, in the initial measurement control, shown in
Thereafter, the controller 242 detects a liquid reduction caused by drying of the microplate 4, before the second dropping operation starts at a time t2 (Act12). Here, the controller 242 acquires transparencies (v) of the microplate 4 at a plurality of set times (t11, t12, t13 . . . ) from the initial measurement time t1 at which the scanner 240 performs the initial transparency measurement. Then, the controller 242 calculates a characteristic curve connecting the transparencies (v) measured at the plurality of set times, and defines the characteristic curve as a drying reduction curve D.
In Act12 in the flowchart of
Thereafter, at time t3 a predetermined time after time t2, the controller 242 acquires the final transparency v31 of the microplate 4 measured by the scanner 240 (Act14). In Act15, the controller 242 determines whether or not v31 is equal to the predicted transparency determined in reference to the drying reduction curve D. When the measured final transparency v32 is smaller than the predicted transparency v31 determined in reference to the drying reduction curve D (v31>v32), the controller 242 determines that some of the nozzles 110 in the nozzle group are not discharging as intended (Act16). If the v31 is equal to the predicted transparency determined in reference the drying reduction curve D, the controller 242 determines that all nozzles 110 in the nozzle group are charging as intended (Act17). After Act16, the controller 242 proceeds to Act18, displays information indicating a non-discharge state, for example, “Error/Stop” on the display unit 233, and aborts further droplet dropping processes. After Act17, the controller 242 proceeds to Act19 and continues further droplet dropping processes until a predetermined number of droplets are dropped to all wells (Act13). When it is confirmed that the predetermined number of droplets has been dropped to all wells (Act10), the controller 242 completes the process.
In the droplet dispensing apparatus 1 according to the second embodiment, the controller 242 acquires weight reduction of droplets due drying based on an initial transparency (v) of the microplate 4 measured by the scanner 240. The controller 242 determines that some of the nozzles 110 in the nozzle group are not discharging as intended, when the transparency (v) of the microplate 4 measured by the scanner 240 is smaller than a predicted transparency (v) of the microplate 4 after an expected transparency reduction due to drying of droplets, which corresponds to a correction value in reference to the drying reduction curve D), during a droplet dropping process. Thus, the controller 242 can detect a discharge failure in which some of the nozzles 110 in a nozzle group are not discharging during a dropping process.
As a result, also in the second embodiment, in the same way as in the first embodiment, liquid is dropped simultaneously from twelve nozzles 110s in one nozzle group into a well opening 4b of the microplate 4, the controller 242 can detect a discharge failure, such as clogging, in which some of the nozzles 110 in the nozzle group are not discharging as intended. When a discharge failure is detected and thus a predetermined amount of liquid cannot be dropped from the droplet ejection array 27 into the well openings 4b of the microplate 4, the controller 242 can quickly stop further solution dropping from the nozzle 110. Thus, the controller 242 can stop the dropping of liquid at an early stage when a discharge failure occurs, which contributes to reduction of waste in a dose-response or the like, and early error detection in an evaluation results of drug performance. As a result, it is possible to provide a droplet dispensing apparatus which can provide more accurate evaluation results of drug performance. Furthermore, in the second embodiment, since the scanner 240 measures the transparency (v) of the microplate 4 by, the controller 242 can detect a discharge failure in individual nozzles 110 for each well-opening 4b of the microplate 4. Therefore, it is possible to more accurately detect a discharge failure in specific nozzles 110 in one nozzle group are not discharging.
In the third embodiment, a second droplet ejecting unit 251 in addition to the droplet ejection array 27 is provided. The second droplet ejecting unit 251 includes a support mechanism (not specifically depicted) which supports the droplet ejecting apparatus 2 so as to be movable to an arbitrary position in the X-Y direction separately from the droplet ejecting apparatus 2.
The second droplet ejecting unit 251 includes, for example, a water tank (not specifically depicted). The second droplet ejecting unit 251 may further include a tank that contains the same liquid as that of the droplet ejection array 27.
In the third embodiment, after a predetermined amount of liquid has been dropped from the droplet ejection array 27 into each well opening 4b of the microplate 4, after a preset set time elapses, a solution (e.g., water) is additionally discharged from the second droplet ejecting unit 251 to each well opening 4b of the microplate 4. This makes it possible to prevent the drying of the cells contained in each well opening 4b of the microplate 4, in a case where the liquid contained in each well opening 4b of the microplate 4 may dry when in contact with air.
For example, in a high density microplate, there is a possibility that cells dry due to liquid evaporation during dropping, due to an increase in dropping time and a decrease in liquid amount due to an increase in the number of wells. In such a case, it is possible to effectively suppress errors due to drying of the cells contained in each well opening 4b of the microplate 4, by dispensing an additional solution from the second droplet ejecting unit 251. This enables high efficiency experimentation using the high density microplate.
Furthermore, the support mechanism of the second droplet ejecting unit 251 may be able to perform a parallel process of dispensing a droplet in parallel with or perpendicular to the droplet ejection array 27.
In the fourth embodiment, a sealed box component 261 that encloses the microplate 4 and a spraying device 262 spraying a humidifying solution within the sealed box component 261 are provided on the baseplate 3. The sealed box component 261 includes, for example, a frame portion having a highly rigid frame structure and a cover made of an elastic material for closing a space between the frame portions of each frame. The inside of the sealed box component 261 can be hermetically sealed by the frame portion and the cover.
The spraying device 262 includes, for example, a water tank (not specifically depicted). The spraying device 262 may further include a tank that contains the same liquid as that of the liquid ejection array 27. The spraying device 262 is provided in the sealed box component 261, and sprays a drying prevention liquid inside of the sealed box component 261 for drying prevention.
In the fourth embodiment, after a predetermined amount of liquid has been dropped from the droplet ejection array 27 into each well opening 4b of the microplate 4, after a preset set time elapses, droplets for preventing drying are sprayed from the spraying device 262 inside of the sealed box component 261. The spraying device 262 may also be configured such that droplets for drying prevention are sprayed simultaneously with the start of the liquid dropping operation from the droplet ejection array 27.
This makes it possible to prevent the drying of the cells contained in each well opening 4b of the microplate 4, in a case where the liquid contained in each well opening 4b of the microplate 4 dries when in contact with air.
A needle-like injection member 273 is provided with the droplet ejection array 27. At the tip end of the injection member 273, there is provided an actuator capable of injecting droplets of a pL order.
In the microplate 4 as modified, the opening of the well opening 4b is blocked by the lid 271 in the standby state (when not in use). In this state, the notch 272 of the lid 271 is closed.
At the time of an operation for dispensing liquid from the droplet ejection array 27 as shown in
When a specified number of droplets are discharged from the injection member 273, the injection member 273 is drawn out of the microplate 4. At this time, the lid 271 elastically returns to a state in which the peripheral portions on both sides of the notch 272 are closed. Therefore, the well opening 4b of the microplate 4 is closed by the lid 271. As a result, the inner space of the well opening 4b of the microplate 4 is maintained in an airtight state by the lid 271, so that evaporation of the droplet injected into the internal space of the well opening 4b of the microplate 4 is prevented.
As a result, it is possible to prevent the liquid contained in each well opening 4b of the microplate 4 from touching the outside air and drying, and to prevent the drying of the cells contained in each well opening 4b of the microplate 4.
While certain embodiments have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. Indeed, the novel embodiments described herein may be embodied in a variety of other forms; furthermore, various omissions, substitutions and changes in the form of the embodiments described herein may be made without departing from the spirit of the inventions. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the inventions.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2017-059796 | Mar 2017 | JP | national |
