Epoxy Microfilters with Photo-Defined Apertures for Cell Analysis
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Solution Overview
Problem
Conventional microfiltration devices lack precise pore dimensions, durability, and are autofluorescent, making them unsuitable for accurate cell filtration and analysis in medical diagnostics, particularly for detecting larger and less flexible cells in bodily fluids.
Innovation Solution
The development of microfilters made from epoxy-based photo-definable dry film with precisely controlled apertures, formed using UV or X-ray exposure, and multi-layer structures, which are strong, flexible, and non-autofluorescent, allowing for effective filtration and analysis of bodily fluids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional microfilters are used, then they can perform basic filtration, but they lack precise pore dimensions and are autofluorescent
Solution Approach 1:
The patent changes the material parameters by using epoxy-based photo-definable dry film instead of conventional filter materials. This material parameter change simultaneously achieves precise pore dimensions through photo-lithographic patterning and eliminates autofluorescence, as the epoxy material does not exhibit autofluorescent properties under fluorescent microscope imaging.
Solution Approach 2:
The patent employs composite material construction by forming microfilters from epoxy-based photo-definable dry film that combines structural integrity with optical properties. The composite nature of the cured epoxy resin provides both mechanical strength for handling and non-autofluorescent characteristics, resolving the contradiction between filtration performance and imaging compatibility.
2Strength
If conventional microfilters are used, then they can be manufactured simply, but they lack durability and break during use
Solution Approach 1:
The patent utilizes phase transition of the epoxy-based photo-definable dry film during curing. The material transitions from a flexible, manufacturable state to a rigid, durable cured state. This phase transition allows the filter to be easily manufactured in the uncured state while achieving high durability and resistance to breakage after curing, resolving the contradiction between ease of manufacture and strength.
Solution Approach 2:
The patent segments the manufacturing process into distinct phases: applying the uncured dry film, patterning through photo-exposure, developing, and curing. This segmentation allows each step to be optimized independently, maintaining ease of manufacture while achieving high durability in the final cured product.
3Manufacturing precision
If multi-layer microfilter structures are used, then filtration precision is improved, but device complexity increases
Solution Approach 1:
The patent addresses filtration precision by adding the dimensional aspect of multiple layers stacked vertically. Each layer can have different aperture sizes or patterns, creating a multi-stage filtration system. This dimensional approach improves filtration precision by capturing cells at different size thresholds while maintaining manageable complexity through systematic layer design.
Solution Approach 2:
The patent implements nested filtering where multiple layers with different aperture characteristics are stacked within a single device structure. Each layer acts as a nested filtering stage, with progressively finer filtration. This nesting approach improves precision by combining multiple filtration criteria in a compact structure without proportionally increasing overall device complexity.
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
The microfilters enable precise filtration and analysis of cells, such as circulating tumor cells, by allowing passage of specific cell types while retaining others, and can be used in various medical assays with improved accuracy and reliability.
Implementation Method 1
a polymer layer formed from epoxy-based photo-definable dry film, and a plurality of apertures each extending through the polymer layer
Data Source
AI summary
A microfilter comprising a polymer layer formed from photo-definable dry film, and a plurality of apertures each extending through the polymer layer. A microfilter comprising two or more polymer layers formed from photo-definable dry film, and a plurality of apertures or open areas each extending through the polymer layer. Methods of forming apertures in one or more layers of photo-definable dry film are also disclosed. Filter holder designs and methods appropriate to hold microfilters to collect the rare cells and to perform of assays in the filter holder are provided. Microfiltration chip designs and methods appropriate to collect the rare cells and to perform assays in the microfluidic chips are provided. The invention also describes the use of the microfilter, filter holder and microfilter chips to collect rare cells from body fluids and perform assays, and these rare cells can be used for medical and biological research applications.