Folded Sheet Metal Microfluidic Component
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for producing microfluidic components with complex structures are time-consuming and not suitable for inexpensive mass production, limiting the variety of structural features and applications in microfluidic reactors and heat exchangers.
Innovation Solution
A microfluidic component is created by folding sheet metal sections with structured and unstructured surfaces, where the structured surface forms closed fluid lines and the unstructured surface forms open fluid lines, allowing for the production of complex structures through embossing and punching processes, enabling efficient and cost-effective manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If material-removing processes are used to produce microfluidic structures, then manufacturing precision can be achieved, but processing time becomes comparatively long and mass production becomes expensive
Solution Approach 1:
The patent replaces material-removing processes (electrical, chemical, electrochemical, or mechanical machining) with a forming process where a pre-structured sheet metal blank is folded along bending lines to create the microfluidic component. This mechanical forming approach maintains manufacturing precision while enabling much faster production suitable for mass manufacturing.
Solution Approach 2:
The sheet metal blank is prepared in advance with the microstructure (channels, pockets, recesses) already embossed or formed on its surface before the folding operation. This preliminary structuring allows the final folding step to simply assemble the pre-formed features into the three-dimensional microfluidic component, dramatically reducing processing time while maintaining precision.
2Adaptability or versatility
If complex microfluidic structures are produced using conventional methods, then structural variety can be achieved, but production cost increases and mass production becomes difficult
Solution Approach 1:
The sheet metal blank is divided into multiple sections (first section with structured surface, second section with unstructured surface, third section with contoured edge) that are folded along specific bending lines to create different functional features. This segmentation allows complex structures to be built from simpler pre-formed sections, reducing overall manufacturing complexity and cost.
Solution Approach 2:
The patent creates a universal manufacturing approach where a single sheet metal blank with integrated microstructure can produce various microfluidic components (microreactors, heat exchangers, mixers) by varying the folding pattern. This multi-functional approach allows structural variety while maintaining cost-effective mass production through a standardized forming process.
3Productivity
If sheet metal is folded to create microfluidic components, then production speed and cost-effectiveness improve, but structural complexity is limited without additional features
Solution Approach 1:
The sheet metal blank has different surface qualities in different sections: the first section has an embossed microstructure for fluid channels, the second section has a smooth unstructured surface for sealing or support, and the third section has a contoured edge for joining. This local differentiation of surface quality allows the simple folding process to create structurally complex components with multiple functional zones.
Solution Approach 2:
The patent transitions from two-dimensional sheet metal with embossed features to three-dimensional folded structures. By folding the sheet along bending lines, the flat microstructure is transformed into volumetric features (pockets, channels, recesses) that provide complex fluid flow paths and thermal exchange surfaces, greatly enhancing structural capability while maintaining production efficiency.
Data Source
Figure 1A~1B
Figure 1C~1D
Figure 1E~1F
AI summary
The invention relates to a microfluidic component made of a metal sheet having a structure which comprises a closed fluid line and which is formed of a structured surface of a first section of the metal sheet and an adjoining structured or unstructured surface of a second section of the metal sheet, wherein the metal sheet is folded such that the sections integrally connected to each other are located on top of each other in a surface-parallel manner. The metal sheet further comprises at least one third section having a contoured edge and is moreover folded such that the third section is also supported in a surface-parallel manner and the contoured edge forms a first wall section and the adjoining structured or unstructured surface of the first or second section forms a second wall section of an open fluid line. The invention further relates to a microfluidic reactor comprising a plurality of such microfluidic components and to a method for producing such components.