Folded Foil Microfluidic System With Embossed Through-Holes
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Solution Overview
Problem
Existing microfluidic systems formed by film folding lack efficient and simple production methods, particularly in creating connected microfluidic structures across different planes without the use of lasers.
Innovation Solution
A film composite is formed by folding a single film with embossed microfluidic structures, where recesses in one film layer are covered by another, and through-holes connect microfluidic structures across planes, enabling efficient production through embossing and UV or thermal bonding without adhesives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If laser processes are used to create microfluidic structures and through-holes, then manufacturing precision is improved, but productivity decreases and manufacturing complexity increases
Solution Approach 1:
The patent replaces laser processes with an embossing process to create microfluidic structures and through-holes. The embossing process uses mechanical pressure and heat to form the structures directly in the film layers, eliminating the need for laser ablation. This substitution maintains manufacturing precision while dramatically improving productivity and reducing manufacturing complexity, as embossing can be performed rapidly and is easier to implement than laser processing.
Solution Approach 2:
The patent changes the manufacturing parameters from laser-based ablation to embossing-based forming. By using embossing, the process transitions from removing material (laser ablation) to shaping material (embossing), which enables higher production speeds and simpler manufacturing while maintaining the required precision for microfluidic structures.
2Adaptability or versatility
If multiple film layers are folded to create microfluidic structures in different planes, then functionality is improved, but device complexity increases
Solution Approach 1:
The patent divides the microfluidic system into multiple separate film layers, each containing specific microfluidic structures in different planes. The structures in one plane are connected to structures in other planes via through-holes. This segmentation allows for increased functionality while managing complexity by organizing different functions into separate layers that can be independently designed and then assembled through folding.
Solution Approach 2:
The patent utilizes the third dimension by creating microfluidic structures in different planes across multiple film layers. By folding the film layers, the system achieves three-dimensional microfluidic functionality while maintaining a compact two-dimensional footprint. The through-holes provide vertical connections between planes, enabling complex fluid handling functions without proportionally increasing the device's planar complexity.
3Strength
If adhesive is used to bond film layers, then strength is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent removes the adhesive bonding step from the manufacturing process by using self-bonding mechanisms. The film layers are bonded to each other through direct contact and inherent adhesion properties, eliminating the need for separate adhesive application and curing steps. This extraction of the adhesive process simplifies manufacturing while maintaining sufficient bond strength for the microfluidic system.
Solution Approach 2:
The film layers possess inherent self-bonding capabilities that allow them to adhere to each other without external adhesives. The bonding is achieved through the material properties of the film layers themselves, which enable direct bonding when brought into contact during the folding process. This self-service approach eliminates additional manufacturing steps and reduces overall manufacturing complexity and cost.
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 method allows for hermetically sealed, mechanically stable microfluidic structures with increased functionality and cost-effectiveness, enabling high-throughput production and integration of multiple functions on a single substrate.
Implementation Method 1
microfluidic structures are formed in that film layers with embossed recesses are covered by the respective film layer adjacent in the layering direction
Implementation Method 2
microfluidic structures of one plane are connected to microfluidic structures of another plane via through-holes in at least one film layer
Data Source
AI summary
A film composite folded from a single film to form a plurality of layered film layers (1) and comprising microfluidic structures (5) in different planes, wherein the microfluidic structures are formed by film layers having embossed recesses covered by the respective film layer adjacent in the layering direction, and wherein microfluidic structures of one plane are connected to microfluidic structures of another plane via through-holes in at least one film layer; a method for producing the film composite; and the use of the film composite.