Fluid control and processing method

BACKGROUND OF THE INVENTION

The present invention relates generally to fluid manipulation and, more particularly, to a method for metering and distributing fluid for processing and analysis.

The analysis of fluids such as clinical or environmental fluids generally involves a series of processing steps, which may include chemical, optical, electrical, mechanical, thermal, or acoustical processing of the fluid samples. Whether incorporated into a bench-top instrument, a disposable cartridge, or a combination of the two, such processing typically involves complex fluidic assemblies and processing algorithms.

Conventional systems for processing fluid samples employ a series of chambers each configured for subjecting the fluid sample to a specific processing step. As the fluid sample flows through the system sequentially from chamber to chamber, the fluid sample undergoes the processing steps according to a specific protocol. Because different protocols require different configurations, conventional systems employing such sequential processing arrangements are not versatile or easily adaptable to different protocols.

SUMMARY OF THE INVENTION

The present invention provides a method for controlling fluid flow between a valve and a plurality of chambers according to claim 1. The valve includes a plurality of external ports and a fluid displacement chamber continuously coupled fluidicly with a fluid sample processing region which is fluidicly coupled with at least two of the external ports. The method may comprise adjusting the valve with respect to the plurality of chambers to place the external ports selectively in fluidic communication with the plurality of chambers. Embodiments of the invention facilitate processing of a fluid sample according to different protocols using the same apparatus, for instance, to determine the presence or absence of an analyte in the sample. In a specific embodiment, a rotary valve configuration is employed that allows fluidic communication between a fluid sample processing region selectively with a plurality of chambers including, for example, a sample chamber, a waste chamber, a wash chamber, a lysate chamber, and a mastermix chamber. The fluid flow among the fluid sample processing region and the chambers is controlled by adjusting the position of the rotary valve. In this way, the metering and distribution of fluids in the apparatus can be varied depending on the specific protocol. Unlike conventional devices, the fluid flow is no longer limited to a specific protocol. As a result, it is more versatile and robust, and is adaptable to different protocols.

The valve includes a fluid sample processing region continuously coupled fluidicly with a fluid displacement chamber. The fluid displacement chamber is depressurizable to draw fluid into the fluid displacement chamber and pressurizable to expel fluid from the fluid displacement chamber. The valve includes a plurality of external ports. The fluid sample processing region may include a plurality of fluid processing ports each fluidicly coupled with one of the external ports. The fluid displacement chamber is fluidicly coupled with at least one of the external ports. The valve is adjustable with respect to the plurality of chambers to allow the external ports to be placed selectively in fluidic communication with the plurality of chambers.

In some embodiments, the valve is adjustable with respect to the chambers to place one external port at a time in fluidic communication with one of the plurality of chambers. The fluid sample processing region is disposed between the fluid displacement chamber and at least one external port. The fluid sample processing region comprises an active member which includes, for example, a microfluidic chip, a solid phase material, a filter or a filter stack, an affinity matrix, a magnetic separation matrix, a size exclusion column, a capillary tube, or the like. An energy transmitting member is operatively coupled with the fluid sample processing region for transmitting energy thereto to process fluid contained therein. In one embodiment, the body includes a crossover channel, and the body is adjustable with respect to the plurality of chambers to place the crossover channel in fluidic communication between two of the chambers.

The method of claim 1 may be implemented using a fluid control and processing system for controlling fluid flow among a plurality of chambers, which comprises a valve including a fluid sample processing region continuously coupled fluidicly with a fluid displacement chamber. The fluid displacement chamber is depressurizable to draw fluid into the fluid displacement chamber and pressurizable to expel fluid from the fluid displacement chamber. The valve includes a plurality of external ports. The fluid sample processing region is fluidicly coupled with at least two of the external ports. The fluid displacement chamber is fluidicly coupled with at least one of the external ports. The valve is adjustable with respect to the plurality of chambers to place at least one of the external ports selectively in fluidic communication with the plurality of chambers.

In some embodiments, the valve is adjustable with respect to the plurality of chambers to place at most one external port at a time in fluidic communication with one of the plurality of chambers. The valve is also adjustable with respect to the plurality of chambers to close the external ports so that the fluid displacement chamber and sample fluid processing region are fluidicly isolated from the chambers. The fluid sample processing region comprises a trapping member for trapping sample components (e.g., cells, spores, viruses, large or small molecules, or proteins) of a fluid sample. The trapping member may comprise one or more filters, a microfluidic chip, filter paper, beads, fibers, a membrane, glass wool, polymers, or gel.

