HK1195810B - Microarray based sample detection system - Google Patents

Description

Sample detection system based on microarray

This application claims priority to U.S. provisional patent application 61/475,107 filed on 13/4/2011. The entire disclosure of the above application is incorporated herein by reference.

FIELD

The field of the technology is microfluidic systems, particularly microfluidic systems having microarrays for sample detection.

Background

Microarrays are most popular as tools for profiling gene expression levels in research laboratories because thousands of samples can be investigated for a single sample. Its utility is not as ubiquitous as clinical diagnostics, environmental and agricultural applications, despite its information density, redundancy, embedded control (positive, negative), i.e., analytical sensitivity. The impediment to the adoption of microarrays, such as diagnostic assays, is primarily due to the complexity and expense of their operation (typically costing hundreds of dollars per test) and the technical problems associated with microfluidic devices containing microarrays, such as unpredictable fluid flow behavior caused by air bubbles in the microfluidic device. For example, air bubbles can block the channel, interfere with biochemical reactions (especially those requiring surface reactions), cause erroneous dosing, interfere with optical readings, and cause unpredictable flow. Unpredictable flow is a problem especially for systems that rely on stable diffusion of the analyte to a binding partner such as an oligonucleotide or capture antibody. Thus, there remains a need for microarray-based microfluidic detection systems that are designed to provide predictable fluid flow and can be manufactured at low cost.

SUMMARY

One aspect of the present application relates to a microarray assembly for detecting target molecules in a sample. In one embodiment, the microarray assembly comprises: an array chamber having a sample inlet at a first end, a sample outlet at a second end, an interior top surface, an interior bottom surface, a plurality of side walls, and a microarray located on the interior bottom surface; a waste chamber in fluid communication with the outlet of the array chamber, wherein the array chamber comprises a hydrophilic interior surface positioned to facilitate complete filling of the array chamber with a water-based fluid and continuous flow of fluid from the inlet to the outlet, wherein the cross-sectional area at a first end of the array chamber is greater than the cross-sectional area at a second end of the array chamber.

In other embodiments, the microarray assembly comprises: an array chamber having a sample inlet, a sample outlet, an interior top surface, an interior bottom surface, a plurality of sidewalls, and a microarray located on the interior bottom surface; a waste chamber comprising a waste inlet and an absorbent material; and a channel having an expansion section with a first end proximate to the outlet of the array chamber and a second end proximate to the inlet of the waste chamber, wherein the interior top surface is a hydrophilic surface that facilitates complete filling of the array chamber with aqueous fluid, and wherein the cross-sectional area at the first end of the expansion section is smaller than the cross-sectional area at the second end of the expansion section.

In other embodiments, the microarray assembly comprises: an array chamber having a sample inlet at a first end, a sample outlet at a second end, an interior top surface, an interior bottom surface, a plurality of side walls, and a microarray located on the bottom surface; a waste chamber in fluid communication with an outlet of the array chamber, wherein the array chamber comprises a hydrophilic interior surface positioned to assist aqueous sample fluid to completely fill the array chamber and comprises a plurality of channels having rectangular cross-sections formed in the interior bottom surface and/or the interior top surface to promote drying.

Another aspect of the present application relates to a method for controlling the quality of fabrication of array elements in a microarray. The method comprises the following steps: illuminating a microarray having a plurality of array spots with a light wave to generate fluorescence from each array spot; measuring the intensity of fluorescence for each array spot, wherein the fluorescence is generated by an internal quality control fluorophore; generating a fluorescence image of the microarray; determining information for each array spot based on the fluorescence image; and encoding the information in a barcode, memory device, or RFID tag, wherein the barcode, memory device, or RFID tag corresponds to the microarray.

Another aspect of the invention relates to a method of manufacturing a microarray assembly. The method comprises the following steps: unwinding the unwound base film from one or more base film reels; printing a microarray onto an unwound backing film; laminating a liner film on the printed carrier film, wherein the liner film is pre-cut to provide space for the array chamber prior to the placing step and is placed onto the printed carrier film by one or more liner film reels; laminating a cover film on the liner film to form a multilayer microarray structure; and cutting the multilayer microarray structure into individual microarray assemblies.

Brief description of the drawings

The detailed description will refer to the following figures:

FIG. 1A is a schematic diagram of an embodiment of a microarray assembly comprising a reservoir, an array chamber of decreasing cross-section, a spot array, a waste chamber, and an absorbent material. FIG. 1B is a cross-sectional view of the array assembly of FIG. 1A.

FIG. 2 is an enlarged view of the array chamber showing a linear array of dots printed on the bottom surface of the chamber with a decreasing cross-sectional area.

FIG. 3 is a microarray assembly having an expansion channel connecting an array chamber to a waste chamber.

FIG. 4A is a schematic diagram showing an array chamber with small rectangular channels that are perpendicular to the direction of liquid flow within the chamber. FIG. 4B is a schematic diagram showing an array chamber with small rectangular channels parallel to the direction of liquid flow within the reaction chamber. FIG. 4C is a schematic diagram showing an array chamber with small rectangular channels that are perpendicular or parallel to the direction of liquid flow within the reaction chamber. FIG. 4D is a schematic diagram showing an array chamber with small rectangular channels that form an angle with respect to the direction of liquid flow within the chamber.

Figure 5 shows a schematic of a continuous assembly line for manufacturing the on-film test device.

Figure 6 shows an array plot of a series of dilutions including Cy5 and Cy3 spots.

Fig. 7 shows an image of a blunt needle print head.

Figure 8 shows bright field images of the arrays and fluorescence images of Cy3 arrays printed on mylar with vacuum manifolds before and after polymerization.

Figure 9 shows a picture of a thin film vacuum manifold for blunt needle printing.

Figure 10 shows a fluorescent image of a material after PCR in combination with a windable material including an array printed polyester film.

Fig. 11 is a photo assembly showing a tape-and-reel printing configuration including a BioDot super non-contact array printer (top plate) and video frames printed with BioDot super non-contact on a moving film (bottom plate) that has not been chemically treated or modified.

Fig. 12 shows a red channel fluorescence image of an MRSA array taken in the factory QC for extracting spot parameters.

FIG. 13 shows a green channel fluorescence image of the hybridized array imaged with an end-user imager. The imager software utilizes the array QC data to place the grid and the circle around each individual point.

FIG. 14 shows fluorescence images of the hybrid array imaged with end-user equipment, but without the use of QC data, making placing the grid and circles around each individual spot more challenging.

Detailed description of the invention

This description is to be read in connection with the accompanying drawings, which are to be considered part of the entire written description of this invention. The drawings are not necessarily to scale and certain features of the invention may be shown exaggerated in scale or in somewhat schematic form in the interest of clarity and conciseness. In the description, relative terms such as "front," "back," "upper," "lower," "top," and "bottom" as well as derivatives thereof should be construed to refer to the orientation as then described or as shown in the introduced figures. Relative terms are used for convenience of description and are not generally intended to require a particular orientation. Terms concerning "attached," "coupled," and the like, such as "connected" and "attached," refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise.

The term "microarray" as used herein refers to an array of ordered spots representing binding of a relevant ligand. The microarray is composed of at least two spots. Related ligands include, but are not limited to, nucleic acids (e.g., molecular beacons, aptamers, locked nucleic acids, peptide nucleic acids), proteins, peptides, polysaccharides, antibodies, antigens, viruses, and bacteria.

The term "hydrophilic surface" as used herein refers to a surface that will make a contact angle of 45 ° or less with a drop of pure water left on such a surface. The term "hydrophobic surface" as used herein refers to a surface that will form an angle of contact of greater than 45 ° with a pure water droplet remaining on such surface. The contact angle may be measured with a contact angle goniometer.

The term "array chamber" as used herein refers to the enclosed space around the microarray, which is in direct or indirect fluid communication with the inlet and outlet. The array chamber, when filled with the liquid sample, allows the microarray to be submerged in the liquid sample so that target molecules in the liquid sample can remain in intimate contact with the microarray for sampling.

Microarray system designed to facilitate fluid flow within the system

One aspect of the present application relates to a microarray-based detection system that includes a microarray assembly including an array chamber having a sample inlet, a sample outlet, and a microarray located therein, a waste chamber in fluid communication with the array chamber. The array chamber has a hydrophilic surface positioned to assist in completely filling the array chamber and fluid flow from the array chamber to the waste chamber. The hydrophilic surface contacts the liquid as it enters the array chamber from the sample inlet and allows for complete filling of the array chamber. In some embodiments, the array chamber is in the shape of an elongated channel of variable width that communicates directly to the waste chamber. In other embodiments, the array chamber is connected to the waste chamber by a waste channel.

