Patent Description:
Certain examples are described in the following detailed description and in reference to the drawings, in which:.

The present invention is defined in and by the appended claims. This present disclosure relates to nucleic acid amplification techniques such as digital polymerase chain reaction (PCR). Digital PCR is a quantitative technique used to measure the quantity of a target DNA sequence in a DNA sample. In digital PCR, the DNA sample is highly diluted and singulated into individual droplets so that some of them do not receive a single molecule of the target DNA. After running PCRs in parallel on each droplet, the target DNA concentration can be calculated using the proportion of negative to positive outcomes. In digital droplet PCR, the sample to be tested is split, diluted, and singulated into droplets such that each droplet contains no more than a single copy of the nucleic acid material. The individual droplets are provided with various reagents that cause nucleic acid amplification. This method requires the step of droplet generation, often performed by a stand-alone instrument, which deposits a large number of separate droplets within separate wells of a microwell plate such that separate PCR reactions take place within each well. Generating the droplets and incorporating the relevant reagents into the droplets often comprises a large cost of the entire the system. This adds complexity and cost to the overall assay.

The present disclosure describes techniques that can be used to perform digital PCR without the use of droplet generation. A system in accordance with the presently disclosed techniques bypasses the droplet generation of digital droplet PCR by using separate, solid, distributed chambers, referred to herein as chamber particles. The chamber particles are small mobile chambers resembling hollow beads that have an internal chamber for the nucleic acid amplification process to occur. The use of chamber particles obviates the need for droplet generation and therefore simplifies the system. Additionally, the chamber particles allow for easy integration with Thermal Inkjet (TIJ) microfluidics without the complexity of a droplet generator.

Each chamber particle can be labeled to facilitate identification and analysis of the assay results. For example, the chamber particles may be labeled (e.g., barcoded) with a marker such as a set of fluorescent, absorbent, Raman, or IR markers that correspond with the primer set included in the chamber particle. This allows simultaneous analysis of a nucleic acid sample by multiple primers in a single assay.

The chamber particles are pretreated to contain some or all of the reagents need for nucleic acid amplification to occur, such as primers, a polymerase enzyme, dNTPs, cofactors, amplification indicators, buffers, and the like. The reagents are lyophilized to immobilize the reagents within the chamber particles, thus enabling the reagents to be stored within the chamber particles for later use, and simplifying the PCR process.

The digital dropletless PCR system described herein operates by obtaining a sample and extracting and purifying the nucleic acid out of it. The system then combines the purified nucleic acid aqueous solution with dry chamber particles. When the dry chamber particles encounter the aqueous solution containing the nucleic acid of interest, the solution imbibes into the chamber of the particles. Due to the dilution of the nucleic acid solution and the size of the internal volume within each chamber particle, each chamber particle will have at most a single copy of the nucleic acid of interest, and some chamber particles may have no copy. Since the chamber particles are pre-treated with PCR reagents, the nucleic acid aqueous solution dissolves the reagents within the internal chamber of the chamber particle. The chamber particles may then be removed from aqueous phase and moved to an oil phase to isolate each internal chamber, and the nucleic acid amplification reaction occurs within the chamber particle. After amplification, the result of the amplification and the identity of the barcode can be read, the barcode indicating the primer set (i.e., the target nucleic acid sequence) and the result of the amplification indicating whether the target nucleic acid sequence is present within the chamber particle.

Some examples of analyses that can be performed using the present techniques include the analysis of single cells, and rare cells, such as in detection and identification of sepsis, fetal cells, circulating tumor DNA, and circulating tumor cells. These analyses may assist in the functional analysis of genes, diagnosis and monitoring of hereditary diseases, amplification of ancient DNA, analysis of genetic fingerprints for DNA profiling in forensic science and parentage testing, detection of pathogens for the diagnosis of infectious diseases, and others.

