Bio-Rad Utilized BOYD Insulation Scheme and Thermal Interface Materials and Implemented It into Their Thermal Cycler Design
Introduction
Thermal Cyclers (also known as DNA cyclers, thermocyclers, PCR
machines, or DNA amplifiers) are used to amplify segments of DNA via the
polymerase chain reaction and are essential for labs that rely on
molecular biology. Their use is crucial for applications such as the detection and diagnosis of infectious diseases and hereditary diseases,
DNA cloning for sequencing, and DNA profiling. Thermal Cyclers provide a
thermally controlled environment for DNA samples that are necessary
during temperature cycling. Because the process relies heavily on
precise temperature control, it is vital that this equipment has proper
thermal management. Because they required the best possible thermal
design for their newest Thermal Cycler design, Bio-Rad contacted BOYD.
Challenge
In order to perform with peak accuracy, uniformity, and speed, the
thermal optimization of the product needed to be designed with a heat
sink configuration that maintained less than +/-0.5°C variation in
temperatures from sample to sample.
Boyd also needed to determine the feasibility of removing edge heaters from the sample block by recommending an appropriate insulation scheme and thermal interface materials.
Solution
Boyd engineers evaluated several fan and heat sink combinations
by creating airflow-thermal simulation models to choose a particular
fan, number of fans, location of fans, heat sink geometry, etc. These
simulations helped in the selection of an optimal combination of fan and
heat sink. The team then created a prototype of the unit to capture all
heat and airflow related details. The prototype was tested for
temperature variation and the data was used to enhance the accuracy and
reliability of simulation predictions.
To further
optimize the overall product design, Boyd engineers evaluated the
feasibility of removing heaters used to minimize the sample-to-sample
temperature variation. It was shown using simulations that placing
polyurethane foam at key locations can maintain the sample-to-sample
temperature variation without the side heaters.
Implementation and Results
Bio-Rad utilized the recommended Boyd solution and implemented
it into their Thermal Cycler design, which is still being produced
today. This Bio-Rad Thermal Cycler has now been in use for several years
with excellent results. Over the years, the final products have
maintained their accuracy and reliability and Bio-Rad is known for its
robust, high performing PCR amplification equipment.
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