BRIEF DESCRIPTION OF THE DRAWINGS

<ul id="ul0001" list-style="none" compact="compact"><li><figref idref="f0001">Fig. 1</figref> is a perspective view of the fluid control and processing system for implementing the method of the present invention;</li><li><figref idref="f0002">Fig. 2</figref> is another perspective view of the system of <figref idref="f0001">Fig. 1</figref>;</li><li><figref idref="f0003">Fig. 3</figref> is an exploded view of the system of <figref idref="f0001">Fig. 1</figref>;</li><li><figref idref="f0004">Fig. 4</figref> is an exploded view of the system of <figref idref="f0002">Fig. 2</figref>;</li><li><figref idref="f0005">Fig. 5</figref> is an elevational view of a fluid control apparatus and gasket in the system of <figref idref="f0001">Fig. 1</figref>;</li><li><figref idref="f0006">Fig. 6</figref> is a bottom plan view of the fluid control apparatus and gasket of <figref idref="f0005">Fig. 5</figref>;</li><li><figref idref="f0007">Fig. 7</figref> is a top plan view of the fluid control apparatus and gasket of <figref idref="f0005">Fig. 5</figref>;</li><li><figref idref="f0008">Fig. 8</figref> is a cross-sectional view of the rotary fluid control apparatus of <figref idref="f0007">Fig. 7</figref> along 8-8;</li><li><figref idref="f0009 f0010 f0011 f0012 f0013 f0014 f0015 f0016 f0017 f0018 f0019 f0020">Figs. 9A-9LL</figref> are top plan views and cross-sectional views illustrating a specific protocol for controlling and processing fluid using the fluid control and processing system of <figref idref="f0001">Fig. 1</figref>;</li><li><figref idref="f0021">Fig. 10</figref> is an exploded perspective view of the fluid control and processing system for implementing the method of the present invention;</li><li><figref idref="f0022">Fig. 11</figref> is a cross-sectional view of a fluid control apparatus in the system of <figref idref="f0021">Fig. 10</figref>;</li><li><figref idref="f0023 f0024 f0025 f0026 f0027 f0028 f0029">Figs. 12A-12N</figref> are plan views illustrating a specific protocol for controlling and processing fluid using the fluid control and processing system of <figref idref="f0021">Fig. 10</figref>;</li><li><figref idref="f0030">Fig. 13</figref> is a cross-sectional view of a soft-walled chamber;</li><li><figref idref="f0030">Fig. 14</figref> is a cross-sectional view of a piston assembly; and</li><li><figref idref="f0030">Fig. 15</figref> is a cross-sectional view of a side filtering chamber.</li></ul>

DESCRIPTION OF THE SPECIFIC EMBODIMENTS AND SYSTEMS FOR IMPLEMENTING THE METHOD

<figref idref="f0001 f0002 f0003 f0004">Figs. 1-4</figref> show a fluid control and processing system 10 including a housing 12 having a plurality of chambers 13. <figref idref="f0001">Fig. 1</figref> shows the chambers 13 exposed for illustrative purposes. A top cover will typically be provided to enclose the chambers 13. As best seen in <figref idref="f0003">Figs. 3</figref> and <figref idref="f0004">4</figref>, a fluid control device 16 and a reaction vessel 18 are connected to different portions of the housing 12. The fluid control device in the embodiment shown is a rotary fluid control valve 16. The valve 16 includes a valve body 20 having a disk portion 22 and a tubular portion 24. The disk portion 22 has a generally planar external port surface 23, as best seen in <figref idref="f0003">Fig. 3</figref>. The valve 16 is rotatable relative to the housing 12. The housing 12 includes a plurality of chamber ports 25 facing the external port surface 23 of the disk portion 22 of the valve 16 (<figref idref="f0004">Fig. 4</figref>) to permit fluidic communication between the chambers 13 and the valve 16. A optional seal or gasket 26 is disposed between the disk portion 22 and the housing 12. The disk portion 22 further includes a filter or a filter stack 27 and an outer cover 28, and a toothed periphery 29. The cover 28 may be a rigid shell or a flexible film.