<FIG> is a cross sectional view of an example chamber particle. The chamber particle <NUM> shown in <FIG> is in the shape of a hollow cylinder. The hollow space, i.e., the chamber <NUM>, within the chamber particle <NUM> provides a volume in which to perform nucleic acid amplification. When the chamber particle <NUM> is contacted with a nucleic acid solution, only a single molecule of the nucleic acid of interest, at most, will enter the chamber <NUM>. This can be controlled by diluting the nucleic acid solution to a concentration that ensures that the internal volume of the chamber particle will statistically receive, at most, one nucleic acid particle. In examples, the internal diameter <NUM> of the chamber may be within a range of approximately <NUM> to <NUM> micrometers, the external diameter <NUM> of the chamber particle may be approximately <NUM> to <NUM> micrometers, and the height <NUM> of the chamber particle may be approximately <NUM> to <NUM> times the external diameter. In some embodiments, the internal diameter <NUM> of the chamber may be within a range approximately <NUM> to <NUM> micrometers. Various other shapes and sizes are possible.

The walls <NUM> of the chamber particle <NUM> may be formed of any suitable material, including glasses such as silicate glasses, crystalline or polycrystalline silicon, polymer materials such as epoxy, and the like. In some examples, the walls <NUM> of the chamber particle <NUM> may be formed of SU-<NUM> photoresist.

The chamber particle may also be magnetic. For example, the chamber particle can be magnetized by adding a magnetic material such as iron oxide particles to the material that forms the chamber walls. As used herein, the term magnetic refers to materials or objects that are affected by magnetic fields. The term magnetic does not necessarily imply that permanent or semi-permanent magnetic fields are formed by an object described as magnetic. While a magnetic item may include items that produce magnetic fields, the use of the phrase "magnetic" in this disclosure also includes objects that can be attracted to magnets or items to which magnets are attracted. The term "magnetized" refers to objects that produce permanent or semi-permanent magnetic fields including permanent magnets and induced magnets. Causing the chamber particles to be magnetic enables the use of magnets to hold, move, or otherwise manipulate the chamber particles within a system for performing PCR.

The chamber particle <NUM> includes a reagent mixture <NUM> that includes one or more reagents for performing a nucleic acid amplification and analysis. The reagent mixture may include a mixture referred to herein as a master mix. A master mix, as that term is used herein, refers to all of the reagents needed for the nucleic acid amplification and analysis except for the primers. For example, the master mix can include an amplification enzyme (e.g., DNA polymerase), deoxynucleotide triphosphates (dNTPs), a buffer, and a cofactor. The master mix can be combined with the primer set to form a reagent mixture customized for the detection of a specific DNA sequence identified by the primer set. In some examples, the reagent mixture added to the chamber particles <NUM> includes the master mix and the primers. In other examples, the chamber particles may include only the primers, and the master mix can be added during the assay. Other combinations are also possible.

The reagent mixture <NUM> is a dry film deposited on the internal walls of the chamber <NUM>. The reagent mixture is formed by introducing a reagent solution to the chamber <NUM> and lyophilizing the reagents within the chamber particle <NUM>. Lyophilizing removes the water from the reagent mixture and immobilizes the reagents within the chamber particle <NUM> while also preserving the chemical integrity of the various reagents.

The reagent mixture may include some or all of the reagents used to perform a PCR amplification and nucleic acid analysis, including DNA polymerase, primers, Deoxynucleoside triphosphates (dNTPs), a buffer, and a cofactor. The dNTPs are nucleotides that serve as the building blocks of a nucleic acid, such as DNA. The DNA polymerase is an amplification enzyme that, under the right conditions, will cause a target segment of DNA to be replicated by assembling the dNTPs according to the sequence exhibited by the target segment of DNA, which serves as a template. The buffer is a chemical that, in solution, provides a suitable chemical environment for optimum activity and stability of the DNA polymerase. The cofactor is a chemical that is used to activate the enzymatic activity of the DNA polymerase.

