Microreactors

DOI: 10.1002/anie.200700306

A Pocket-Sized Convective PCR Thermocycler**

Nitin Agrawal, Yassin A. Hassan, and Victor M. Ugaz*

The ability to make technologies for rapid diagnosis of infectious disease broadly available in a portable, low-costformat would mark a revolutionary step forward in globalpublic health.

[1,2]

A critical challenge to these efforts is that alarge segment of the population that is most in need of theseadvances resides in locations that offer limited or nonexistentlaboratory infrastructure.

[3,4]

At the same time, many diag-nostic assays rely on the polymerase chain reaction (PCR),which requires thermocycling instruments that are relativelyslow and consume considerable electrical power to performrepeated heating and cooling steps.

[5]

Herein, we introduce aninnovative thermocycling system that harnesses natural con-vection phenomena to amplify DNA rapidly by the PCR in agreatly simplified format. A key element of this design is anarchitecture that allows the entire thermocycling process tobe actuated pseudo-isothermally by simply maintaining asingle heater at a constant temperature, thereby enabling apocket-sized battery-powered device to be constructed at acost of about US$10. These devices are straightforward todesign and build, easy to operate, and uniquely address acritical need for expanded availability of PCR-based diag-nostics.The PCR continues to be an indispensable tool in adiverse array of genomic analysis applications includingmedical diagnostics, pathogen and infectious disease detec-tion, forensics, population-scale polymorphism, and mutationstudies.

[6,7]

The development of capabilities to amplify longtargets (

1 kb) and to coamplify multiple targets simulta-neously (multiplex PCR) has further extended the inherentlyrobust capacity of the PCR for efficient DNA replication.Despite these advances, the timescales required to perform atypical reaction generally remain on the order of hours—arate much slower than would be expected on the basis of kinetics alone. This is because conventional thermocyclinginstruments typically employa hot-plate designconsisting of ametal block whose high heat capacity, combined with therelatively low thermal conductivity of the plastic tubes ormultiwell plates used to contain the reagents, severely limitsachievable heating and cooling rates. Consequently, themajority of time and electrical power consumed is expendedregulating the temperature of the instruments structuralcomponents rather than driving the reaction.Buoyancy-driven natural convection phenomena offer anattractive way to overcome these limitations. By applying astatic temperature gradient across an appropriately designedreactor geometry (e.g., a cylindrical cavity or closed loop), acontinuous circulatory flow can be initiated that will repeat-edly transport PCR reagents through temperature zonesassociated with each stage of the reaction.

[8–11]

This arrange-ment is highly advantageous because the need for activeheating and cooling is eliminated, which greatly simplifiesinstrument design. Furthermore, rapid thermocycling isachievable since reagents quickly attain local thermal equi-librium as they travel through the temperature field. Despitethis promise, the development of convective thermocyclingtechnology has not yet advanced beyond the proof-of-conceptlevel, with results obtained over a very limited range of template and target sizes (without multiplex capability) andemploying instrument designs that are cumbersome forroutine use.

[12–15]

Herein, we show that these shortcomingscan be addressed through the design of simplified closed-loopconvective thermocyclers capable of rapidly amplifying awide range of targets in both single and multiplex formats.First, we illustrate the basic concept in a thermocyclingdevice constructed by positioning two thermoelectric heatersalong the perimeter of a fluoropolymer tubing loop thatfollows a triangular path (Figure 1a and the SupportingInformation). PCR reagents are pipetted directly into 9-cm-long tubing segments and then the free ends are joinedtogether by a small sleeve of larger diameter tygon tubing toyield a loop that is affixed around the heater assembly. Theheaters are independently adjusted to maintain denaturation(95

C) and extension (72

C) temperatures across the twoinclined legs, while the horizontal leg passively attainsannealing conditions (ca. 58

C). In this way, thermocyclingis passively actuated by the unidirectional convective flowgenerated in response to the imposed thermal gradient (theheater temperatures are held constant during the reaction).The fluoropolymer tubing used to construct the flow loops isstable at high temperatures (up to 205

C) and is chemicallyinert, which eliminates the need for surface pretreatmentprocesses that are often required to minimize nonspecific

[*] Dr. N. Agrawal,

[+]

Prof. V. M. UgazArtie McFerrin Department of Chemical EngineeringTexas A

M UniversityCollege Station, TX 77843 (USA)Fax: (

1)979-458-1002E-mail: ugaz@tamu.eduProf. Y. A. HassanDepartment of Nuclear EngineeringTexas A

M UniversityCollege Station, TX 77843 (USA)[

] Present address:Center for Engineering in Medicine/Department of SurgeryMassachusetts General HospitalShriners Burns Hospital andHarvard Medical SchoolBoston, MA 02114 (USA)[**] This work was supported by the National Institutes of Health undergrants K22-HG02297 and R01-HG003364. We thank Prof. Mihir Senfor helpful discussions regarding modeling the convective flow. Weare also grateful to Ling Zhen for assistance with computational-flow simulations.Supporting information for this article is available on the WWWunder http://www.angewandte.org or from the author.