The surface tension of the liquid sample or reaction mixture generally prevents the liquid sample or reaction mixture from completely filling a small space such as an array chamber of a microarray system. Surface tension is the product of attraction between liquid-like molecules by various intermolecular forces. In this type of liquid sample, each molecule is equally pulled in all directions by adjacent liquid molecules, so that the net force is zero. On the surface of the liquid sample, many molecules are pulled inward by other molecules located deeper within the liquid, without being attracted equally strongly by molecules in the adjacent medium (presumably vacuum, air or other fluid). Thus, all molecules on the surface are subject to inward molecular attraction, which can only be balanced by the liquid-like resistance to compression. Pulling inward tends to reduce the surface area, and in this regard, the liquid surface acts like a stretched elastic membrane. Thus, the liquid squeezes itself together until it has the smallest local surface area possible. The net result is that the liquid sample can remain nearly spherical in small spaces and does not fill corners, especially the square corners of small spaces. The typical small gap separating the cover from the microarray surface within the array chamber usually presses the liquid into a column shape.

In the case of microarray systems, the liquid filling the microarray cavity is most likely an aqueous solution such as a hybridization buffer or wash buffer. The surface tension of the aqueous solution can be overcome by coating at least a portion of the interior surface of the array chamber with a hydrophilic material. In certain embodiments, the microarray is located on the bottom surface of an array chamber, and the top surface, or at least a portion of the top surface, of the array chamber is coated with a hydrophilic coating.

Examples of hydrophilic materials include, but are not limited to, hydrophilic polymers such as polyethylene glycol, polyhydroxyethyl methacrylate, Bionite, poly (N-vinyl lactam), poly (vinyl pyrrolidone), poly (ethylene oxide), poly (propylene oxide), polyacrylamide, cellulose, methyl cellulose, polyanhydride, polyacrylic acid, polyvinyl alcohol, polyvinyl ether, alkylphenol ethoxylates, pluronic polyol monoesters, polyoxyethylene oleate, polyoxyethylene sorbitan monooleate, and sorbitan fatty acid esters; inorganic hydrophilic materials such as inorganic oxides, gold, zeolites, and diamond-like carbon; and surfactants such as polyethylene glycol octylphenyl ether (TritonX-100), polysorbate (Tween), Sodium Dodecyl Sulfate (SDS), ammonium lauryl sulfate, alkyl sulfate, sodium laureth sulfate (SLES), alkyl benzene sulfonate, soap, fatty acid salts, cetyl trimethylammonium bromide (CTAB), also known as cetyl trimethylammonium bromide, alkyl trimethylammonium salts, cetylpyridinium chloride (CPC), poly-o-ethoxyaniline (POEA), benzalkonium chloride (BAC), benzethonium chloride (BZT), dodecyl betaine, dodecyl dimethyl amine oxide, cocamidopropyl betaine, cocoamphoglycinate poly (ethylene oxide), copolymers of poly (ethylene oxide) and poly (propylene oxide) (commercially known as poloxamers or Poloxamines), alkyl polyglycosides, fatty alcohols, cocomonoethanolamide, cocodiethanolamide, cocoamidodiacetate.

In certain embodiments, at least one surfactant is mixed with reactive polymers such as polyurethanes and epoxies to serve as the hydrophilic coating. In other embodiments, the top or bottom surface of the array chamber is made hydrophilic, for example, by a surface treatment, such as an atmospheric plasma treatment, corona treatment, or gas corona treatment.

Examples of hydrophilic bands include, but are not limited to, Adhesives Research (AR) band 90128, AR band 90469, AR band 90368, AR band 90119, ARTape 92276 and AR tape 90741 (AdhesivesStrearch, Glen Rock, Pa.). Examples of hydrophilic membranes include, but are not limited toFilms andmembranes (Film Specialties, Hillsborough, NJ) and Lexan HPFAF (ge plastics, Pittsfield, MA). Other hydrophilic surfaces are available from Surmodics corporation (EdenPririe, MN), Biocoat corporation (Horshim, PA), Advanced surface technology (Billerica, MA), and Hydromer corporation (Branchburg, N.J.).

In certain embodiments, the hydrophilic band or membrane has a sufficiently high transparency to allow optical interrogation of the microarray from the top surface of the array chamber.

The microarray may be any type of microarray including, but not limited to, oligonucleotide microarrays and protein microarrays. In one embodiment, the microarray is an antibody array, and the microarray system is used to capture and label a target antigen. In one embodiment, the microarray is formed using a printed gel-dot method, for example as described in U.S. Pat. Nos. 5,741,700, 5,770,721, 5,981,734, 6,656,725 and U.S. patent applications 10/068,474, 11/425,667 and 60/793,176, all of which are incorporated herein by reference in their entirety. In certain embodiments, the microarray includes a plurality of array spots printed on an array substrate that forms the bottom surface of the array chamber. In certain embodiments, the array substrate is glass or plastic.

In certain embodiments, the array dots comprise an internal control fluorophore having an emission spectrum that is different from the emission spectrum of the fluorophore associated with the target molecule (i.e., the target molecule will be labeled with a fluorophore having an emission spectrum that is different from the emission spectrum of the internal control fluorophore). Internal controls in the field or during manufacturing can be analyzed to improve quality. Internal control will provide a quantitative means of assessing spot fluorescence intensity (such as an average, median, or integral) that may vary due to droplet size, morphology, porosity, or any factor that can alter the reproducibility between a spot and a spot. Factors that affect these properties include UV dose, temperature, surface properties, composition, viscosity, concentration, cleaning (i.e., due to effects caused by temperature, viscosity, flow rate, immediate differences, or anything that may affect the removal or distortion of dots), the depth of immersion of the needle in the polymer solution in needle printing techniques, or any property that may affect the morphology of the gel element or the concentration of samples therein. Field imaging will be accompanied by: misuse by the user, destruction of the gel element due to poor handling, washing of the gel element, brightness enhancement due to the presence of salt, thermal cycling, high temperature conditions to reduce fluorescence effects, low temperature conditions to enhance fluorescence effects, shelf degradation and/or anything that contributes to fluorescence signal changes after the initial QA/QC in array fabrication.

Examples of fluorophores include, but are not limited to, pyrene, 7-methoxycoumarin, cascade blue, 6-MI, 3-MI, 7-aminocoumarin-X (AMCA-X), 6-MAP, Pacific blue, Marina blue, dimethylaminocoumarin, BODIPY (BODIPY) 493/503, BODIPY-FI-X, DTAF (5-DTAF), 6-FAM (fluorescent), dansyl-X, Oregon green500, Oregon green488(5 isomers), Rodol green, Oregon green 514, rhodamine green-X, NBD-X, TET, 2 '4' 5 '7' -tetrabromosulfonic acid lucifer yellow, BODIPY-BR 2, BODIPY-R6G, 6-JOE, BODIPY530/550, HEX, carboxyrhodamine 6G, BODIPY 558/558, BODIPY-TMR-X, Py, BODIPY564/570, Cy3 MPO, TAMRA-X, rhodamine Red-X, BODIPY576/589, BODIPY581/591, Texas Red-X, Cy3.5, ROX, BODIPY-TR, Syto-81, Cy5, naphthalene yellow fluorescence, Cy5.5, VIC, SYBR Green I and SYBR Green II.

In other embodiments, the internal control is a colorimetric signal change that differs from point to point. In other embodiments, the internal control is a chemiluminescent signal change that differs from point to point. In other embodiments, the internal control is an electrochemical signal change that differs from point to point.

In certain embodiments, the array spots are gel spots comprising a first fluorophore (e.g., Cy 5). The target in the sample is labeled with a second fluorophore (e.g., Cy3) in the PCR and then hybridized to the sample covalently bound to the glue-drop polymer. The first fluorophore has a different emission peak than the second fluorophore. Under this set of conditions, the first fluorophore (e.g., Cy5) is used to allow accurate positioning of the gel spot with an imaging system capable of detecting the first and second fluorophores (e.g., Cy3 and Cy 5).

In certain embodiments, the imaging system is part of a microarray inspection system. In other embodiments, the imaging system is part of a machine vision system used in the manufacture of the microarray assembly, so that the coordinates of each spot can be accurately determined during viewing. These coordinates are uploaded onto a barcode or RFID tag attached to the microarray assembly for future analysis. To do this effectively, the first fluorophore (i.e., the internal control fluorophore) coordinates require that a second fluorophore (i.e., the target fluorophore) reference datum be added as part of the assembly map so that the grid can be placed. However, unlike conventional schemes (which either attempt to place a grid based on precisely spaced dots or require two color fluorophore imagers), the disclosed scheme uses coordinates from the bar code to place a fixed circle for dot detection. The position of the first fluorophore (i.e., the internal control fluorophore) point can be used with a thresholding algorithm to find the center that is then used for fixed circle placement.