An example of DNA polymerase that can be used includes polymerase sold under the trademark KAPA2G™ available from Kapa Biosystems, a Foreign Corporation registered in Massachusetts as a division of Roche Company headquartered in Basel, Switzerland. Another example of DNA polymerase that can be used include polymerase sold under the trademark PHUSION™ or PHIRE™ available from Thermo Fischer Scientific® Inc. headquartered in Waltham, Massachusetts. An example of a suitable cofactor includes Magnesium chloride (MgCl2).

The primers are short single-strand DNA fragments that form a complementary sequence to a target region of the DNA sample under test. In PCR, two primers specific to a particular DNA fragment to be amplified by the PCR process can be included in the reagent mixture <NUM>. If the DNA fragment corresponding to the primers is not present in the sample under test, then amplification of the target segment will not occur. If the DNA fragment corresponding to the primer is present, amplification will occur.

Selection of the primer set will depend on the target to be identified within a sample of DNA. The identity of the primers included within a specific chamber particle indicates the genomic information included within the DNA sample in the event that amplification occurs. For example, the primers may correspond with a specific gene sequence know to be present with a certain type of virus. In this case, a positive test result indicating that amplification has occurred would indicate the presence of viral DNA within the DNA sample. In other words, since the primers are known, the genotyping information of the sample can be identified. Various primers may be used to identify specific genes within human DNA, identify a particular type of virus or bacteria, etc..

In some embodiments, the reagent mix can include one or more amplification indicators used to determine whether the targeted nucleic acid sequence is present within the chamber particle. One type of amplification indicator is a fluorescent intercalating dye whose fluorescence increases when it intercalates nucleic acid. The fluorescence can be detected by an optical system. The detection of florescence associated with a chamber particle indicates that the targeted nucleic acid sequence is present within the chamber particle.

In some examples, the walls of the chamber particle can incorporate one or more identification indicators used to identify the chamber particle's type, which indicates the primer set used in the reagent mix. The identification indicators may be referred to herein as a barcode. The barcode for a specific chamber particle can be specified to coincide with the primer set used in the reagent mix. In this way, the detection of the barcode identifies the primer set and, by extension, the nucleic acid sequence that was amplified. The barcode can be created by embedding one or more of the identification indicators within the material making up the chamber particle. Examples of suitable identification indicators include colored dies, color absorbent markers, florescent markers, Raman markers, Infrared markers, and others. The barcoding of individual chamber particles allows multiple primer sets and multiple targets to be tested for within a single assay and a single piece of PCR equipment.

<FIG> shows the chamber particle of <FIG> after the chamber particle is contacted with the nucleic acid solution. The nucleic acid solution <NUM> is an aqueous solution that includes that nucleic acid of interest and may also include some of the reagents used to perform a PCR amplification and nucleic acid analysis, including DNA polymerase, Deoxynucleoside triphosphates (dNTPs), a buffer, cofactor, and others. Any reagents needed for the nucleic acid amplification and analysis that are not included in the pre-treated chamber particle may be included in the nucleic acid solution instead. The surface of the chamber particle <NUM> is hydrophilic. Therefore, contact with the nucleic acid solution <NUM> will cause the nucleic acid solution to imbibe into the internal chamber <NUM>. The nucleic acid solution <NUM> will be diluted to be statistically ensured by Poisson distribution that only one nucleic acid particle, at most, will be included within the internal chamber <NUM>.

After the nucleic acid solution <NUM> is imbibed within the chamber <NUM> of the chamber particle <NUM>, the aqueous solution will begin to dissolve the lyophilized reagents <NUM> included within the pre-treated chamber particle <NUM>. After a sufficient time has passed for all of the reagents to dissolve, the amplification process can be initiated.

<FIG> is a cross sectional views of additional chamber particles in accordance with examples. The chamber particles <NUM> shown in <FIG> are similar to the chamber particle of <FIG>, except that the chamber particles <NUM> are shaped like a cup. Unlike the chamber particle of <FIG>, which has a through hole, the chamber particles of <FIG> have a bottom surface and the chamber <NUM> is open only at one end. The bottom surface of the chamber <NUM> may help the chamber particle to better retain the nucleic acid solution and other reagents.

