Droplet actuator fabrication apparatus, systems, and related methods
Inventors
Fischer, Andrew • Petyt, Adrian • Laurenson, Sophie
Assignees
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Publication Number
US-12201980-B2
Publication Date
2025-01-21
Expiration Date
Abstract
Example methods, apparatus, systems for droplet actuator fabrication are disclosed. An example non-transitory computer readable medium includes instructions that, when executed, cause at least one processor to at least control movement of a laser to cause the laser to etch an electrode pattern in a first substrate, the electrode pattern including a first set of electrodes, a second set of electrodes, and a third set of electrodes; control a printer driver to cause a hydrophobic material and a dielectric material to be applied to the second set of electrodes and not the first set of electrodes via a printer; control a bonding driver to cause a gap to be defined between the first substrate and a second substrate; and control a dicing driver to cause a portion the first substrate and a portion of the second substrate to be cut into a droplet actuator.
Core Innovation
The invention relates to fabrication of droplet actuators using roll-to-roll processing. A conductive layer on a base substrate is ablated with a laser to form an electrode pattern with spaced electrode sets, including an electrode pattern suitable for microfluidic droplet actuation. Laser ablation includes forming a master pattern and using laser rastering or scribing to create high-resolution electrode patterns with smooth edges.
After forming the electrode pattern, a printer selectively applies hydrophobic material and/or dielectric material. The printer applies the hydrophobic material and dielectric material to selected electrode array portions while leaving connection electrodes exposed, thereby defining treated and untreated electrode regions within the electrode array. The treated coating is cured in a curing station to harden the applied material.
A top substrate is prepared with an electrode configuration, then aligned with the base substrate at a defined gap while preserving the gap during bonding. One or more projections including capillaries are inserted at least partially in the gap to define droplet space. The merged web is then diced to separate the first substrate and the second substrate into individual droplet actuators.
Claims Coverage
The independent claims cover a computer-implemented manufacturing workflow and a manufacturing method/system for droplet actuators, with inventive features including laser-etched electrode sets, selective hydrophobic and dielectric application, gap formation with capillary projections, alignment/bonding, and dicing into droplet actuators. The coverage spans three independent claims and includes multiple additional inventive refinements in dependent claims.
Multi-set laser-etched electrode pattern with intermediate electrodes
control of a laser to etch an electrode pattern in a first substrate, the electrode pattern including a first set of electrodes, a second set of electrodes, and a third set of electrodes, each spaced apart from each other, with the second set disposed between the first set and the third set
Selective printer application of hydrophobic and dielectric material to only the second set
a printer applies a hydrophobic material and a dielectric material to the second set of electrodes and not the first set of electrodes
Gap formation and capillary projections between first and second substrates
a gap is defined between the first substrate and a second substrate, and one or more projections including capillaries are at least partially inserted into the gap
Dicing into a droplet actuator with edge-proximate electrode sets
a portion of the first substrate and a portion of the second substrate are cut into a droplet actuator, with the first set of electrodes and the third set of electrodes disposed proximate to respective edges
Laser patterning of spaced portions and roller-based printer isolation of electrode sets
a first electrode pattern is patterned on a first portion of a first substrate, a second electrode pattern is patterned on a second portion of the first substrate spaced apart from the first portion, and rollers move the second set of electrodes away from the printer during patterning of the second electrode pattern
Printer-applied hydrophobic and dielectric during patterning of a spaced portion
a printer applies a hydrophobic material and a dielectric material to the first set of electrodes during patterning of the second electrode pattern on the second portion of the first substrate
Frame-based gap formation, capillary projections insertion, and dicing into droplet actuator
a bonding driver inserts a frame between the first substrate and the second substrate to form a gap therebetween to receive a droplet, one or more projections including capillaries are at least partially inserted into the gap, and a dicing driver cuts the first portion of the first substrate and a portion of the second substrate into a droplet actuator
Laser ablation to form an electrode array and formation of a treated layer
a first substrate is ablated with a laser to form an electrode array, and at least one of a hydrophobic material or a dielectric material is applied to at least a portion of the electrode array to form a first treated layer
Alignment with a gap between treated layers and insertion of capillary projections
the first substrate is aligned with a second substrate including a second treated layer, with a gap between at least a portion of the first treated layer and at least a portion of the second treated layer, and one or more projections including capillaries are inserted at least partially in the gap
Dicing to form droplet actuators from aligned, inserted substrates
the first substrate and the second substrate are diced to form a first droplet actuator including a first portion of the first substrate and a second droplet actuator including a second portion of the first substrate
Across the independent claims, the droplet actuator manufacture is centered on laser ablation to form electrode patterns or electrode arrays, printer-based selective application of hydrophobic material and dielectric material to defined electrode regions, alignment and bonding that define a gap, insertion of projections including capillaries into the gap, and dicing to form droplet actuators. Dependent claim refinements further specify electrode and spacing relationships and selective deposition on particular electrode sets.
Stated Advantages
Reduced chemical residues compared to lithography/PCB methods.
Improved cost and speed compared to lithography/PCB methods.
Improved conductivity compared to lithography/PCB methods.
Improved roughness/edge quality and resolution compared to lithography/PCB methods.
Documented Applications
Manufacturing of droplet actuators for microfluidic applications using digital microfluidics via an electrode array and capillary-defined droplet space.
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