The advantage of using machine vision to identify spots is that the same system can be used to reject multiple spots, rather than the entire microarray, which would improve efficiency. Multiple points can be rejected based on a number of criteria such as internally controlled fluorescence intensity values that are out of range, asymmetry, and diameter. Accordingly, certain embodiments of the present invention relate to a method of controlling the quality of fabrication of array elements in a microarray, comprising: illuminating a microarray having a plurality of array spots with a light wave to generate fluorescence from each array spot; measuring the intensity of fluorescence for each array spot, wherein the fluorescence is generated by an internal quality control fluorophore; generating a microarray fluorescence image; determining information for each array spot based on the fluorescence image; and encoding the information in a barcode, memory or RFID tag, wherein the barcode, memory or RFID tag is associated with the microarray. The information for each array spot may include the location of each spot, the fluorescence intensity of each spot, the diameter of each spot, and the morphology of each spot. Microarray image analysis may be performed by placing a fixed circle for each microarray spot on the microarray image using spot position information determined based on intrinsic control fluorescence.

In one embodiment, the present application provides a microarray image analysis method. The method comprises the following steps: obtaining a microarray image; placing a fixed dot boundary circle around each microarray dot on the microarray image based on array dot position information obtained by internally controlling fluorescence in the above array dots; measuring for each array point the target fluorescence intensity within the fixed point boundary circle; and determining the number of target molecules in the sample based on the ratio of the target fluorescence intensity to the internal fluorescence intensity at each array spot.

In another embodiment, a microarray image analysis method includes the steps of: determining target fluorescence intensity for a target in the microarray; determining internal fluorescence intensity for the target in the microarray; determining a signal intensity for said target in the microarray, wherein the signal intensity is the ratio of the target fluorescence intensity to the internal fluorescence intensity, wherein the internal fluorescence intensity of the microarray target is determined as described above.

In another embodiment, the present application provides a method of imaging array elements in a microarray. The method comprises the following steps: illuminating a microarray having a plurality of array spots with light of a first wavelength to control fluorophore generation from within; determining the position of an array spot of the microarray based on fluorescence generated by the internal control fluorophore (control fluorescence); illuminating the microarray with light waves of a second wavelength to generate fluorescence from target fluorophores associated directly or indirectly with target molecules bound to the array spots; measuring the fluorescence generated by the target fluorophore (target fluorescence); and determining the number of target molecules in the sample based on the ratio of the control fluorescence intensity to the target fluorescence intensity in the associated array spot.

The waste chamber can be any shape and generally has a volume greater than the volume of the array chamber. In one embodiment, the waste chambers are constructed in a gasket strip that is then attached to the substrate on which the microarray is printed. In yet another embodiment, the top surface of the substrate has a cut-out. The size and location of the cutouts can be matched to the size and location of the waste chambers in the gasket so that the waste chambers, once formed between the substrate and the gasket, will have a thickness greater than the thickness of the array chambers. In another embodiment, the substrate is constructed of plastic so that the cuts can be easily formed on the substrate. In yet another embodiment, the array chamber and the waste chamber are formed in the substrate without the use of a gasket. The waste chamber may have a depth greater than the depth of the array chamber.

In one embodiment, the waste chamber contains an absorbent material that wicks liquid away from the array chamber upon contact with liquid in the array chamber, thereby allowing the microarray to be prepared in a dry state.

The absorbent material may be any material that is capable of retaining a relatively large amount of liquid. In one embodiment, the absorbent material is comprised of a mass of fibers. In another embodiment, the absorbent material is a nonwoven fabric made by through-air bonding. The constituent fibers of the nonwoven fabric may be natural cellulose fibers or regenerated cellulose fibers such as hydrophilic synthetic fibers or pulp. The fibers may be coated or impregnated with a surfactant or hydrophilic oil to improve liquid absorbency. Without being limited to through-air bonding, the nonwoven fabrics used herein may be made in any other manner, such as spunbond processes, air-laid processes, spunlace processes, and the like. In one embodiment, the absorbent material is cellulose paper (C048) from Millipore (Billerica, MA).

In some embodiments, the waste chamber is vented to atmosphere through a vent. In one embodiment, the vent is created simply by punching a hole in the waste chamber cover.

In another embodiment, the liquid in the array chamber is removed by forcing the liquid in the reservoir into the array chamber and establishing contact between the liquid in the array chamber and the absorbent material in the waste chamber. The contact may be established by applying pressure to the liquid in the array chamber to push the liquid out of the array chamber or by applying suction at the waste chamber outlet to pull the liquid out of the array chamber. The pressure on the liquid in the array chamber can be generated by applying pressure through a control valve (e.g., with a burette or syringe). If the array chamber is covered with only a hydrophilic tape or film, the pressure on the liquid in the array chamber can be generated simply by pressing the hydrophilic tape or film that constitutes the top surface of the array chamber. Alternatively, contact of the liquid in the array chamber with the absorbent material may be established by placing the absorbent material adjacent to the array chamber so that the absorbent material contacts the liquid in the channels.

Once contact is established, liquid within the array chamber is drawn through the array chamber into the absorbent material in the waste chamber. The liquid flow rate is determined by the array chamber size, surface tension and liquid viscosity, and the wicking speed of the absorbent material. In addition, the flow rate decreases as the absorbent material becomes more saturated.

In another embodiment, the microarray system further comprises a one-way valve for injecting a liquid (such as a sample, a PCR buffer containing a target, a hybridization buffer, or a wash buffer) into the array chamber. Samples are injected into the array chamber through one-way valves to prevent environmental contamination, which is an important concern in certain applications such as biological reagent testing. The one-way valve may be a control valve, a dome valve or a duckbill valve positioned at the inlet of the array chamber. Dome valves of various sizes are commercially available, for example, from Minivalve International (Yellow Springs, OH).

In certain embodiments, the sidewalls of the array chamber are hydrophobic to trap air bubbles. In other embodiments, the array chamber has a hydrophilic cover designed to form a hydrophilic region near the exit of the array chamber. In a related embodiment, hydrophilic regions are created using a hydrophilic gel member.

In another embodiment, the array chamber inlet contains a pierceable septum/band or dome valve, a control valve, or a duckbill valve to allow washing to occur without causing the contents of the array chamber to release out of the microarray assembly.

In another embodiment, the microarray system further comprises a reservoir for injecting a liquid into the array chamber. In a related embodiment, the reservoir is loosely bound to the device so that it can be broken off and removed for imaging in a conventional microarray or colorimetric reader. In another embodiment, the array chamber is connected to multiple waste chambers to ensure that wicking occurs at the proper intervals.

Once the gas bubbles enter the array chamber, the gas bubbles can reside in the array chamber and partially or completely block the flow of liquid within the array chamber. The air bubbles may also stop the wicking action of the absorbent material if they are located right at the interface of the liquid and the absorbent material. In certain embodiments, the shape of the array chamber of the microarray assembly facilitates movement of the gas bubble within the array chamber. In some embodiments, the cross-sectional area of the array chamber decreases continuously or stepwise from one end of the chamber to the other to facilitate movement of liquid and gas bubbles from the inlet of the array chamber to the outlet of the array chamber.

FIG. 1A illustrates one embodiment of a microarray assembly 100 designed to aid in the removal of air bubbles from within the array chamber. The microarray assembly 100 includes a funnel-shaped array chamber 110 spanning from a sample inlet 112 to an outlet 114 that leads to a waste chamber 120 having an absorbent material 122. The microarray cavity 110 contains a plurality of microarray spots 130 (see FIG. 1C) that are positioned on a substrate 150 that also forms the bottom surface of the array cavity 110. In certain embodiments, the array chamber 110 is connected to a reservoir 140. In this embodiment, the array chamber 110 has a decreasing cross-sectional area toward the waste chamber 120, so that the capillary pressure continuously increases as the liquid in the array chamber 110 reaches the waste chamber 120. This pressure differential causes the liquid to move toward the absorbent material 122 in the waste chamber 120. In other words, the shape of the array chamber 110 provides for continuous wicking of liquid within the array chamber 110 toward the waste chamber 120 until the liquid reaches the absorbent material 122 in the waste chamber 120. In some embodiments, the cross-sectional area at the entrance end of the array chamber 110 is 2, 3, 4, or 5 times larger than the cross-sectional area at the exit end of the array chamber 110.