In <FIG>, the internals walls of the chamber <NUM> are substantially straight. By contrast, the chamber particle of <FIG> is tapered outward from the bottom of the chamber <NUM> toward the top of chamber <NUM>. The outward taper may assist the penetration of the nucleic acid solution into the chamber <NUM>.

In <FIG> the chamber particle is tapered inward from the bottom of the chamber <NUM> toward the top of chamber <NUM>. The inward taper may be useful to further help the chamber particle <NUM> to retain the nucleic acid solution and other reagents.

The chamber particles <NUM> shown in <FIG> will be used in same manner described above in relation to <FIG>. For example, the chamber particles <NUM> will be pre-treated with some or all of the reagents used in the amplification process. Furthermore, it will be appreciated that additional shapes may also be possible.

<FIG> is a cross sectional view of another chamber particle in accordance with examples. The chamber particle <NUM> shown in <FIG> is similar to the chamber particle of <FIG>, except that the reagents are added to the chamber particle <NUM> in separate layers. The chamber particle <NUM> of <FIG> includes two layers of reagents, the primer layer <NUM> and the additional reagent layer <NUM>. The primer layer <NUM> includes the primers, which may be attached to the surface, often with a covalent bond. The additional reagent layer may be a master mix and can include one or more of the additional reagents used for the amplification and analysis process, including the DNA polymerase, dNTPs, a buffer, and a cofactor, for example.

The layers may be formed by successive depositions. For example, the primer layer <NUM> can be formed by introducing a primer solution into the chamber, lyophilizing the primer solution, and then introducing the additional reagents to be added to the additional reagent layer <NUM> and lyophilizing the additional reagents. Forming different reagent layers in successive iterations may be useful to make the manufacturing of pre-treated chamber particles more efficient. For example, separate groups of chamber particles may undergo separate deposition processes for the primer layer <NUM> so that each group can receive a different primer set. After customizing each group of chamber particles, all of the chamber particles may be treated together for the addition of the additional reagent layer <NUM>.

The layers may be created in a different order compared to what is shown in <FIG>. Additionally, the layered configuration shown in <FIG> is applicable to additional chamber particle shapes, including the chamber particle shapes shown in <FIG>.

<FIG> is a cross sectional view of another chamber particle in accordance with examples. The chamber particle <NUM> shown in <FIG> is similar to the chamber particle of <FIG>, except that the chamber particle <NUM> includes a delayed delivery film <NUM>. As in <FIG>, the chamber particle <NUM> includes the reagent mixture <NUM>, which may include some or all of the reagents used for the amplification and analysis process, including the DNA polymerase, primers, Deoxynucleoside triphosphates (dNTPs), a buffer, and a cofactor, for example. The reagent mixture is formed by introducing a reagent solution to the chamber <NUM> and lyophilizing the reagents within the chamber particle <NUM>.

After the reagent mixture is lyophilized, the delayed delivery film <NUM> may be deposited over the lyophilized reagent mixture <NUM>. Suitable films include sucrose, dextrose, trehalose, or a mixture thereof. Other water soluble materials may also be used. The film may be formed by introducing a solution containing the film material to the chamber <NUM> and lyophilizing the solution within the chamber particle <NUM> to form a film that covers the lyophilized reagent mixture <NUM>.

The delayed delivery film <NUM> delays the solvation of the lyophilized reagent mixture into solution. This can help to ensure that the reagents dissolve in the oil phase at which point the reagent solution will be trapped within the chamber particle. In this way, the risk of cross talk between chamber particles with different primer sets can be reduced. The delayed delivery film <NUM> shown in <FIG> may also be applied to the multi-layer reagent configuration described in relation to <FIG> and other chamber particle shapes, including the chamber particle shapes shown in <FIG>.