Communications

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 2007 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim

Angew. Chem. Int. Ed.

2007

, 4316–4319

binding interactions in many miniaturized PCR systems.

[16–17]

No modifications to standard reaction protocols are neces-sary, and the tubing is optically transparent, which makes itamenable for use in real-time PCR applications.The versatility of this convective-flow thermocyclingsystem is demonstrated by its ability to amplify a multiplexmixture of targets associated with five different respiratoryviruses in 50 minutes with a 16-

L flow-loop reactor (Fig-ure 1b). Simultaneous coamplifications were also performedin mixtures containing primers and template for a 1.3-kbtarget from a

-DNA template and a 242-bp human L32 genetarget (Figure 1c), as well as 191-bp influenza-A virus and242-bp human L32 gene targets (Figure 1d) in 50 minuteswith a 16-

L loop. Finally, we characterized amplificationspeeds in 10-, 16-, and 25-

L closed-loop reactors (samelength but different diameters of tubing) with correspondingcycling times of 102, 69, and 42 s, respectively (flow velocitiesin the loops scale with tubing diameter). Amplification of a191-bp target with a 25-

L loop was detectable by agarose gelanalysis after as little as 10 minutes of reaction time (Fig-ure 1e). Smaller-volume flow loops (i.e., constructed fromsmaller-diameter tubing) deliver longer cycling times andproduce detectable products in 20–30 minutes (see theSupporting Information). This level of speed and versatilityis comparable to that achievable in many advanced thermo-cyclers, but in a format that offers an exceptional degree of electronic and mechanical simplicity.Next, we demonstrate how the convective thermocyclingconcept can be adapted for use in portable diagnosticapplications by introducing a pocket-sized device incorporat-ing three aluminum blocks, each corresponding to one of thethree PCR temperature zones. Thermal interconnections(e.g., screws made from materials of different thermalconductivity) are incorporated to regulate the heat flowbetween blocks so that when the denaturing block is heated to95

C, the remaining blocks passively attain the desiredannealing and extension conditions (Figure 2a and theSupporting Information). This arrangement makes it possibleto actuate the entire thermocycling process pseudo-isother-mally by simply maintaining a single heater at constanttemperature (i.e., 95

C). Furthermore, the temperatures ateach stage of the reaction can be independently adjusted bypurely mechanical means (by appropriate selection of screwsize, material, and number of screws), which significantlyreduces the cost and complexity. Another feature of thisdesign is that the 72

C extension zone is structured to occupythe largest fraction of the loop perimeter to promoteamplification of longer targets (

1 kb). We incorporatedthis architecture into a prototype by employing a simple on–off temperature control circuit that allows the entire device tobe powered by two AA-size batteries (Figure 2b). Despite itssimplicity and low cost (hardware costs approximatelyUS$10; disposable tubing costs only a few cents per reaction),a 1.3-kb target can be amplified from a

-DNA template in50 minutes with a 7-

L reaction volume (Figure 2c).Finally, we present a simplified analytical model thathighlights the underlying physics and establishes generaldesign criteria for convective-loop thermocyclers. The keyphysical parameters that influence convective-loop flowsbecome evident by first noting that the magnitude of thedestabilizing buoyant forces relative to the thermal andviscous restoring forces can be expressed in terms of adimensionless Rayleigh number

(

cos

)

(

)

.Here,

cos

is the component of gravitational accelerationacting along the flow direction (i.e.,

is the angle that asegment of the flow loop makes with respect to the vertical),

is the temperature difference imposed between the twoheaters,

is the tube diameter, and

, and

are fluidproperties (thermal-expansion coefficient, thermal diffusivity,and kinematic viscosity, respectively). Consequently, themagnitude of

(and hence the flow velocity) increaseswith increasing

and with increasing tube diameter, whichis consistent with data obtained by monitoring fluorescent

Figure 1.