As best seen in <figref idref="f0004">Fig. 4</figref>, the disk portion 22 includes a fluid sample processing region 30. As used herein, the term "fluid sample processing region" refers to a region in which a fluid sample is subject to processing including, without limitation, chemical, optical, electrical, mechanical, thermal, or acoustical processing. For example, chemical processing may include a catalyst; optical processing may include U.V. activation; electrical processing may include electroporation or electrophoresis; mechanical processing may include filtering, pressurization, and cell disruption; thermal processing may include heating or cooling; and acoustical processing may include the use of ultrasound. The fluid sample processing region may include an active member, such as the filter 27, to facilitate processing of the fluid. Examples of active members include a microfluidic chip, a solid phase material, a filter or a filter stack, an affinity matrix, a magnetic separation matrix, a size exclusion column, a capillary tube, or the like. Suitable solid phase materials include, without limitation, beads, fibers, membranes, filter paper, glass wool, polymers, or gels. In a specific embodiment, the fluid sample processing region is used to prepare a sample for further processing, for instance, in the reaction vessel 18.

As shown in <figref idref="f0005 f0006 f0007 f0008">Figs. 5-8</figref>, the outer cover 28 encloses the fluid sample processing region 30 and the bottom end of the disk portion 22 of the valve 16. In <figref idref="f0008">Fig. 8</figref>, the processing region 30 includes a first fluid processing port 32 coupled to a first fluid processing channel 34, and a second fluid processing port 36 coupled to a second fluid processing channel 38. The first fluid processing channel 34 is coupled to a first outer conduit 40 ending at a first external port 42 at the external port surface 23, while the second fluid processing channel 38 is coupled to a second outer conduit 44 ending at a second external port 46 at the external port surface 23. A fluid displacement channel 48 is coupled to the first fluid processing channel 34 and first conduit 40 near one end, and to a fluid displacement chamber 50 at the other end. The first outer conduit 40 serves as a common conduit for allowing fluidic communication between the first external port 42 and either or both of the first fluid processing channel 34 and the fluid displacement channel 48. The processing region 30 is in continuous fluidic communication with the fluid displacement chamber 50.

As shown in <figref idref="f0006 f0007 f0008">Figs. 6-8</figref>, the external ports 42,46 are angularly spaced from one another relative to the axis 52 of the valve 16 by about 180°. The external ports 42, 46 are spaced radially by the same distance from the axis 52. The axis 52 is perpendicular to the external port surface 23. In another embodiment, the angular spacing between the external ports 42, 46 may be different. The configuration of the channels in the disk portion 22 may also be different in another embodiment. For example, the first fluid processing channel 34 and the first outer conduit 40 may be slanted and coupled directly with the fluid displacement chamber 50, thereby eliminating the fluid displacement channel 48. The second fluid displacement channel 38 may also be slanted and extend between the second fluid processing port 36 and the second external port 46 via a straight line, thereby eliminating the second outer conduit 44. In addition, more channels and external ports may be provided in the valve 16. As best seen in <figref idref="f0003">Fig. 3</figref>, a crossover channel or groove 56 is desirably provided on the external port surface 23. The groove 56 is curved and desirably is spaced from the axis 52 by a constant radius. In one embodiment, the groove 56 is a circular arc lying on a common radius from the axis 52. As discussed in more detail below, the groove 56 is used for filling the vessel.

As shown in <figref idref="f0008">Fig. 8</figref>, the fluid displacement chamber 50 is disposed substantially within the tubular portion 24 of the valve 16 and extends partially into the disk portion 22. A fluid displacement member in the form of a plunger or piston 54 is movably disposed in the chamber 50. When the piston 54 moves upward, it expands the volume of the chamber 50 to produce a suction for drawing fluid into the chamber 50. When the piston 54 moves downward, it decreases the volume of the chamber 50 to drive fluid out of the chamber 50.

As the rotary valve 16 is rotated around its axis 52 relative to the housing 12 of <figref idref="f0001 f0002 f0003 f0004">Figs. 1-4</figref>, one of the external ports 42,46 may be open and fluidicly coupled with one of the chambers 13 or reaction vessel 18, or both external ports 42,46 may be blocked or closed. In this embodiment, at most only one of the external ports 42, 46 is fluidicly coupled with one of the chambers or reaction vessel 18. Other embodiments may be configured to permit both external ports 42, 46 to be fluidicly coupled with separate chambers or the reaction vessel 18. Thus, the valve 16 is rotatable with respect to the housing 12 to allow the external ports 42, 46 to be placed selectively in fluidic communication with a plurality of chambers which include the chambers 13 and the reaction vessel 18. Depending on which external port 42,46 is opened or closed and whether the piston 54 is moved upward or downward, the fluid flow in the valve 16 can change directions, the external ports 42, 46 can each switch from being an inlet port to an outlet port, and the fluid flow may pass through the processing region 30 or bypass the processing region 30. In a specific embodiment, the first external port 42 is the inlet port so that the inlet side of the processing region 30 is closer to the fluid displacement chamber 54 than the outlet side of the processing region 30.

