Capillary Pore Alteration via Sequential Fluid Flow
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Solution Overview
Problem
Current technologies face challenges in controlling the alteration of pores, particularly in creating complex structures within small capillaries and optical fibers, which limits the fabrication of high-density electrical and optical conductors and fibers.
Innovation Solution
The method involves using sequential fluid flow of surface-altering materials to deposit and remove materials within porous substrates through controlled reactions, such as self-assembly, electrochemical deposition, and chemical reactions, allowing for the formation of microscopic structures with high aspect ratios and complex geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional fabrication methods are used to create small electrical conductors and optical fibers, then manufacturing simplicity is maintained, but manufacturing precision and structural complexity are limited
Solution Approach 1:
The fabrication process is segmented into distinct sequential steps: pore formation, material deposition, and material removal. Each step is independently controlled through fluid flow, enabling precise manipulation of pore structures without requiring complex integrated processes
Solution Approach 2:
The invention controls pore alteration by changing fluid flow parameters (flow rate, composition, pressure) to precisely control deposition and removal rates. This allows dynamic adjustment of structural complexity and precision during fabrication
2Manufacturing precision
If material is deposited radially inwardly on pore walls to form structures, then manufacturing precision of microscopic structures is improved, but loss of pore volume increases
Solution Approach 1:
The fabrication employs periodic alternation between deposition phases (building structures) and removal phases (clearing excess material). This periodic action enables precise control over final pore volume and structure formation, achieving high precision while minimizing net material loss
Solution Approach 2:
Material deposition and removal are localized to specific pore regions through controlled fluid flow patterns. This allows selective alteration of pore walls where needed while preserving overall pore volume and structure in other regions
3Manufacturing precision
If sequential fluid flow is used to deposit and remove materials in pores, then manufacturing precision of complex geometries is improved, but productivity decreases due to sequential processing
Solution Approach 1:
Multiple fabrication operations (deposition, removal, cleaning) are merged into a single sequential fluid flow process. By combining these steps into one continuous workflow with automated fluid switching, the invention maintains high precision while improving productivity compared to separate manual processes
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the precise creation of microscopic structures and assemblies with high aspect ratios, facilitating the development of advanced microelectrodes and opto-electrode arrays for enhanced electrochemical and optical analysis, with applications in chemistry, biology, and medicine.
Implementation Method 1
maintaining the stream until a layer is built up along an inner wall of the capillary from material deposited from the flowing stream
Implementation Method 2
by selectively depositing materials on the substrate walls using controlled reactions (e.g., by self assembly, electrochemical deposition, electroless deposition, in situ polymerization, biological reaction, and/or chemical reaction, hereinafter termed 'deposition')
Implementation Method 3
The deposition and removal process is achieved using fluid flow to transport materials into pores and to enable the controlled deposition or removal of materials
Implementation Method 4
establishing a flowing stream of a solution containing a colloidal suspension of particles within the capillaries and maintaining the flowing stream of the colloidal suspension of particles until a layer of particles is built up on the bonding layer
Data Source
AI summary
The invention relates to microscopic structures and methods of making and using the structures. A method of forming a microscopic structure of a material includes obtaining a solution (310) containing the material, establishing a flowing stream of the solution (310) in a capillary (104), wherein the capillary (104) has an inner dimension that is smaller than about 300 micrometers, and maintaining the stream until a layer is built up along an inner wall of the capillary (104) from material deposited from the flowing stream, thereby forming a microscopic structure.