In one embodiment, the array chamber 110 is trapezoidal in shape with an inlet end having a dimension of between 0.5 mm and 20mm and an outlet end having a dimension of between 0.1 mm and 5 mm. In another embodiment, the array chamber 110 includes a set of stepped structures having a cross-sectional area that tapers from an inlet end to an outlet end. These features are designed to have a smaller radius of curvature at the advancing front than the receding front so that bubbles within the array chamber 110 advance toward the waste chamber 120, preventing the above-described problems associated with bubbles.

FIG. 1B is a cross-sectional view of the microarray assembly 100 taken along line AA in FIG. 1A. In this embodiment, microarray assembly 100 includes an array underlayer 150, a backing layer 160, and a cover layer 170. In one embodiment, the liner is a double-sided adhesive tape such as an inner gasket strip (available from 3M, part No. 9087) having a thickness of 0.25 mm. In other embodiments, array substrate 150 is injection molded plastic with structural features that create pockets for the walls of array chamber 110 and waste chamber 120, and in these embodiments liner 160 is absent.

In other embodiments, a hydrophilic film is laminated to the plastic array substrate 150 using heat and/or pressure to form a hydrophilic surface on which the microarray is printed. Lamination may be performed using laser welding or ultrasonic welding.

Fig. 2 provides an enlarged view of the funnel-shaped array chamber 110 of fig. 1A. As shown in fig. 2, the decreasing chamber width or wedge shape of the array chamber allows for increased capillary pressure to act on the waste chamber 120 side. This configuration allows bubbles to flow through the array chamber and avoids the bubbles from clogging the array chamber 110. The funnel-shaped narrow chamber 110 also helps the target molecules in the sample to diffuse to the array spot 130. In some embodiments, the sample is loaded into the reservoir 140 and flows continuously through the array chamber 110 to the waste chamber 120.

In certain embodiments, the microarray spots 130 are arranged in a plurality of strips (e.g., a protein strip array) that are perpendicular to the flow within the array chamber 110 to improve the interaction between the target molecules in the sample and the array elements. In one embodiment, an array of proteins or protein strips is printed within the array chamber 110. Proteins extracted from the sample are loaded into the reservoir 140 and flow continuously through the array dots 130 or strips 30 into the waste chamber 120.

One of ordinary skill in the art will appreciate that the microarray assembly 100 may have many variations. For example, the entire microarray assembly 100 may be molded in half, creating a parting line that spans the centerline of the substrate 150, the waste chamber 120, and the reservoir 140. The dividing line may be in the form of a contoured path to allow hydrophilic surface treatment of the top surface of the array chamber 110 and/or easy printing of the array dots 130 on the top surface of the substrate 150. The upper half of the array assembly may be treated to be hydrophilic, for example with plasma treatment, a surfactant or any of the above techniques, and bonded in place using ultrasonic welding, laser welding, snap-fit designs, glue, tape or any bonding means. In certain embodiments, the coating 170 can be sized to cover only the chamber area, but not the entire upper surface of the microarray assembly 100.

FIG. 3 shows another embodiment of a microarray assembly 100 designed to help remove air bubbles from within the array chamber 110 and to keep the sample in the array chamber 110 when subjected to extreme temperatures (up to 95℃.) for extended periods of time. In this embodiment, the microarray assembly 100 includes an array chamber 110 having a sample inlet 112, a sample outlet 114, and a plurality of microarray spots 130 located above a substrate 150, a waste chamber 120 having an absorbent material 122, an inlet 116, and an outlet 124, and a channel 118 communicating the sample outlet 114 of the array chamber 110 and the inlet 116 of the waste chamber 120. In this embodiment, the channel 118 has an expanded section 118A and a tortuous section 118B. The expanding section 118A has an increasing cross-sectional area toward the waste chamber 120 so that bubbles within the array chamber 110 are trapped on the expanding section 118A side walls once they enter the channel 118, unblocking the fluid flow within the channel 118. The flared section 118A helps "pin" the liquid contact line onto the lobe of the section during sample expansion when the array chamber 110 is subjected to high temperatures. In one embodiment, the channel 118 sidewalls are hydrophobic to trap air bubbles. In certain embodiments, the cross-sectional area at the waste chamber end of channel 118A is at least 2 times, 3 times, 4 times, or 5 times greater than the cross-sectional area at the array chamber end of channel 118A. In some embodiments, the serpentine segment 118B includes two turns to form an S-shaped or Z-shaped channel segment. In one embodiment, the two bends are 90 ° bends.

In other embodiments, the array chamber 110 is machined with small rectangular channels 180 (i.e., channels with rectangular cross-sections) that are perpendicular to the flow direction to provide a means for drying the array (see FIG. 4A). These channels 180 have acute angles that result in a small bend radius of the fluid-air interface and provide a high capillary pressure that advances the liquid along the sidewall to the waste chamber 120. In another embodiment, the plurality of rectangular channels 180 are parallel to the liquid flow path (see FIG. 4B). In another embodiment, the plurality of rectangular channels 180 are both parallel to the fluid flow path and perpendicular to the liquid flow path (see FIG. 4C). In another embodiment, the plurality of rectangular channels 180 intersect the liquid flow path at an angle in a range from 30 to 120 degrees (see fig. 4D). In another embodiment, the top surface of substrate 150 is roughened to provide the same wicking along surface cracks.

The top surface may also be roughened so that there are a plurality of square microchannels in parallel, intersecting, perpendicular fashion, or some or all of these. The contact angle at the corners should be less than 90 degrees to allow liquid to travel along these channels towards the waste chamber (absorbent material). This is done similarly to what is done in the tracheids (square capillaries) in conifers, which allow the liquid to travel up the length of the tree trunk against the action of hydrostatic forces.

Detection of target molecules with microarray assemblies

Another aspect of the present application relates to a method for detecting a target molecule in a sample using the above-described microarray assembly. The sample may be any biological sample such as a swab, nasopharyngeal aspirate or whole blood sample. The total nucleic acid can be isolated using techniques known to those of ordinary skill in the art. In one embodiment, total nucleic acids are isolated using commercially available nucleic acid isolation reagents or kits, such as Qiagen reagents. In another embodiment, total nucleic acid is isolated using a preparative instrument developed by Akonni Biosystems. A generalized sequence of events for the sample preparation method of Akonni involves denaturing the sample in lysis buffer; continuously perfusing the lysed sample through a sample preparation instrument; washing and eluting the nucleic acids from the sample preparation device.

The isolated nucleic acids are loaded into a microarray system and amplified in a microarray assembly using methods known to those skilled in the art. After amplification, the microarray assembly is incubated at the desired temperature for a period of time (e.g., 10-60 minutes at 50-65 ℃) to allow for hybridization of the amplicons to the microarray. After incubation, the microarray system is washed (e.g., with water) and imaged on a microarray reader, such as the portable microarray reader of Akonni. In one embodiment, the microarray system is dried prior to imaging. In another embodiment, the drying process is accomplished by injecting acetone into the array chamber and/or heating the array chamber. In another example, amplification of the isolated nucleic acid and labeling of the amplification product occurs in an asymmetric PCR master mix that contains far more (e.g., 5-20 fold more) fluorescently labeled "reverse" primer than unlabeled "positive" primer. This approach mainly yields a simple standard target with a single label at its 5' end.

Array assays can be performed with a variety of variations. In one embodiment, the amplification products remain in the reaction chamber after hybridization and are not washed prior to imaging of the microarray. In another example, amplification products are held in an array chamber and array spots are imaged in real time during hybridization to display a growth curve described by Khodakov et al (2008). In yet another embodiment, the array chamber supports a series of incubation and washing steps for use in a multi-step assay such as an ELISA. In one embodiment, the incubation step is performed with periodic or continuous shaking to improve the interaction between the array elements and the target protein.

Fabrication of microarray assemblies

Another aspect of the present application relates to a method of manufacturing a microarray assembly having a base layer, a backing layer, and a cover layer using a windable film material and a web rewind apparatus. Briefly, a windable film material is used for the base, backing and cover layers of a microarray assembly. These films are laminated together by opening several rolls one above the other, resulting in a sandwich structure of the desired components, which is cut to length at the end of the production line. Specifically, the windable carrier film is advanced onto the manufacturing platform. The array dots are printed onto the film to form a microarray with fixed inter-array spacing. The printed base film is then laminated to a windable backing tape that has been pre-cut using a separate tape-and-reel manufacturing process to create space for the array chamber. A wrappable cover film is then laminated over the backing film to seal the array cavity. In certain embodiments, the windable backing tape is pre-cut to create space for the array chamber and the one or more waste chambers. An absorbent material is placed into each waste chamber before the cover film is laminated to the backing film. The advantage of this manufacturing method is that mass production is very cost-effective, since the assembly of microarray assemblies can be fully automated at high speed using standard production equipment.