<FIG> is a diagram of a microfluidic device for performing PCR, in accordance with examples. It will be appreciated that the diagram is a simplified representation of a microfluidic device <NUM>, and that the microfluidic device in accordance with examples can have additional elements not shown in <FIG>. In some examples, the microfluidic device <NUM> is disposed on a chip, which can be loaded into an instrument for performing PCR or other nucleic acid amplification tests.

The microfluidic device <NUM> can include a sample preparation chamber <NUM>. The sample preparation chamber <NUM> can be a reservoir in which the nucleic acid solution is prepared. For example, after insertion of a sample (e.g., blood) into the sample preparation chamber <NUM>, the sample can then be pre-concentrated, any cells containing the sample can be lysed, and the nucleic acids may be absorbed, washed and eluted. The sample can then be diluted to a specified concentration suitable for digital PCR. In some examples, the sample preparation chamber <NUM> can be eliminated and sample preparation can be performed separately. The nucleic acid solution contains the nucleic acid of interest and, depending on the details of a specific implementation, may also include some of the reagents needed for amplification and analysis.

The nucleic acid solution can then be introduced to a microfluidic channel <NUM>, which contains a plurality of chamber particles <NUM>. Prior to introduction of the nucleic acid solution, the chamber particles <NUM> will be in the form of a dry powder. The chamber particles <NUM> may be any of the chamber particles described above in relation to <FIG>.

In the example shown in <FIG>, the microfluidic channel <NUM> is loaded with three different types of chamber particles <NUM>, which are shown as group A <NUM>, group B <NUM> and group C <NUM>. Each group of chamber particles <NUM> may differ with respect to the primer set included within the chamber particle. This allows for different nucleic acid sequences to be tested for within a single assay.

The nucleic acid solution can be pulled through the microfluidic channel <NUM> by a pull pump <NUM>. As the nucleic acid solution flows through the channel <NUM>, it encounters the chamber particles <NUM> and the chamber particles <NUM> become entrained within the solution flow. The nucleic acid solution imbibes within the chamber particles <NUM> and begins to dissolve the reagents and/or the delayed delivery film, depending on the specific configuration of the chamber particle <NUM>.

The chamber particles <NUM> are pulled toward an oil-phase microfluidic channel <NUM>. The oil-phase microfluidic channel <NUM> may be separated from the aqueous-phase microfluidic channel <NUM> by a porous semipermeable membrane <NUM>. When the chamber particles <NUM> reach interface between the aqueous-phase microfluidic channel <NUM> and the oil-phase microfluidic channel <NUM>, the chamber particles <NUM> will move into the oil-phase microfluidic channel <NUM>. For example, in examples wherein the chamber particles <NUM> are magnetic, the chamber particles <NUM> can be pulled into the oil phase by a magnet, which may be a permanent magnet or a coil such as a Helmholtz coil configured to generate a magnetic field. Once in the oil-phase, the oil surrounding the chamber particles <NUM> will confine the nucleic acid solution and reagents within each chamber particle <NUM>, preventing cross talk between chamber particles <NUM>.

The oil-phase microfluidic channel <NUM> is also coupled to another pull pump <NUM> which pulls the chamber particles <NUM> through the oil-phase microfluidic channel <NUM> to an amplification region <NUM> and then a detection region <NUM>. The amplification region <NUM> is a region of the chip in which nucleic acid amplification is induced by the instrument in which the chip is inserted. The instrument can induce the amplification through any suitable means, including isothermal amplification such as Loop-mediated isothermal amplification (LAMP), or thermocylcing, for example. Accordingly, the instrument may include a heating element to control the temperature of the chamber particles within the amplification region. Depending on the particular technique used, the temperature may be held at a constant temperature or the temperature may be cycled through a series of alternating temperature steps. Repeated thermocycling aids in denaturing the DNA and allowing the primers to potentially bind to a target such that replication of the target can occur as the amplification region <NUM>. In an example, a thermocycling element can include a heater, thermoelectric cooler (TEC), air cooling, liquid cooling or other components that may controllably raise or lower the temperature in the amplification region.

