Digital Dispense Cartridge With Segmented Ejectors
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Solution Overview
Problem
Current methods for dispensing fluids onto substrates are either manual, expensive, or limited in precision and versatility, particularly in medical and micro-manufacturing applications, where accurate and efficient dispensing of multiple fluids in precise locations is required.
Innovation Solution
A digital fluid dispense system utilizing an open fluid droplet ejection cartridge with multiple fluid chambers, a chamber separator, and fluid ejection devices on a semiconductor substrate, allowing for precise and versatile dispensing of fluids onto substrates through a combination of cartridge and substrate translation mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual pipetting or hand-operated pipettes are used to fill wells, then the system cost is low, but the productivity and precision are insufficient
Solution Approach 1:
The dispense head is segmented into multiple independent fluid ejection devices (e.g., 96 ejectors) arranged in a grid pattern, allowing parallel dispensing into multiple wells simultaneously. Each ejector can be independently controlled to dispense precise volumes, achieving high throughput without requiring a complex robotic arm or sequential operation
Solution Approach 2:
Multiple fluid ejection devices are merged into a single integrated dispense head assembly that can dispense multiple fluids simultaneously. The system combines the functions of multiple pipettes into one device, with a common control system and fluid management architecture, achieving high productivity without proportionally increasing system complexity
2Measurement precision
If high-end automated devices with open well dispense heads are used, then the precision and automation level are high, but the system cost is extremely expensive
Solution Approach 1:
The system replaces complex mechanical positioning systems with a simplified approach: the dispense head is electronically addressed with each ejector independently controllable via digital signals. This substitution of mechanical complexity with electronic control achieves high precision at lower system complexity and cost
Solution Approach 2:
The dispense head is designed as a universal platform that can handle multiple fluid types and dispense into various well plate configurations. The same basic ejector array can be used for different applications by changing the fluid reservoirs or control parameters, reducing the need for multiple specialized devices
3Manufacturing precision
If conventional ink jet printing technology is used for fluid dispensing, then the device complexity is low, but the manufacturing precision and fluid volume control are insufficient
Solution Approach 1:
Each fluid ejection device is optimized for its specific local function with precisely engineered nozzle geometry, fluid reservoir configuration, and ejection parameters. The system applies different ejection forces, volumes, and timing to different locations on the substrate based on specific requirements, achieving high manufacturing precision through localized optimization rather than uniform approach
Solution Approach 2:
The system dynamically adjusts ejection parameters (volume, force, timing) for each fluid ejection event based on real-time feedback and programmatic control. This dynamic control allows precise manipulation of fluid volume and placement accuracy, far exceeding static ink jet printing capabilities while maintaining manageable system complexity through software control
Data Source
AI summary
An open fluid droplet ejection cartridge containing one or more fluids to be dispensed by digital fluid dispense system and a method for digitally dispensing fluids. The open fluid droplet ejection cartridge includes a cover having one or more openings therein, fluid funnels pending from each of the one or more openings in the cover, a chamber separator attached to the fluid funnels for directing fluid to one or more fluid chambers, a fluid overflow chamber for fluid overflow from the one or more fluid chambers, fluid vias associated with each of the one or more fluid chambers, and a plurality of fluid ejection devices adjacent to the fluid vias on a single semiconductor substrate in fluid flow communication with the fluid vias.