The primary coating may be any film having a surface with double-bonded carbon atoms. The carrier film preferably has a hydrophobic surface. Examples of the base film include, but are not limited to, polyester films, polyester/polycarbonate film composite films, polytetrafluoroethylene, polyethylene, polyetherimide, polyetheretherketone, and polystyrene. In certain embodiments, the carrier film has a thickness in the range of 20-200 microns, preferably in the range of 50-125 microns.

The liner film may be a double-sided adhesive tape having a desired thickness. In some embodiments, the liner is made of a hydrophobic material and has a thickness in the range of 20-500 microns, preferably 100-300 microns. Examples of liner films include, but are not limited to, polyester films, polyester/polycarbonate blend films, polypropylene, polycarbonate, acetal, polymethyl methacrylate, 256M tape film from Adchem, and polytetrafluoroethylene. The coating may be any film having a hydrophilic surface. Examples of hydrophilic membranes include, but are not limited toFilms andmembranes (Film Specialties, Hillsborough, NJ) and Lexan HPFAF (ge plastics, Pittsfield, MA). Other hydrophilic surfaces are available from Surmodics corporation (EdenPririe, MN), Biocoat corporation (Horshim, PA), Advanced Surface Technology corporation (Billerica, MA), and Hydromer corporation (Branchburg, N.J.).

In some embodiments, the thickness of the coating is in the range of 25-250 microns, preferably 50-150 microns.

In certain embodiments, the microarray is a gel-dot microarray printed onto a bottom film with a non-contact microarray printer (e.g., a piezoelectric printer) that allows printing on a moving film. In certain embodiments, the gel point comprises a sample, such as a protein sample or a nucleotide sample, that is covalently crosslinked to the polymer backbone by uv-induced copolymerization.

FIG. 5 shows a tape rewind assembly line for microarray device fabrication of the present invention. Briefly, the carrier film 510 is laid onto the assembly line 500 by a carrier film reel 512. A gel dot printer 514 prints the array dots onto the bottom film 510. Samples in the gel spots were covalently cross-linked to the polymer backbone by UV irradiation. In one embodiment, crosslinking is accomplished in UV chamber 516 in a single step argon atmosphere UV induced copolymerization process. In one embodiment, the film is held in place on the system by the inherent tension between the spools. This improves the uniformity of UV irradiation across the film surface by keeping the film flat within the UV chamber during copolymerization. The crosslinked microarray is washed at a wash station 518, dried by an air knife 520, and inspected by a Quality Control (QC) camera 522. The defective array is marked with a reject marker 524 and a liner film 526 is laminated to the base film 510 by a liner film spool 528. The backing film 526 may be pre-cut prior to lamination to create spaces for the array chamber and one or more waste chambers. The absorbent material 530 is then fed into the waste chamber so that the sized pre-cut absorbent material segment containing the adhesive backing is placed into the open waste chamber by the absorbent material spool 532. The cover film 534 is then laminated to the carrier/liner film structure by a cover film reel 536. The resulting multilayer structure is then cut by knife block 538 to produce individual microarray assemblies.

Examples of the present invention

Example 1

Method of compensating for microarray printing variations

Gel-drop microarrays containing Cy3 and Cy5 fluorophores were printed onto ten individual slides according to the following combinatorial pattern. The following steps were used to print the microarray: (1) preparing a suitable Cy3/Cy5 oligo mixture and drying on a CentriVap, (2) preparing a polymer solution (monomer + crosslinker + glycerol + buffer), (3) dissolving the dried oligo mixture in a copolymer solution, (4) placing the solution into a source plate, and (5) using the source plate for array printing/polymerization/washing.

Combined drawing

Analysis was performed using GenePix4000B with the following settings: 100% laser power was used for both colors, 500 gain for red channel photomultiplier setting, 375 gain for green channel photomultiplier setting, 5 μm resolution, 175 μm diameter circle. For each point, the integrated intensity was calculated using GenePix software, and the Relative Standard Deviation (RSD) was calculated for all ratios of 198 Cy5 spots, 198 Cy3 spots and Cy3/Cy5 spots. As shown in table 1, for all 10 slides, the Coefficient of Variation (CV) was lower when the ratio of the combined intensities of Cy3/Cy5 was used compared to the signal intensity of Cy3 or Cy5, in some cases by up to 3-fold lower. This data supports the implementation of internal fluorescence control, for example Cy5 dye, which is scanned or shaped as part of the fabrication QC to compensate for variations caused by UV dose, temperature, surface properties, synthesis, viscosity, coagulation, washing (i.e. because of effects due to temperature, viscosity, flow rate, contingent differences or anything that might affect the removal or distortion of a spot), the depth of immersion of the needle in the polymer solution for needle printing technology, or any property that can affect the sampling morphology and/or concentration in a certain spot.

TABLE 1

Example 2

Image analysis method

Internal fluorescence control was performed on Akonni's MRSA microarray and was shown to be effective to compensate for fluorescence intensity variations. Table 2 shows data for fluorescence of a set of 4 gel drops in MRSA microarrays doped with Cy5 fluorophore and MecA sampling. The integrated signal intensities were tabulated for all 4 identical droplets taken in the factory QC (red channel) and after hybridization (green channel). Because of physical damage to the same sample 3, the red and green channels showed significantly reduced overall signal intensity for the same sample 3. As a result of the same sample 3 signal intensity being attenuated, the relative deviation was 23.8% and 29.5% for the red channel and the green channel, respectively. When the green and red channel data are calculated as a ratio, the relative deviation is reduced to 12.2%. This indicates that internal fluorescence control data (red channel) can be used to reduce microarray image and/or microarray manufacturing variability.

TABLE 2

Example 3

Image generation algorithm

Algorithm 1

The algorithm takes images of array Cy5QC before hybridization and generates a data file containing array QC parameters.

1. The Cy5QC image was read and two local copies were produced, one being the unchanged original (Cy5_ original) and the other being converted to a binary image in steps 2 and 3 (Cy5_ process).

2. The Cy5_ processed image was taken, digitally filtered and pixel calculated to produce an image containing a uniform zero background.

3. The image start is transferred to the binary image and stored as Cy5_ process.

4. The identified binary image of the filtered object (Cy5_ processed) was subjected to particle analysis based on size. The measured and recorded parameters of the object are: center of mass, bounding box, particle area, and ellipticity.

5. Check to see if the number of objects identified in step 4 meets the minimum requirements, otherwise reject the slide.

6. And searching for grids.

a. An object is selected and its center of mass is assumed to be the grid origin.

b. A grid is formed and the pixel position of each grid cell is calculated.

c. All objects were applied to the grid and it was checked whether at least 80% of the grid cells that should contain the drops of Cy3 contained an object. If so, the mesh is found and the process proceeds to step 7. If not, 6A-6C are repeated with the center of mass of the different object as the starting point of the grid.

7. The image was rotated so that the angle formed by the Cy3 droplet was less than 0.2 degrees from the horizontal axis.

8. And (5) fine-tuning the grids. Since the grid origin is determined in the binary image by the center of mass of an object in step 6, the center of mass can be slightly off the true object center.

a. The grid origin is shifted by (0,1), i.e. 0 pixels are subtracted from the X-coordinate and 1 pixel is subtracted from the Y-coordinate.

b. For each Cy3 droplet, calculate:

i. offset X-the X-coordinate distance between the center of the Cy3 droplet and its grid cell center.

Deviation Y-the Y-coordinate distance between the center of the Cy3 droplet and the center of its grid cell.

The sum of the deviations was determined for all Cy3 droplets, and the value = (abs (deviation X) + abs (deviation Y)) was used. Lower values mean better grid placement.

c. 8A-8C were repeated for a total of 24 combinations as shown in the following table.

d.

e. The grid center is chosen so that its value is lowest.