After the amplification process is completed, the chamber particles <NUM> can be moved from the amplification region <NUM> to the detection region <NUM> to detect the results. Accordingly, the instrument may include an optical system, such as a fluorescence microscope, for detecting the amplification indicators for each chamber particle separately. For example, the optical system can detect the presence of fluorescence created by intercalating dyes. The optical system can also read the barcode applied to the chamber particles <NUM> by detecting the identification indicators added to the chamber particle material. The chamber particles <NUM> can be moved through the detection region <NUM> and analyzed one at a time. The results may be read by the instrument and stored electronically for further processing or to be displayed to the user.

<FIG> is a diagram of another example microfluidic device for performing PCR, in accordance with examples. The microfluidic device <NUM> of <FIG> is similar to the microfluidic device <NUM> of <FIG> and operates in a similar manner. In the microfluidic device <NUM> of <FIG>, the aqueous-phase microfluidic channel includes a main channel <NUM> and a number of branches <NUM> for controlling the type of nucleic acid analysis to be performed. Although three branches are shown, it will be appreciated that the device can include any suitable number of branches, including <NUM>, <NUM>, <NUM>, <NUM> or more. Each branch <NUM> is loaded with a different type of chamber particle, e.g., chamber particles with a different primer set. Each branch <NUM> may be coupled to a push pump <NUM> which determines whether the corresponding branch is activated. If a branch is activated, the nucleic acid solution will flow through the branch and entrain the chamber particles contained therein. Any combination of the available branches may be activated. In this way, the user can specify which of the available primer sets will be used in a specific assay. The remaining elements of the testing process may be the same as those described in relation to <FIG>.

<FIG> is a process flow diagram summarizing a method of performing nucleic acid amplification process in accordance with examples. The method <NUM> may be performed by an electronic instrument configured to perform digital PCR and other types of amplification processes using the microfluidic device <NUM> or <NUM> described above. However, some or all of the actions shown in <FIG> may be performed manually using suitable lab equipment or separate instrumentation.

At block <NUM>, the nucleic acid sample of interest is prepared. For example, the nucleic acid can be extracted and separated from other components of the biological sample (e.g., blood). The nucleic acid sample can then be diluted to the desired concentration. In some examples, preparing the nucleic acid sample includes adding a set of primers and a master mix that includes reagents such as DNA polymerase, dNTPs, a buffer, and cofactor, for example. In some examples, the primers and/or the master mix is included in the chamber particles and is therefore not added to the nucleic acid sample. Additionally, some components of the reagent mixture may be added to the nucleic acid sample, while other components may be included within the chamber particles as a pre-treatment. The result of the sample preparation performed at block <NUM> is a purified nucleic acid aqueous solution, optionally containing one or more reagents.

At block <NUM>, dry chamber particles are wetted with the nucleic acid solution. The chamber particles may be any of the chamber particles described herein and are pre-treated to include a set of primers and other reagents. After the chamber particles are wetted, each chamber particle will include, at most, one copy of the nucleic acid. This can be controlled by controlling the concentration of nucleic acid within the sample with respect the size of the internal chamber within the chamber particle. At this point, the chamber particle will also include all of the reagents used to perform amplification and analysis of the results.

At block <NUM>, the chamber particles are extracted to an oil phase. In the oil-phase, each chamber particle is immersed in an oil that isolates each internal chamber.

At block <NUM>, the amplification reaction is induced. The amplification reaction can be induced using an isothermal amplification process, for example a LAMP process. After the amplification process is complete, the process flow can advance to block <NUM>.

At block <NUM>, the result of the amplification can be detected and the barcode can be read to identify the chamber particle type. The barcode indicates the primer set (i.e., the target nucleic acid sequence) and the result of the amplification indicates whether the target nucleic acid sequence is present within the chamber particle.