To demonstrate the fluid metering and distribution function of the valve 16, <figref idref="f0009 f0010 f0011 f0012 f0013 f0014 f0015 f0016 f0017 f0018 f0019 f0020">Figs. 9A-9LL</figref> illustrate the operation of the valve 16 for a specific protocol. In <figref idref="f0009">Figs. 9A and 9AA</figref>, the first external port 42 is placed in fluidic communication with a sample chamber 60 by rotating the valve 16, and the piston 54 is pulled upward to draw a fluid sample from the sample chamber 60 through the first outer conduit 40 and fluid displacement channel 48 to the fluid displacement chamber 50, bypassing the processing region 30. For simplicity, the piston 54 is not shown in <figref idref="f0009 f0010 f0011 f0012 f0013 f0014 f0015 f0016 f0017 f0018 f0019 f0020">Figs. 9A-9LL</figref>. The valve 16 is then rotated to place the second external port 46 in fluidic communication with a waste chamber 64 as shown in <figref idref="f0010">Figs. 9B and 9BB</figref>. The piston 54 is pushed downward to drive the fluid sample through the fluid sample processing region 30 to the waste chamber 64. In a specific embodiment, the fluid sample processing region 30 includes a filter or a filter stack 27 for capturing sample components (e.g., cells, spores, microorganisms, viruses, proteins, or the like) from the fluid sample as it passes therethrough. An example of a filter stack is described in commonly assigned, copending <patcit id="pcit0001" dnum="US58432700A" dnum-type="L"><text>U.S. Patent Application No. 09/584,327</text></patcit>, entitled "Apparatus and Method for Cell Disruption," filed May 30, 2000, which is incorporated herein by reference in its entirety. In alternative embodiments, other active members may be provided in the processing region 30. These first two steps of capturing sample components may be repeated as desired.

In <figref idref="f0011">Figs. 9C and 9CC</figref>, the valve 16 is rotated to place the first external port 42 in fluidic communication with a wash chamber 66, and the piston 54 is pulled upward to draw a wash fluid from the wash chamber 66 into the fluid displacement chamber 50, bypassing the processing region 30. The valve 16 is then rotated to place the second external port 46 in fluidic communication with the waste chamber 64 as shown in <figref idref="f0012">Figs. 9D and 9DD</figref>. The piston 54 is pushed downward to drive the wash fluid through the fluid sample processing region 30 to the waste chamber 64. The above washing steps may be repeated as desired. The intermediate washing is used to remove unwanted residue within the valve 16.

In <figref idref="f0013">Figs. 9E and 9EE</figref>, the valve 16 is rotated to place the first external port 42 in fluidic communication with a lysate chamber 70, and the piston 54 is pulled upward to draw a lysate fluid (e.g., a lysing reagent or buffer) from the lysate chamber 70 into the fluid displacement chamber 50, bypassing the processing region 30. The valve 16 is then rotated to place the second external port 46 in fluidic communication with the waste chamber 64 as shown in <figref idref="f0014">Figs. 9F and 9FF</figref>. The piston 54 is pushed downward to drive the lysate fluid through the fluid sample processing region 30 to the waste chamber 64. In <figref idref="f0015">Figs. 9G, and 9GG</figref>, the valve 16 is rotated to close the external ports 42, 46. The piston 54 is pushed downward to pressurize the remaining lysate fluid and the sample components captured in the fluid sample processing region 30. Additional energy may be applied to the mixture in the processing region 30. For instance, a sonic member 76 such as an ultrasonic horn may be placed in contact with the outer cover 28 to transmit sonic energy into the processing region 30 to facilitate lysing of the sample components. In one embodiment, the outer cover 28 is made of a flexible film which is stretched under pressure to contact the sonic member 76 during lysing to allow transmission of the sonic energy into the processing region 30.

The cover 28 in one preferred embodiment is a flexible film of polymeric material such as polypropylene, polyethylene, polyester, or other polymers. The film may either be layered, e.g., laminates, or the films may be homogeneous. Layered films are preferred because they generally have better strength and structural integrity than homogeneous films. In particular, layered polypropylene films are presently preferred because polypropylene is not inhibitory to polymerase chain reaction (PCR). Alternatively, the cover 28 may comprise other materials such as a rigid piece of plastic.