9. QC data was calculated for each point.

a. And the deviation X is the X coordinate of the center of the liquid drop minus the X coordinate of the center of the grid.

b. And the deviation Y is the difference between the Y coordinate of the droplet center and the Y coordinate of the grid cell center.

c. Rejection marking: reject points based on diameter, ovality, etc.

d. Dot density

e. Diameter of

10. Referring to table 3, the QC data was written as a text file.

TABLE 3 exemplary array QC data

Grid line	Grid array	Dot type	Refusal?	Grid center X	Grid center Y	Deviation X	Deviation Y	Dot density	Diameter of
										1	1	Cy3	Mistakes	105	88	3	1	2143818	8.85
1	2	Air conditioner	Mistakes	135	88	0	0	261	0.00
										1	3	Air conditioner	Mistakes	166	88	0	0	568	0.00
1	4	Air conditioner	Mistakes	196	88	0	0	-87	0.00
										1	5	Air conditioner	Mistakes	226	88	0	0	228	0.00
1	6	Cy3	Mistakes	257	88	0	3	1612600	9.72
										1	7	Cy3	Mistakes	287	88	1	3	1567664	9.02
1	8	Air conditioner	Mistakes	318	88	0	0	506	0.00
										1	9	Air conditioner	Mistakes	348	88	0	0	1426	0.00
1	10	Air conditioner	Mistakes	378	88	0	0	3420	0.00
										1	11	Air conditioner	Mistakes	409	88	0	0	991	0.00
1	12	Cy3	Mistakes	439	88	-1	3	2216029	9.65
										2	1	Air conditioner	Mistakes	105	119	0	0	-319	0.00
2	2	Air conditioner	Mistakes	135	119	0	0	334	0.00
										2	3	Sample 31	Mistakes	166	119	5	0	1618379	10.12
2	4	Air conditioner	Mistakes	196	119	0	0	486	0.00
										2	5	Air conditioner	Mistakes	226	119	0	0	83	0.00
2	6	H	Mistakes	257	119	-1	-1	1750396	8.99
										2	7	Air conditioner	Mistakes	287	119	0	0	40709	0.00
2	8	Air conditioner	Mistakes	318	119	0	0	-162	0.00
										2	9	Sample 31	Mistakes	348	119	0	3	2061064	10.61
2	10	Air conditioner	Mistakes	378	119	0	0	127	0.00
										2	11	Air conditioner	Mistakes	409	119	0	0	289	0.00

Grid line	Grid array	Dot type	Refusal?	Grid center X	Grid center Y	Deviation X	Deviation Y	Dot density	Diameter of
										2	12	H	Mistakes	439	119	-1	3	2030635	9.19
3	1	Air conditioner	Mistakes	105	149	0	0	1143	0.00
										3	2	Sample 14	Mistakes	135	149	4	1	2222565	9.43
3	3	Sample 35	Mistakes	166	149	2	1	2088478	9.16
										3	4	Air conditioner	Mistakes	196	149	0	0	3938	0.00
3	5	Air conditioner	Mistakes	226	149	0	0	-96	0.00
										3	6	Air conditioner	Mistakes	257	149	0	0	-33	0.00
3	7	Air conditioner	Mistakes	287	149	0	0	582	0.00
										3	8	Sample 14	Mistakes	318	149	0	1	2073261	9.90
3	9	Sample 35	Mistakes	348	149	2	1	1651170	8.86
										3	10	Air conditioner	Mistakes	378	149	0	0	837	0.00
3	11	Air conditioner	Mistakes	409	149	0	0	370	0.00
										3	12	Air conditioner	Mistakes	439	149	0	0	315	0.00
4	1	Air conditioner	Mistakes	105	180	0	0	162	0.00
										4	2	Air conditioner	Mistakes	135	180	0	0	-179	0.00
4	3	Sample 36	Mistakes	166	180	3	2	1782715	8.49
										4	4	Air conditioner	Mistakes	196	180	0	0	633	0.00
4	5	Sample 29	Mistakes	226	180	3	0	1715205	9.51
										4	6	Air conditioner	Mistakes	257	180	0	0	274	0.00
4	7	Air conditioner	Mistakes	287	180	0	0	242	0.00
										4	8	Air conditioner	Mistakes	318	180	0	0	329	0.00
4	9	Sample 36	Mistakes	348	180	-1	-1	1666545	9.66
										4	10	Air conditioner	Mistakes	378	180	0	0	12157	0.00
4	11	Sample 29	Mistakes	409	180	-1	1	1706590	10.47
										4	12	Air conditioner	Mistakes	439	180	0	0	1180	0.00
5	1	Air conditioner	Mistakes	105	210	0	0	308	0.00
										5	2	Air conditioner	Mistakes	135	210	0	0	180	0.00

Grid line	Grid array	Dot type	Refusal?	Grid center X	Grid center Y	Deviation X	Deviation of Y point density	Diameter of
									5	3	Sample 37	Mistakes	166	210	2	11537455	9.70
5	4	dN20	Mistakes	196	210	1	01854849	10.35
									5	5	Air conditioner	Mistakes	226	210	0	0486	0.00
5	6	Sample 90	Mistakes	257	210	2	11697651	9.01
									5	7	Air conditioner	Mistakes	287	210	0	0-115	0.00
5	8	Air conditioner	Mistakes	318	210	0	0-382	0.00
									5	9	Sample 37	Mistakes	348	210	1	22009715	9.84
5	10	dN20	Mistakes	378	210	0	12187695	10.80
									5	11	Air conditioner	Mistakes	409	210	0	01099	0.00
5	12	Sample 90	Mistakes	439	210	0	02007504	10.03
									6	1	Cy3	Mistakes	105	240	5	01264671	8.35
6	2	Air conditioner	Mistakes	135	240	0	0-203	0.00
									6	3	Air conditioner	Mistakes	166	240	0	0476	0.00
6	4	Air conditioner	Mistakes	196	240	0	0214	0.00
									6	5	Air conditioner	Mistakes	226	240	0	0695	0.00
6	6	Air conditioner	Mistakes	257	240	0	0218	0.00
									6	7	Cy3	Mistakes	287	240	1	31125959	9.57
6	8	Air conditioner	Mistakes	318	240	0	0107	0.00
									6	9	Air conditioner	Mistakes	348	240	0	0874	0.00
6	10	Air conditioner	Mistakes	378	240	0	0617	0.00
									6	11	Air conditioner	Mistakes	409	240	0	0528	0.00
6	12	Air conditioner	Mistakes	439	240	0	0580	0.00
									7	1	Cy3	Mistakes	105	271	1	-11734877	9.71
7	2	Air conditioner	Mistakes	135	271	0	0-634	0.00
									7	3	Air conditioner	Mistakes	166	271	0	0-69	0.00
7	4	Air conditioner	Mistakes	196	271	0	0276	0.00
									7	5	Air conditioner	Mistakes	226	271	0	0-199	0.00

Grid line	Grid array	Dot type	Refusal?	Grid center X	Grid center Y	Deviation X	Deviation Y	Dot density	Diameter of
										7	6	Cy3	Mistakes	257	271	0	-2	1581737	10.49
7	7	Cy3	Mistakes	287	271	0	0	1522026	9.37
										7	8	Air conditioner	Mistakes	318	271	0	0	-748	0.00
7	9	Air conditioner	Mistakes	348	271	0	0	2635	0.00
										7	10	Air conditioner	Mistakes	378	271	0	0	747	0.00
7	11	Air conditioner	Mistakes	409	271	0	0	246	0.00
										7	12	Cy3	Mistakes	439	271	-1	0	1640104	10.37
8	1	Air conditioner	Mistakes	105	301	0	0	586	0.00
										8	2	Air conditioner	Mistakes	135	301	0	0	439	0.00
8	3	Sample 31	Mistakes	166	301	1	-1	2008843	10.06
										8	4	Air conditioner	Mistakes	196	301	0	0	247	0.00
8	5	Air conditioner	Mistakes	226	301	0	0	319	0.00
										8	6	H	Mistakes	257	301	-1	0	1534132	10.46
8	7	Air conditioner	Mistakes	287	301	0	0	-477	0.00
										8	8	Air conditioner	Mistakes	318	301	0	0	13815	0.00
8	9	Sample 31	Mistakes	348	301	-1	-1	1704828	10.04
										8	10	Air conditioner	Mistakes	378	301	0	0	260	0.00
8	11	Air conditioner	Mistakes	409	301	0	0	2993	0.00
										8	12	H	Mistakes	439	301	0	2	1569671	9.96
9	1	Air conditioner	Mistakes	105	332	0	0	148	0.00
										9	2	Sample 14	Mistakes	135	332	2	-3	1969286	9.77
9	3	Sample 35	Mistakes	166	332	3	-1	1636381	9.53
										9	4	Air conditioner	Mistakes	196	332	0	0	792	0.00
9	5	Air conditioner	Mistakes	226	332	0	0	-377	0.00
										9	6	Air conditioner	Mistakes	257	332	0	0	594	0.00
9	7	Air conditioner	Mistakes	287	332	0	0	570	0.00
										9	8	Sample 14	Mistakes	318	332	1	-3	1812677	10.36