It is to be understood that the block diagram of <FIG> is not intended to indicate that the method <NUM> is to include all of the actions shown in <FIG>. Rather, the method <NUM> can include fewer or additional components not illustrated in <FIG>.

<FIG> illustrate an example technique related to the present disclosure for fabricating chamber particles. The chamber particles may be fabricated using any suitable semiconductor fabrication techniques. For example, the creation of various structures may be accomplished though deposition, removal, and patterning of structures. Deposition techniques include techniques such as chemical vapor deposition, electrochemical deposition, spin coating, and others. The patterning of various features maybe accomplished through the use of photolithography in combination with various etching techniques, including wet etching techniques and plasma etching techniques, for example.

<FIG> shows a structure that includes a substrate layer <NUM>, a release layer <NUM>, a chamber particle layer <NUM>, and a mask layer <NUM>. The substrate layer <NUM> may be any suitable substrate, including glass, polymers, silicon, and the like. The release layer <NUM> is formed over the substrate and can include a thermal release layer or ultraviolet (UV) release layer, for example. The release layer <NUM> may be an adhesive film that can be rolled over the substrate layer <NUM>.

The chamber particle layer <NUM> is formed over the release layer <NUM>. The chamber particle material may be any suitable material, including polymers such as SU8. The chamber particle layer <NUM> can be formed by spin-coating a polymer over the release layer <NUM>, for example. The chamber particle layer <NUM> may also be infused with magnetic particles and one or more identification indicators used to form a barcode that identifies the chamber particle type (e.g., primer set). The magnetic particles and one or more identification indicators can be mixed into the polymer before spin-coating the polymer on top of the release layer <NUM>.

The mask layer <NUM> may then be deposited over the chamber particle layer <NUM> and patterned to form the outline of a plurality of chamber particles. The mask layer <NUM> may be a photolithography mask such as SU8, Polydimethylsiloxane (PDMS), polymethylmethacrylate, phenol-formaldehyde resin and any other positive or negative photoresist. The patterning process can be performed using photolithography, embossing, silk screening, or any other suitable micro-patterning technique.

Next, as shown in block 8B, the chamber particle layer <NUM> is etched to form the walls of the chamber particles. The chamber particle layer <NUM> may be etched using Reactive-Ion Etching (RIE), which is a type of dry etching that uses chemically reactive plasma to remove material deposited on wafers. The mask protects the material underneath it, leaving the walls of the chamber particles intact.

Next, as shown in block 8C, the mask can be removed. The mask may be removed by any suitable solvent and depends on the type of material used for the mask.

Next, as shown in block 8D, a reagent mixture <NUM> is deposited over the chamber particle layer <NUM>. The reagent mixture can include the master mix, the desired primer set, or some combination thereof depending on the implementation details of a specific example. The reagent mixture <NUM> is an aqueous mixture that penetrates into the spaces formed in the chamber particle layer <NUM> by the etching process.

Next, as shown in <FIG>, the reagent mixture is lyophilized. This causes the reagent mixture to dry, forming a dry film <NUM> that adheres to the walls of the chamber particles. Additional layers, such as different layers of reagents or a delayed delivery film, may be formed by successive deposition and lyophilization of additional materials.

Next, as shown in <FIG>, the release layer <NUM> can be removed, for example, by heating or radiating with UV radiation, thereby releasing the individual chamber particles <NUM>.

<FIG> illustrate another example technique related to the present disclosure for fabricating chamber particles. <FIG> shows a structure that is similar to that of <FIG>, in that it includes a substrate layer <NUM>, a release layer <NUM>, and a mask layer <NUM>. However, the structure shown in <FIG> includes two layers of chamber particle material, referred to herein as a base layer <NUM> and a side wall layer <NUM>.