Design and performance of a simplified convective thermocy-cler. a) Thermocycler assembly constructed with a fluoropolymertubing reactor and scaffold incorporating two thermoelectric heaters(see the Supporting Information for a photograph and more detaileddescription).

direction of gravity. b–e) Agarose gel electrophoresisanalysis of PCR products from different template/target combinationsunder various thermocycling conditions. M

marker. b) Multiplexamplification of five different human respiratory infection associatedvirus targets in 50 minutes with a 16-

L flow loop. c) Coamplificationof 1.3-kb

-DNA and 242-bp L32 gene targets in 50 minuntes with a16-

L loop. d) Coamplification of 191-bp influenza virus and 242-bpL32 gene targets in 50 minutes with a 16-

L loop. e) Amplification as afunction of reaction time for a 191-bp target associated with mem-brane channel proteins M1 and M2 of the influenza-A virus with a25-

L flow loop.

Angewandte

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www.angewandte.org

microsphere tracers inside the flow loops (Figure 3a). UnderPCR conditions, average flow velocities of approximately 0.9,1.3, and 2.1 mms

were obtained in 10-, 16-, and 25-

L loops,respectively.Over the range of flow conditions of interest for PCR,analysis of the momentum and energy-balance relationshipsfor the case of a loop geometry symmetric about the verticalcenterline (e.g., the triangular configuration in Figure 1a)suggests that

should scale with

(

is the averagevelocity; see the Supporting Information). This scaling isevident when cycling times determined both from flowvisualization experiments and from computational simula-tions are plotted versus the parameter

(

is the looplength): data for various reactor volumes collapse onto asingle curve (Figure 3b). This relationship permits strategicdesign of reactors that satisfy virtually any combination of volume and cycling time.

Experimental Section

Thermocycler construction (see the Supporting Information forfurther details): Convective-flow loop reactors were constructed byusing 9-cm lengths of thin-wall fluorinated ethylene propylene (FEP)tubing (Zeus Industrial Products, Inc.). Loops were constructed fromthree different tubing diameters: inside diameter 320, 400, and510

m (28-, 26-, and 24-gauge sizes), corresponding to reactorvolumes of 10, 16, and 25

L, respectively. Lengths of tubing werefilled with PCR reagents and then the two open ends were joinedtogether by using a short sleeve of tygon tubing.After being loaded, the loops were mounted on a fixtureincorporating two independently controlled thermoelectric Peltierheaters (Melcor Corporation) positioned on an aluminum scaffolddesigned to create a triangular flow path. The flow loops were affixeddirectly to the heater surfaces by using aluminum adhesive tape(Axygen Scientific) to ensure thermal contact and a uniform temper-ature distribution. Flat thermocouple probes (Model #SA1-(K),Omega Engineering, Inc.) were affixed to the heater surfaces tomonitor their temperature. The heaters were independently main-tained at 95

C (denaturing) and 72

C (extension), while the third(annealing) arm of the loop passively attained a temperature of 58

C.The two Peltier heaters were powered by independent external DCpower supplies, and temperatures were maintained by manually

Figure 3.

Experimental and computational analysis of the convectiveflow in the triangular loop configuration depicted in Figure 1a. Averageflow rates were measured by observing the motion of fluorescentmicrosphere tracers, and 2D flow simulations were performed byusing FLUENTsoftware. a) Volumetric flow rate as a function of thetemperature difference applied between heaters (

) and the reactorvolume (volumes of 10, 16, and 25

L correspond to tubing diametersof 320, 400, and 510

m, respectively). b) Flow data plotted as afunction of cycle time follow a scaling that allows the points tocollapse onto a master design curve. The temperature dependence of fluid properties

, and

is accounted for in these calculations;reactor volumes are determined from the tubing length and insidediameter;

Figure 2.

A pocket-sized battery-powered convective thermocycler.a) Design schematic depicting three blocks joined by thermal intercon-nections (i.e., screws of different thermal conductivity) that regulateheat flow such that when the denaturing block is heated to 95

C, theremaining blocks passively attain the desired reaction temperatures.The 72

C block is larger to allow extension to occur during a greaterfraction of time in each cycle. See the Supporting Information for aphotograph and more detailed description. b) The assembled PCRthermocycler shown with accompanying temperature-control circuit. Asthe design in (a) makes it possible to perform the reaction bymaintaining a single heater at constant temperature, the entire devicecan be powered by two AA-size batteries. c) Products from twoindependent amplifications of a 1.3-kb target from a

-DNA templatein 50 minutes with a 7-

L loop in the device shown in (b).

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 2007 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim

Angew. Chem. Int. Ed.

2007

, 4316–4319