Grid line	Grid array	Dot type	Refusal?	Grid center X	Grid center Y	Deviation X	Deviation Y	Dot density	Diameter of
										9	9	Sample 35	Mistakes	348	332	0	-2	1881764	9.97
9	10	Air conditioner	Mistakes	378	332	0	0	444	0.00
										9	11	Air conditioner	Mistakes	409	332	0	0	-423	0.00
9	12	Air conditioner	Mistakes	439	332	0	0	287	0.00
										10	1	Air conditioner	Mistakes	105	362	0	0	426	0.00
10	2	Air conditioner	Mistakes	135	362	0	0	-23	0.00
										10	3	Sample 36	Mistakes	166	362	1	-4	1582212	9.85
10	4	Air conditioner	Mistakes	196	362	0	0	1518	0.00
										10	5	Sample 29	Mistakes	226	362	1	-1	1629291	11.09
10	6	Air conditioner	Mistakes	257	362	0	0	4511	0.00
										10	7	Air conditioner	Mistakes	287	362	0	0	201	0.00
10	8	Air conditioner	Mistakes	318	362	0	0	-397	0.00
										10	9	Sample 36	Mistakes	348	362	-1	1	1683589	9.69
10	10	Air conditioner	Mistakes	378	362	0	0	75	0.00
										10	11	Sample 29	Mistakes	409	362	0	1	1763951	10.31
10	12	Air conditioner	Mistakes	439	362	0	0	607	0.00
										11	1	Air conditioner	Mistakes	105	392	0	0	-321	0.00
11	2	Air conditioner	Mistakes	135	392	0	0	437	0.00
										11	3	Sample 37	Mistakes	166	392	0	-4	1782130	9.95
11	4	dN20	Mistakes	196	392	3	-2	1886735	10.28
										11	5	Air conditioner	Mistakes	226	392	0	0	293	0.00
11	6	Sample 90	Mistakes	257	392	0	-4	1569567	10.77
										11	7	Air conditioner	Mistakes	287	392	0	0	1805	0.00
11	8	Air conditioner	Mistakes	318	392	0	0	-262	0.00
										11	9	Sample 37	Mistakes	348	392	-1	-3	1872819	9.83
11	10	dN20	Mistakes	378	392	1	-4	2034194	10.21
										11	11	Air conditioner	Mistakes	409	392	0	0	-258	0.00

Grid line	Grid array	Dot type	Refusal?	Grid center X	Grid center Y	Deviation X	Deviation Y	Dot density	Diameter of
										11	12	Sample 90	Mistakes	439	392	0	0	1693534	10.95
12	1	Cy3	Mistakes	105	423	3	-1	1658433	8.06
										12	2	Air conditioner	Mistakes	135	423	0	0	521	0.00
12	3	Air conditioner	Mistakes	166	423	0	0	285	0.00
										12	4	Air conditioner	Mistakes	196	423	0	0	-447	0.00
12	5	Air conditioner	Mistakes	226	423	0	0	-436	0.00
										12	6	Air conditioner	Mistakes	257	423	0	0	-129	0.00
12	7	Cy3	Mistakes	287	423	1	0	1392853	8.72
										12	8	Air conditioner	Mistakes	318	423	0	0	257	0.00
12	9	Air conditioner	Mistakes	348	423	0	0	649	0.00
										12	10	Air conditioner	Mistakes	378	423	0	0	-108	0.00
12	11	Air conditioner	Mistakes	409	423	0	0	64	0.00
										12	12	Air conditioner	Mistakes	439	423	0	0	-84	0.00

Algorithm 2

This procedure photographs two sheets of the hybridized array: one with normal exposure (image _ normal exposure) and one with height exposure highlighting the Cy3 mark (image _ height exposure).

1. Image _ high exposure and image _ normal exposure are read into the storage device.

2. Read from the QC text file.

3. Operate on the image _ height exposure image to find the grid.

a. A Cy5_ high exposure image was taken, digitally filtered and pixel calculated to produce an image with a uniform zero value background.

b. The image is started to be transferred to the binary image.

c. A particle analysis is performed on the binary image of the identified filtered object based on the size. Measurement and recording parameters of the object: center of mass, bounding box, particle area and ellipticity.

d. Check to see if the number of objects identified in step 3C meets the minimum requirements and if not reject the slide.

e. Similar to step 6 in algorithm 1, a grid is found.

f. The image was rotated so that the angle formed by the Cy3 droplet was less than 0.2 degrees from the horizontal axis.

g. The grid is trimmed, similar to step 8 in algorithm 1.

4. The grid found in the image _ height exposure is used in the image _ normal exposure.

5. The relevant point parameters are determined using the X-bias, Y-bias, diameter and rejection target from the QC-file.

a. If the rejection criteria are true, then the point is excluded from the analysis.

b. Point X coordinate: x coordinate, grid center + X offset.

c. Point X coordinate: y coordinate, grid center + Y offset.

d. Point diameter: dot paths from QC data.

6. The dot density and background were calculated.

7. Final calculations are performed to determine the analysis results.

Example 4

Protein microarray assemblies are constructed using antibody-containing gel droplet elements. Glass slides printed with gel element microarrays were blocked with 1% BSA in PBS for 1 hour at room temperature. Slides were rinsed with DI water and allowed to air dry in a dust free environment. The microarray assembly was then combined with the enclosed glass slide and the 256M tape from Adchem, i.e. the hydrophilic membrane and reservoir, was laser cut. About 0.5mL of SEB (1. mu.g/mL in PBS with 0.05% Tween-20 and 1% BSA) was titrated into the microarray system reservoir and aspirated continuously through the array chamber at room temperature. Next, 0.2mL of a dilution of anti-SEB monoclonal antibody in 1% BSA in PBST was titrated into the reservoir of the microarray system, which was continuously aspirated through the array chamber into the waste chamber. Next, 0.2mL of PBST is titrated into the reservoir of the microarray system, which is continuously aspirated through the array chamber into the absorbent material of the waste chamber. Subsequently, 0.1mL of Alexa 568-labeled anti-mouse antibody was titrated at 2 μ g/mL in PBST containing 1% BSA into the reservoir of the microarray system, which was continuously aspirated through the array chamber to the absorbent material of the waste chamber. An additional 0.2mL of PBST lotion was titrated into the reservoir of the microarray system, which was continuously drawn through the array chamber into the absorbent material of the waste chamber. The microarray system was then imaged on an Aurora PortArray5000 with a green laser (532nm) with a 605nm filter.

Example 5

Oligonucleotide mixtures were synthesized for MRSA according to the array diagram shown in fig. 9. Each sample was synthesized along the internal control sample Cy5. Additional Cy3 control samples related to the same oligonucleotide sequence were also mixed with the Cy5 control samples. Cy3/Cy5 dots were printed at a density of 0.1nM to 10 μ M in 1log concentration change in order to create a calibration curve. The imaging system consists of two series of optical elements. The two series of optical elements consist of an LED and an uncooled CCD camera. One series of optical elements was used to detect Cy3 spots (550nm excitation and 570nm luminescence) and the other series of optical elements was used to detect Cy5 spots (650nm excitation and 670nm luminescence). The series of optical elements are fixed in spatial position relative to the instrument. Moving the gantry to move the array to the green channel and acquire 10 images to improve the dynamic range; the multiple image requirement of short exposure times prevents saturation that may occur from using materials containing high auto-fluorescence, while also allowing signal averaging to mitigate the effects of chaotic noise. The gantry moves the array to the red channel and 10 images are acquired. This process is repeated 5 times to account for possible misalignment due to positioning accuracy, false exposure time, defocus and/or any other anomalies that may compromise correct imaging. Calibration curves were drawn for the Cy3/Cy5 series of concentration dilutions, as indicated by the outer boundary of the array in the combinatorial graphs below. The calibration curve derived from the concentration gradient is to correct for factors affecting the entire assembly such as sample shelf degradation, temperature, UV dose variation, synthesis variation, or any system artifact that may lead to non-reproducible behavior. Calibration curves for Cy5 were drawn when analyzed using the Cy3 calibration curve.