The substrate layer <NUM> and release layer <NUM> may be formed as described in relation to <FIG>. The base layer <NUM> is then formed over the release layer <NUM>, and the side wall layer <NUM> is formed over the base layer <NUM>. The chamber particle material used for the base layer <NUM> and side wall layer <NUM> may be the same material, and may include polymers such as SU8. However, in some examples, the material used for the base layer <NUM> and side wall layer <NUM> may be different. For example, the base layer material may be silicon, and the side wall material silicon dioxide (SiO2). Before applying the mask layer <NUM>, the chamber particle material may be infused with magnetic particles and one or more identification indicators used to form a barcode that identifies the chamber particle type (e.g., primer set). The mask layer <NUM> may then be deposited over the side wall layer <NUM> and patterned to form the outline of a plurality of chamber particles.

Next, as shown in block 9B, the side wall layer <NUM> is etched to form the walls of the chamber particles using reactive-ion etching, for example. The etching process penetrates through the side wall material <NUM> while leaving the base material intact <NUM>. The depth of the etch may be controlled by controlling the etching time in accordance with a known etch rate.

Next, as shown in block 9C, the mask is removed.

Next, as shown in block 9D, a reagent mixture <NUM> is deposited over the side wall layer <NUM>, filling the spaces (e.g., cups) formed by the etching of the side wall layer <NUM>. The reagent mixture <NUM> can include the master mix, the desired primer set, or some combination thereof depending on the implementation details of a specific example.

Next, as shown in <FIG>, the reagent mixture is lyophilized, causing the reagent mixture to dry and form a film <NUM> that adheres to the internal surfaces of the chamber particles. Additional layers, such as different layers of reagents or a delayed delivery film, may be formed by successive deposition and lyophilization of additional materials.

Next, as shown in <FIG>, the release layer can be removed by heating or UV radiation, thereby releasing the base layer <NUM> and side wall layer <NUM> forming the chamber particles <NUM>. At this point, the chamber particles <NUM> will be coupled together via the base layer <NUM>. The chamber particles <NUM> can be separated from one another using laser singulation.

<FIG> illustrate another example technique related to the present disclosure for fabricating chamber particles. <FIG> shows a capillary fiber <NUM>, which serves as the chamber particle material for forming a plurality of chamber particles. The capillary fiber <NUM> may be glass or polymer, for example. In some examples, the capillary fiber <NUM> can include magnetic particles and one or more identification indicators used to form a barcode that identifies the chamber particle type (e.g., primer set).

As shown in block 10B, a reagent mixture <NUM> is loaded into the capillary fiber <NUM> and fills the volume inside the capillary fiber <NUM>. The reagent mixture <NUM> can include the master mix, the desired primer set, or some combination thereof depending on the implementation details of a specific example.

Next, as shown in <FIG>, the reagent mixture is lyophilized. This causes the reagent mixture to dry and form a film <NUM> that adhere to the walls of the capillary fiber <NUM>. After lyophilizing the reagent mixture, additional layers may be deposited inside the capillary fiber. For example, a delayed delivery film may be deposited over the lyophilized reagent mixture using chemical vapor deposition. The delayed delivery film may be a polylactide formed by depositing a monomer over the surface of the lyophilized reagent mixture via chemical vapor deposition and polymerizing the monomer on the surface.

A delayed delivery film may also be formed by aerosol layering. Aerosol layering may be accomplished by aerosolizing a concentrated solution of the film material (e.g., trehalose), depositing the aerosol on the surface of the lyophilized reagent mixture, and allowing it to dry. Successive iterations of aerosol deposition and drying may be repeated until a desired level of the film thickness is achieved.

Claim 1:
A chamber particle (<NUM>) used to perform a nucleic acid amplification reaction, comprising:
a chamber (<NUM>) for receiving a nucleic acid solution;
lyophilized reagents (<NUM>) within the chamber for causing nucleic acid amplification within the chamber after receiving the nucleic acid solution; and
a delayed delivery film (<NUM>) disposed over the lyophilized reagents and configured to delay solvation of the lyophilized reagents when the chamber particle is put into solution.