In general, the energy transmitting member that is operatively coupled to the processing region 30 for transmitting energy thereto may be an ultrasonic, piezoelectric, magnetostrictive, or electrostatic transducer. The energy transmitting member may also be an electromagnetic device having a wound coil, such as a voice coil motor or a solenoid device. It is presently preferred that the energy transmitting member be a sonic member, such as an ultrasonic horn. Suitable horns are commercially available from Sonics &amp; Materials, Inc. having an office at 53 Church Hill, Newton, Connecticut 06470-1614, U.S.A. Alternatively, the sonic member may comprise a piezoelectric disk or any other type of ultrasonic transducer that may be coupled to the cover 28. In alternative embodiments, the energy transmitting member may be a thermal element (e.g., a heater) for transmitting thermal energy to the processing region 30 or an electrical element for transmitting electrical energy to the processing region 30. In addition, multiple energy transmitting members may be employed simultaneously, e.g., simultaneously heating and sonicating the processing region to effect lysis of cells, spores, viruses, or microorganisms trapped in the processing region.

In <figref idref="f0016">Figs. 9H and 9HH</figref>, the valve 16 is rotated to place the second external port 46 in fluidic communication with a mastermix chamber 78, and the piston 54 is pushed downward to elute the mixture from the processing region 30 to the mastermix chamber 78. The mastermix chamber 78 typically contains reagents (e.g., PCR reagents and fluorescent probes) to be mixed with the sample. Any excess mixture is dispensed into the waste chamber 64 via the second external port 46 after rotating the valve 16 to place the port 46 in fluidic communication with the waste chamber 64, as shown in <figref idref="f0017">Figs. 9I and 9II</figref>. The mixture is then mixed in the mastermix chamber 78 by toggling. This is carried out by placing the fluid displacement chamber 50 in fluidic communication with the mastermix chamber 78 as shown in <figref idref="f0018">Figs. 9J and 9JJ</figref>, and moving the piston 54 up and down. Toggling of the mixture through the filter in the processing region 30, for instance, allows larger particles trapped in the filter to temporarily move out of the way to permit smaller particles to pass through.

In <figref idref="f0019">Figs. 9K, 9KK, and 9K'K'</figref>, the valve 16 is rotated to place the first external port 42 in fluidic communication with a first branch 84 coupled to the reaction vessel 18, while the second branch 86 which is coupled to the reaction vessel 18 is placed in fluidic communication with the crossover groove 56. The first branch 84 and second branch 86 are disposed at different radii from the axis 52 of the valve 16, with the first branch 84 having a common radius with the first external port 42 and the second branch 86 having a common radius with the crossover groove 56. The crossover groove 56 is also in fluidic communication with the mastermix chamber 78 (<figref idref="f0019">Fig. 9K</figref>), and serves to bridge the gap between the mastermix chamber 78 and the second branch 86 to provide crossover flow therebetween. The external ports are disposed within a range of external port radii from the axis and the crossover groove is disposed within a range of crossover groove radii from the axis, where the range of external port radii and the range of crossover groove radii are non-overlapping. Placing the crossover groove 56 at a different radius from the radius of the external ports 42, 46 is advantageous because it avoids cross-contamination of the crossover groove 56 by contaminants that may be present in the area near the surfaces between the valve 16 and the housing 12 at the radius of the external ports 42, 46 as a result of rotational movement of the valve 16. Thus, while other configurations of the crossover groove may be used including those that overlap with the radius of the external ports 42, 46, the embodiment as shown is a preferred arrangement that isolates the crossover groove 56 from contamination from the area near the surfaces between the valve 16 and the housing 12 at the radius of the external ports 42, 46.

To fill the reaction vessel 18, the piston 54 is pulled upward to draw the mixture in the mastermix chamber 78 through the crossover groove 56 and the second branch 86 into the reaction vessel 18. In such an arrangement, the reaction vessel 18 is the aspiration chamber or referred to as the first chamber, and the mastermix chamber 78 is the source chamber or referred to as the second chamber. The valve 16 is then rotated to place the second external port 46 in fluidic communication with the first branch 84 and to close the first external port 42, as shown in <figref idref="f0020">Figs. 9L and 9LL</figref>. The piston 54 is pushed downward to pressurize the mixture inside the reaction vessel 18. The reaction vessel 18 may be inserted into a thermal reaction chamber for performing nucleic acid amplification and/or detection. The two branches 84, 86 allow filling and evacuation of the reaction chamber of the reaction vessel 18. The vessel maybe connected to the housing 12 by ultrasonic welding, mechanical coupling, or the like, or be integrally formed with the housing 12 such as by molding. The use of a reaction vessel for analyzing a fluid sample is described in commonly assigned, copending <patcit id="pcit0002" dnum="US58432800A" dnum-type="L"><text>U.S. Patent Application No. 09/584,328</text></patcit>, entitled "Cartridge for Conducting a Chemical Reaction," filed May 30, 2000.