I_red＝m_red×moles(Cy5)+b_red

I_green＝m_green×moles(Cy3)+b_green

Wherein, I_redAnd I_greenIs the combined intensity of the background removed. Slope m_redAnd m_greenAnd coordinates b_redAnd b_greenCalculated from these calibration curves. The average of the calibration curve is plotted, rejectingValues outside the range. To account for the reproducibility from spot to spot, assembly to assembly and batch to batch, a combined intensity value of Cy5 divided by background was calculated for each spot. During synthesis, for each spot, the sampled (14,31,35,36,37,29,90, H or dN20) concentration of each spot had an equimolar concentration of oligonucleotide sample and Cy5 fluorophore. Then, the following relationship holds:

cy3 concentration ≈ Cy5 concentration

Therefore, the temperature of the molten metal is controlled,

I_{green，saturation}≈m_green×moles(Cy5)+b_green

wherein, I_{green,saturation}Representing a hypothetical case when all samples in the gel element were bound to a labeled Cy3 molecule. Note that moles (Cy5) are substituted for moles (Cy3) because of the equimolar equivalents in the above equation. The background corrected integrated intensity of the samples of these points used to determine the presence of MRSA was measured and calculated at representative points. If the strength meets the following criteria:

the value is considered positive. That is, more than 0.1% of the possible sample molecules have a bound target to the Cy3 tag. The method can also be used for quantitative elucidation.

Example 6

A kiss cut strip spool is manufactured for the backing tape spool containing the cut backing film with inlet and exhaust fill holes pre-punched into the backing tape spool. As shown in fig. 5, in manufacture, the carrier film roll is unwound and the paid-out backing material is collected on the upper roll. The gel element printer prints gel elements on a base film. The film is then subjected to UV irradiation under an inert atmosphere (e.g., argon). Argon positive pressure is slowly added to the argon chamber because it is denser than air, so that argon precipitates to the bottom of the chamber where the substrate is located. This allows argon to flow slowly into the chamber, thus placing minimal requirements on the chamber to be air-conditioned. To ensure that unpolymerized polymer remains on the substrate, the substrate is moved past a cleaning station so positioned that splatter into the polymerization chamber is eliminated. The washed array was dried using a conventional air knife assembly. The QC camera ensures that these components are printed according to specifications, and the rejection of the marking machine warns the operator to remove the non-compliant components. The double-sided tape defining the microarray cavity is unwound and adhered to the substrate. The openings in the backing tape are designed to allow for relatively loose tolerances in the lamination of the backing tape to the substrate, which allows for the manufacture of arrays of gel elements with variable shape and complexity without the need to modify the assembly line. The windable absorbent material is opened and mounted to the waste chamber of the assembly where it is sealed in place with glue or double-sided tape. An alternative to adding the absorbent material is to insert the absorbent material into the waste chamber using a pick-and-place robot. Current flow cell designs utilize an additional liner to contain the absorbent material twice as thick as the reaction chamber. Finally, a cover film having a plurality of filled holes is applied. The fill holes may be significantly larger or smaller than the holes in the liner film, allowing for a coarse error in alignment. The blade then cuts the tape to the appropriate size.

Pin printing robots typically have a print head that is typically provided with precisely machined pins. The print head is connected to a precision xyz shaft control arm (fig. 7). The control arm is responsible for moving the print head with micron-scale precision between a printing solution source plate (e.g., 384 well microtiter plate), a substrate printing station (plate), and a cleaning station (for cleaning pins between unique solution depositions). Alternatively, a high throughput non-contact print head simultaneously deposits multiple solutions within a microarray-PCR reaction chamber.

In certain embodiments, the entire microarray is printed at one time. Electrical Discharge Machining (EDM) can be used to fabricate printheads with 125 micron pins and 300 micron centers currently used (pin diameters currently used). Also, the parallel synthesis design provides a 24576 well plate with wells having 560 micron centers. This translates to about 350 points/cm. While this number of dots is sufficient for most fault diagnosis applications, the test requiring additional dots can be accomplished with multiple printers arranged in series on a combined line, with the printing time extending only the travel time from one printer to the next. Another example of printing on a moving film includes using a non-contact printer that employs a piezoelectric crystal and capillary action that draws in a microarray printing solution and disperses picoliters of liquid into nanoliter drops onto a substrate. The print head may include multiple capillaries for simultaneously printing a series of unique microarray dots containing independent samples. Also, the print head may be a high density capillary array for increasing the number of unique microarray spots. Alternatively, the print head can scan the carrier film crosswise, up, down, left, and right, to print the replication dots, or the print head scanning method can be used to aspirate a single polymer-sampling suspension to print multiple independent dots with the same print head. Another option is to reload the base film onto a web rewind system after the first printing process to print additional (individual) dots on the base film roll for each microarray again. The replication practice may include fiducials to properly align the film at the second, third and nth prints. One example of a relevant reference is the use of a perforated edge, such as that used in conjunction with 35 mm film. Another printing option includes the acoustic ejection non-contact method from Labcyte, where high frequency acoustic waves eject nanoliter droplets from the source plate to the target plate.

Example 7

FIG. 8 shows the results of printing a Cy3 gel element on a 0.005 "polyester film, which is available from McMaster-Carr (Santa Fe Springs, Calif.) in a roll-to-roll format. The film was placed in a vacuum chuck as shown in fig. 9 and printed. It is imaged with bright long illumination before and after polymerization. The array was also imaged with an Akonni imager consisting of LEDs and an uncooled camera. After printing, the MRSA array described above was printed onto a polyester film and encountered a Qiagen MasterMix with 300pg of purified MRSA dna. Thermocycling was performed on a Quanta Bioscience slide block thermocycler. Fig. 10 shows the results when a windable film is used for the top, bottom and backing tape, which shows the positive identification of MRSA. Fig. 11 shows a web rewind print setup with video frames using a BioDot Ultra non-contact array printer (top plate) and non-contact printing using BioDot Ultra on a moving film that has not been chemically treated and modified (bottom plate). These results show the feasibility of printing microarrays on a moving film using a non-contact array printer that allows for high-speed, low-cost manufacturing of the microarray assemblies of the present invention.

Example 8

Fig. 12-14 illustrate an array image analysis process. FIG. 12 is an array image taken at the factory QC with a red channel imager to extract array QC data. The QC software algorithm automatically finds each point in the array and assigns each point to its respective location in the array grid. The software displays a 12 x 12 square grid and draws a circle around each point. The QC software calculates the relative position of each circle in its bounding square grid box (deviation X, deviation Y) and stores this information as part of the QC data to aid post-hybridization image analysis.

FIG. 13 is an array image taken with an end-user green channel imager after hybridization. The image analysis software mapped the array grid based on Cy3 fluorescence and drawn a 12 x 12 square grid. Image analysis then locates each point using the relative point locations (offset X and offset Y from the array QC file) and draws a circle around the point for visual recognition. Note that with the help of array QC data, the software was able to locate each point on this column and draw a circle completely around each point.

FIG. 14 is an image of the array taken with an end-user green channel imaging instrument after hybridization. The image analysis software mapped the array grid based on Cy3 fluorescence and drawn a 12 x 12 square grid. For this image, the image analysis software does not obtain information about the relative point locations from the array QC file. Instead, the image analysis software identifies each point assuming that the center of each square grid cell is the center of the point. The software misidentifies several points by drawing some circles that do not completely surround the point. The erroneously identified points include points located at row 2, column 2 and row 11, column 6. Note that this image analysis without array QC data is less robust in point recognition than image analysis using array QC data as shown in fig. 13.

Claims (12)

1. A method of fabricating a microarray assembly, comprising:

unwinding the unwound base film from one or more base film reels;

printing a microarray onto an unwound backing film;

laminating a liner film onto the printed carrier film, wherein the liner film is pre-cut to provide space for the array chamber prior to the placing step and the liner film is placed onto the printed carrier film by one or more liner film reels;

laminating a cover film on the liner film to form a multilayer microarray structure; and

the multilayer microarray structure is cut into a plurality of individual microarray assemblies.

2. The method of claim 1, wherein the liner film is pre-cut to provide space for one or more waste chambers.

3. The method of claim 2, wherein the liner film is pre-cut to provide space for one or more array chambers.

4. The method of claim 1, wherein the printing step is performed on a moving carrier film in a production line.

5. The method according to claim 1, wherein the base film is a hydrophobic film and the cover film is a hydrophilic film.

6. The method of claim 1, wherein the carrier film has a thickness in the range of 20-200 microns.

7. The method of claim 1, wherein the coating has a thickness in the range of 25-250 microns.

8. The method of claim 1, wherein the liner film has a thickness in the range of 20-500 microns.

9. The method according to claim 1, wherein the surface of the base film has double-bonded carbon atoms.

10. The method of claim 1, wherein the backing film is made of a hydrophobic material.

11. The method of claim 1, wherein the microarray is a gel-dot microarray printed onto the base film with a non-contact microarray printer.

12. The method of claim 11, wherein the gel-spot microarray comprises a protein sample or a nucleotide sample covalently cross-linked to a polymer backbone by uv-induced copolymerization.