Method of continuously manufacturing microfluidic chips with BoPET film for a microfluidic device and microfluidic chips with BoPET film
Inventors
PATEL, Tej • REVILLA, Ryan • D'OOGE, MATTHEW
Assignees
Publication Number
US-9120298-B2
Publication Date
2015-09-01
Expiration Date
2033-09-16
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Abstract
A microfluidic chip includes a thin biaxially-oriented polyethylene terephthalate (“BoPET”) film and a micro-channel in the BoPET film. A method for manufacturing a microfluidic chip includes coating UV epoxy on a first side of a BoPET film, placing the BoPET film on a first substrate with the first side facing the first substrate, curing the UV epoxy on the first side of the BoPET film to attach the BoPET film on the first substrate; forming at least one microfluidic pathway in the BoPET film, coating UV epoxy on a first side of a second substrate, placing the second substrate on the BoPET film with the first side of the second substrate facing a second side of the BoPET film, and curing the UV epoxy on the first side of the second substrate to attach the BoPET film to the second substrate. The microfluidic chip may be a multi-layered chip.
Core Innovation
The invention relates to a method of continuously manufacturing microfluidic chips that handle fluid samples on a microfluidic level using a thin biaxially-oriented polyethylene terephthalate (BoPET) film with micro-channels formed therein. Unlike the traditional batch fabrication process relying on molds and PDMS blocks, this method involves coating UV epoxy on one side of a BoPET film, bonding it to a first substrate, forming microfluidic pathways in the BoPET film by laser ablation, and subsequently sealing the micro-channels by bonding a second substrate coated with UV epoxy onto the film.
The problem being solved addresses limitations in the prior art where microfluidic chips are manufactured in batches using molds and PDMS, which is time-consuming, costly, and inflexible. The prior art process requires making a master mold and then replicating micro-channels in PDMS blocks, limiting throughput and adaptability to new channel designs. There is a need for a manufacturing method that continuously, reliably, quickly, and cost-effectively forms micro-channels while enabling dynamic adjustment of channel designs.
The proposed method achieves continuous manufacturing by performing the steps sequentially on a production line where the BoPET film is coated with UV epoxy, attached on a substrate, ablated by a dynamically controlled laser to form micro-channels, and then sealed by bonding a second substrate, optionally followed by adding further layers for multi-layered chips. This process avoids the use of molds and enables fast and reliable formation of micro-channels in transparent, stable, and electrically insulative BoPET films such as Mylar.
Moreover, the invention provides microfluidic chips produced by this method, consisting of a BoPET film bonded between first and second substrates with microfluidic pathways directly formed in the BoPET film via laser ablation. Multi-layer chips are achievable by repeating these layering and ablation steps. This approach allows real-time adjustments of channel designs through laser control, enhancing production flexibility and efficiency.
Claims Coverage
The patent includes several independent claims covering methods for manufacturing microfluidic devices and the microfluidic chips produced by such methods. The main inventive features focus on the continuous method steps using BoPET film, UV epoxy bonding, and laser ablation without the need for molds, and multi-layer embodiments.
Continuous method to manufacture microfluidic devices using BoPET film and UV epoxy bonding
The method comprises coating UV epoxy on one side of a BoPET film, placing it on a first substrate with the coated side facing the substrate, curing the UV epoxy to bond the film, forming at least one microfluidic pathway in the BoPET film, coating UV epoxy on a second substrate, placing the second substrate on the BoPET film with the coated side facing the film, and curing the UV epoxy to bond all layers.
Micro-channel formation by laser ablation
Forming the microfluidic pathway includes applying a laser beam to ablate the BoPET film and optionally the first substrate to create channels and inlets/outlets without using molds.
Multi-layer microfluidic chip manufacture by repeated layering and laser ablation
Extending the method by coating UV epoxy on a second BoPET film, bonding it to the second substrate, forming microfluidic pathways by laser ablation in the second film, and bonding a third substrate with UV epoxy to the second film, enabling production of multi-layer chips.
Microfluidic chip with BoPET film bonded between substrates and micro-channels formed without molds
A microfluidic chip comprising a first substrate bonded to a UV epoxy-coated BoPET film having at least one microfluidic pathway formed by laser ablation, and a second substrate bonded on the BoPET film, where the microfluidic pathways are formed without using a mold.
The claims cover a continuous, mold-free method for manufacturing microfluidic chips using BoPET films bonded via UV epoxy and laser ablation to form micro-channels, including multi-layer configurations, and the microfluidic chips produced by this method.
Stated Advantages
Enables continuous manufacturing of microfluidic chips, overcoming batch limitations of prior art.
Allows reliable and quick formation of micro-channels without needing master molds.
Facilitates dynamic and real-time adjustment of micro-channel designs via laser ablation.
Provides a cost-effective, simple, and flexible process for microfluidic chip production.
Supports multi-layer microfluidic chip fabrication with transparent, stable, and electrically insulative BoPET films.
Documented Applications
Use of the manufactured microfluidic chips for handling fluid samples on a microfluidic level.
Performing analyses such as polymerase chain reaction (PCR) analysis.
Manipulating or analyzing micro-sized fluid samples typically in extremely small volumes (down to less than pico liters).
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