To operate the valve 16 of <figref idref="f0003 f0004 f0005 f0006 f0007 f0008">Figs. 3-8</figref>, a motor such as a stepper motor is typically coupled to the toothed periphery 29 of the disk portion 22 to rotate the valve 16 relative to the housing 12 for distributing fluid with high precision. The motor can be computer-controlled according to the desired protocol. A linear motor or the like is typically used to drive the piston 54 up and down with precision to provide accurate metering, and may also be computer-controlled according to the desired protocol.

<figref idref="f0021">Fig. 10</figref> shows another valve 100 which is rotatably coupled to a fluid control channel housing or block 102. A reaction vessel 104 is detachably coupled to the housing 102. The valve 100 is a generally tubular member with a longitudinal axis 105 as shown in <figref idref="f0022">Fig. 11</figref>. A piston 106 is movably connected to the valve 100 to change the volume of the fluid displacement chamber 108 as the piston 106 is moved up and down. A cover 109 is placed near the bottom of the valve 100. A fluid sample processing region 110 is disposed in the valve 100 and is in continuous fluidic communication with the fluid displacement chamber 108. The valve 100 includes a pair of apertures serving as a first port 111 and a second port 112, as best seen in <figref idref="f0022">Fig. 11</figref>. In the embodiment shown, the ports 111, 112 are angularly spaced by about 120°, but the spacing may be different in alternate embodiments. A crossover channel or groove 114 is formed on the external surface 116 of the valve 100 and extends generally in the longitudinal direction, as seen in <figref idref="f0021">Fig. 10</figref>. The two ports 111, 112 are disposed at different levels longitudinally offset from one another along the longitudinal axis 105, and the crossover groove 114 extends in the longitudinal direction of the axis 105 bridging the two levels of the ports 111, 112.

The housing 102 has an opening 118 for receiving the portion of the valve 100 having the ports 111, 112 and groove 114. The internal surface 120 around the opening 118 is shaped to cooperate with the external surface 116 of the valve 100. Although a gasket may be placed between the internal surface 120 and the external surface 116, a preferred embodiment employs tapered or conical surfaces 120, 116 that produce a sealing effect without the use of an additional gasket. The housing 102 includes a plurality of channels and ports and the valve 100 is rotatable around its axis 105 to allow the ports 111,112 to be placed selectively in fluidic communication with the plurality of channels in the housing 102. Depending on which port is opened or closed and whether the piston 106 is moved upward or downward, the fluid flow in the valve 100 can change directions, and the ports 111, 112 can each switch from being an inlet port to an outlet port.

To demonstrate the fluid metering and distribution function of the valve 100, <figref idref="f0023 f0024 f0025 f0026 f0027 f0028 f0029">Figs. 12A-12N</figref> illustrate the operation of the valve 100 for a specific protocol. As shown in <figref idref="f0023">Fig. 12A</figref>, the housing 102 includes a plurality of fluid channels. For convenience, the channels are labeled as follows: mastermix channel 130, lysate channel 132, sample channel 134, wash channel 136, waste channel 138, first branch 140, and second branch 142. The channels 130-138 extend from the internal surface 120 to one external surface 144 which is generally planar, and the branches 140,142 extend from the internal surface 120 to another external surface 146 which is also generally planar (<figref idref="f0021">Fig. 10</figref>). When assembled, the first port 111 and the channels 130-134 lie on a first transverse plane that is perpendicular to the longitudinal axis 105, while the second port 112, the channels 136,138, and the two branches 140, 142 lie on a second transverse plane that is perpendicular to the longitudinal axis 105. The second transverse plane is longitudinally offset from the first transverse plane. For convenience, the second port 112, the channels 136, 13 8, and the branches 140,142 are shaded to indicate that they are longitudinally offset from the first port 111 and the channels 130-134. The crossover groove 114 extends longitudinally to bridge the offset between the first and second transverse planes. A chamber body 150 is connected to the housing 102 (<figref idref="f0021">Fig. 10</figref>), and includes the mastermix chamber, lysate chamber, sample chamber, wash chamber, and waste chamber that are respectively coupled fluidicly with the channels 130-138. The first and second branches 140,142 are fluidicly coupled with the reaction vessel 104.

