Micro-molded cytometer cartridge with integrated optics

1. An apparatus comprising:

a cytometer cartridge insert, the cytometer cartridge insert comprising:

a micro-molded component; and

a plastic laminate component;

wherein the micro-molded component is embedded in the plastic laminate component;

wherein the micro-molded component comprises:

a sample via comprising a diameter ranging from approximately 20 microns to approximately 100 microns;

a measurement channel with an integrated optical lens, the measurement channel coupled to the sample via by way of a lysing and sphering channel, the measurement channel comprising a diameter ranging from approximately 20 microns to approximately 200 microns, the integrated optical lens permitting detection of scatter angles of about 90 degrees; and

a cuvette coupled to the sample via by way of a sample channel, the cuvette comprising an optical mask;

wherein the integrated optical lens is aligned with the measurement channel such that the measurement channel walls do not produce random scatter noise; and wherein the measurement channel walls have a low RMS planarity level and optical finish characteristics such that an illumination beam on the walls generates light scatter having a same group of angles as the illumination beam, thereby occupying a small solid angle of a budget of angles and not producing the random scatter noise, thereby providing for a cell stream to be close to the measurement channel walls, thereby reducing the need for a sheathing fluid and reducing an amount of liquid waste.

2. The cytometer cartridge insert of claim 1 , wherein the cuvette comprises a cuvette for measuring hemoglobin.

3. The cytometer cartridge insert of claim 1 , comprising an alignment device for aligning the integrated optical lens with a light source and a light detector on a cytometer instrument.

4. The cytometer cartridge insert of claim 3 , wherein the alignment device comprises a three point registration surface configured to couple with a registration surface of a manifold of a cytometer.

5. The cytometer cartridge insert of claim 1 , wherein the plastic laminate component comprises a waste chamber coupled to the cuvette and the measurement channel, the waste chamber comprising a volume of approximately 3 milliliters.

6. The cytometer cartridge insert of claim 1 , wherein the plastic laminate component comprises a lysing and sphering channel, a reagent channel, and a sample tank.

7. The cytometer cartridge of claim 1 , wherein the micro-molded component comprises an injection molded component, a soft-embossed component, or a hot-embossed component.

8. A process to manufacture a cytometer cartridge insert comprising:

forming a plastic laminate component; and

embedding a micro-molded component in the plastic laminate component;

forming a sample via in the micro-molded component such that a diameter of the sample via ranges from approximately 20 microns to approximately 100;

forming a measurement channel in the micro-molded component by way of a micro-molded process such that a diameter of the measurement channel ranges from approximately 20 microns to approximately 200 microns and such that a wall of the measurement channel has a low RMS planarity level and optical finish characteristics such that an illumination beam on the wall generates light scatter having a same group of angles as the illumination beam, thereby occupying a small solid angle of a budget of angles and producing no random scatter noise;

forming an integrated optical lens in the measurement channel, the integrated optical lens oriented for scatter detection of angles between 2-9 degrees, between 9-20 degrees, and at 90 degrees;

forming a cuvette in the micro-molded component such that the cuvette is coupled to the sample via by way of a sample channel, and such that the cuvette comprises an optical mask;

forming a lysing and sphering channel in the plastic laminate component, the lysing and sphering channel coupling the measurement channel to the sample via.

9. The process to manufacture a cytometer cartridge insert of claim 8 , wherein the cuvette comprises a hemoglobin cuvette.

10. The process to manufacture a cytometer cartridge insert of claim 8 , comprising forming an alignment device in the micro-molded component, the alignment device configured to align the integrated optical lens with a light source and a light detector.

11. The process to manufacture a cytometer cartridge insert of claim 10 , comprising forming a three point registration surface on the alignment device, the registration surface configured for coupling with a registration surface of a manifold of a cytometer.

12. The process to manufacture a cytometer cartridge insert of claim 8 , comprising aligning the integrated optical lens with the measurement channel such that the measurement channel walls do not produce random scatter noise; and forming the measurement channel walls having a low RMS planarity level and optical finish characteristics such that an illumination beam on the walls generates light scatter having a same group of angles as the illumination beam, thereby occupying a small solid angle of a budget of angles and not producing the random scatter noise.

13. The process to manufacture a cytometer cartridge insert of claim 8 , comprising forming a waste chamber on the plastic laminate component such that the waste chamber is coupled to the cuvette and the measurement channel, and such that the waste chamber comprises a volume of approximately 3 milliliters.

14. The process to manufacture a cytometer cartridge insert of claim 8 , comprising forming a lysing and sphering channel, a reagent channel, and a sample tank in the plastic laminate component.

15. The process to manufacture a cytometer cartridge insert of claim 8 , comprising forming the micro-molded component via injection molding, soft-embossing, or hot-embossing.

16. A cytometer cartridge insert comprising:

a micro-molded component; and

a plastic laminate component;

wherein the micro-molded component is embedded in the plastic laminate component; and

wherein the micro-molded component comprises:

a sample via comprising a diameter ranging from approximately 20 microns to approximately 100;

a measurement channel with an integrated optical lens, the measurement channel coupled to the sample via by way of a lysing and sphering channel, the measurement channel comprising a diameter ranging from approximately 20 microns to approximately 200 microns; and

a cuvette coupled to the sample via by way of a sample channel, the cuvette comprising an optical mask;

wherein the integrated optical lens is aligned with the measurement channel such that the measurement channel walls do not produce random scatter noise; and wherein the measurement channel walls have a low RMS planarity level and optical finish characteristics such that an illumination beam on the walls generates light scatter having a same group of angles as the illumination beam, thereby occupying a small solid angle of a budget of angles and not producing the random scatter noise.

17. The cytometer cartridge insert of claim 16 , comprising an alignment device for aligning the integrated optical lens with a light source and a light detector; wherein the alignment device comprises a registration surface configured to couple with a registration surface of a manifold of a cytometer.