In <figref idref="f0023">Fig. 12A</figref>, the first port 111 is placed in fluidic communication with the sample channel 134 and the piston 106 is pulled upward to draw a fluid sample into the fluid displacement chamber 108 (<figref idref="f0022">Fig. 11</figref>). The valve 100 is then rotated to place the second port 112 in fluidic communication with the waste channel 138 and the piston 106 is pushed downward to drive the fluid sample from the displacement chamber 108 through the processing region 110, and out through the waste channel 138, as shown in <figref idref="f0023">Fig. 12B</figref>. These steps are typically repeated until an entire sample is processed through the processing region 110, for instance, to capture sample components on a trapping member such as a filter.

In <figref idref="f0024">Fig. 12C</figref>, the valve 100 is rotated to place the second port 112 in fluidic communication with the wash channel 136 to aspirate a wash fluid into the processing region 110 by pulling the piston 106 upward. The valve 100 is then rotated to place the second port 112 in fluidic communication with the waste channel 138 and the piston 106 is pushed downward to drive the wash fluid from the processing region 110 out through the waste channel 138. The above washing steps can be repeated as desired to remove unwanted residue inside the valve 100.

For lysing, the valve 100 is rotated to place the first port 111 in fluidic communication with the lysate channel 132 and the piston 106 is pulled upward to draw a lysate fluid into the fluid displacement chamber 108, as shown in <figref idref="f0025">Fig. 12E</figref>. In <figref idref="f0025">Fig. 12F</figref>, the valve 110 is rotated to close both ports 111, 112. The piston 106 is pushed downward to push the lysate fluid into the processing region 110 and to pressurize the lysate fluid and the sample components captured in the fluid sample processing region 110. Additional energy may be applied to the mixture in the processing region 110 including, for instance, sonic energy transmitted into the processing region 110 by operatively coupling a sonic member with the cover 109 (<figref idref="f0022">Fig. 11</figref>).

In <figref idref="f0026">Fig. 12G</figref>, a desired preset amount of wash fluid is aspirated into the processing region 110 from the wash channel 136 through the second port 112 to dilute the mixture. The valve 100 is then rotated to place the first port 111 in fluidic communication with the mastermix channel 130 to discharge a preset amount of the mixture from the processing region 110 to the mastermix chamber, as shown in <figref idref="f0026">Fig. 12H</figref>. The piston 106 is moved up and down to agitate and mix the mixture by toggling. The balance of the mixture is discharged through the second port 112 to the waste channel 138, as shown in <figref idref="f0027">Fig. 12I</figref>. Another wash is performed by drawing a wash fluid from the wash channel 136 through the second port 112 into the processing region 110 (<figref idref="f0027">Fig. 12J</figref>), and discharging the wash fluid from the processing region 110 through the second port 112 to the waste channel 138 (<figref idref="f0028">Fig. 12K</figref>).

In <figref idref="f0028">Fig. 12L</figref>, the valve 100 is rotated to place the second port 112 in fluidic communication with the first branch 140 coupled to the reaction vessel 104, while the second branch 142 which is coupled to the reaction vessel 104 is placed in fluidic communication with the crossover groove 114. The second branch 142 is longitudinal offset from the mastermix channel 130. In the position as shown in <figref idref="f0028">Fig. 12L</figref>, the crossover groove 114 extends longitudinally to bridge the offset between the second branch 142 and the mastermix channel 130 to place them in fluidic communication with one another. As a result, the fluid sample processing region 110 is in fluidic communication, through the first branch 140, the reaction vessel 104, the second branch 142, and the crossover groove 114, with the mastermix channel 130.

By pulling the piston 106 upward, the mixture in the mastermix chamber is drawn from the mastermix channel 130 through the crossover groove 114 and the second branch 142 into the reaction vessel 104. The valve 100 is then rotated to place the second port 112 in fluidic communication with the second branch 142 and to close the first port 111, as shown in <figref idref="f0029">Fig. 12M</figref>. The piston 106 is pushed downward to pressurize the mixture inside the reaction vessel 104. In <figref idref="f0029">Fig. 12N</figref>, the valve 100 is rotated to close the ports 111, 112 and isolate the reaction vessel 104. The reaction vessel 104 may be inserted into a thermal reaction chamber for performing nucleic acid amplification and/or detection.

As illustrated in the above embodiments, the fluid control and processing system is advantageously a fully contained system that is versatile and adaptable. The fluid displacement chamber is the motivating force for moving fluid in the system. By maintaining a continuous fluidic communication between the fluid displacement chamber and the fluid sample processing region, the motivating force for moving fluid in the system is fluidicly coupled to the processing region at all times. The fluid displacement chamber (motivating force) also acts as a temporary storage area for the fluid being driven through the system. A single motivating force is used to move fluid through the system. While the embodiments shown employ a moving piston in the fluid displacement chamber as the motivating force, other mechanisms may be used including, e.g., pneumatic pump mechanisms or the like which use pressure as the motivating force without a change in volume of the fluid displacement chamber. The inlet or outlet side of the fluid sample processing region can address any of the chambers to permit random access to reagents and other fluids. Complex protocols can be programmed relatively easily into a computer controller and then executed using the versatile fluid control and processing system. A myriad of different protocols can be performed using a single platform.

In the embodiments shown, the fluid control occurs by addressing a pair of ports in the valve to place only one port at a time selectively in fluidic communication with the chambers. This is accomplished by keeping the pair of ports out of phase relative to the chambers. A crossover or bypass channel provides additional fluid control capability (e.g., allowing convenient filling and emptying of the reaction vessel within the closed system). Of course, different porting schemes may be used to achieve the desired fluid control in other embodiments. Moreover, while the embodiments shown each include a single fluid sample processing region in the valve body, additional processing regions can be located in the valve body if desired. Generally, the valve body needs (n+1) ports per n processing regions.

The use of a single valve produces high manufacturing yields due to the presence of only one failure element. The concentration of the fluid control and processing components results in a compact apparatus (e.g., in the form of a small cartridge) and facilitates automated molding and assembly. As discussed above, the system advantageously includes dilution and mixing capability, intermediate wash capability, and positive pressurization capability. The fluid paths inside the system are normally closed to minimize contamination and facilitate containment and control of fluids within the system. The reaction vessel is conveniently detachable and replaceable, and may be disposable in some embodiments.

The components of the fluid control and processing system may be made of a variety of materials that are compatible with the fluids being used. Examples of suitable materials include polymeric materials such as polypropylene, polyethylene, polycarbonate, acrylic, or nylon. The various chambers, channels, ports, and the like in the system may have various shapes and sizes.

The above-described arrangements of apparatus and methods are merely illustrative of applications of the principles of this invention and many other embodiments and modifications may be made without departing from the scope of the invention as defined in the claims.

For instance, <figref idref="f0030">Fig. 13</figref> shows a soft-walled chamber 200 that may be incorporated into the fluid control and processing system. Typically, an on-board reagent style cartridge requires a total fluid volume of at least twice the total volume of reagents and sample combined in rigid systems. The use of soft-walled chambers can reduce the required volume. These chambers have flexible walls, and can typically be formed using films and thermoforming. An added advantage of soft walls is that venting need not be provided if the walls are sufficiently flexible to allow them to collapse when the chamber is emptied. In <figref idref="f0030">Fig. 13</figref>, a flexible sidewall 202 separates a reagent chamber 204 and a waste chamber 206. Because the waste is composed of the sample and reagents, the volume required for waste is no more than the sum of the sample and reagents. The reagent chamber 204 contracts while the waste chamber 206 expands, and vice versa. This can be a closed system with no connection to the exterior. The configuration can reduce the overall size of the cartridge, and can allow fast change-overs of chamber volumes. It can also eliminate venting, and can cut costs by reducing the number of platforms that would otherwise need to be built with hard tooling. In one embodiment, at least two of the plurality of chambers in the system are separated by a flexible wall to permit change-over of chamber volumes between the chambers.

<figref idref="f0030">Fig. 14</figref> shows a piston assembly 210 including a piston rod 212 connected to a piston shaft 214 having a smaller cross-section than the rod 212 for driving small amounts of fluids. The thin piston shaft 214 may bend under an applied force if it is too long: The piston rod 212 moves along the upper portion of the barrel or housing 216, while the piston shaft 214 moves along the lower portion of the barrel 216. The movement of the piston rod 212 guides the movement of the piston shaft 214, and absorbs much of the applied force so that very little bending force is transmitted to the thin piston shaft 214.

<figref idref="f0030">Fig. 15</figref> shows a side chamber 220 that may be incorporated into the system. The side chamber 220 includes an inlet port 222 and an outlet port 224. In this example, the side chamber 220 includes a filter 226 disposed at the inlet port 222. Fluid is directed to flow via the inlet port 222 into the side chamber 220 and out via the outlet port 224 for side filtering. This allows filtering of a fluid sample or the like using the fluid control system of the invention. The fluid may be recirculated to achieve better filtering by the filter 226. This prefiltering is useful to remove particles before introducing the fluid into the main chambers of the system to prevent clogging. The use of a side chamber is advantageous, for instance, to avoid contaminating the valve and the main chambers in the system.