Laser Channel Formation in Transparent Materials
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Solution Overview
Problem
Current microfluidic chip production methods are time-consuming, expensive, and result in low yield due to complex and costly tooling requirements, limited 2D design capabilities, and difficulties in bonding layers, which can lead to seal failures and leaks.
Innovation Solution
A method and system using a laser source to form continuous channels in transparent materials by converging and moving a laser beam to create channels with vents, allowing for 3D channel formation without the need for bonding processes, using a focus optic, translation stages, and a controller to control the laser and movement, and incorporating ablation product removal systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If photolithographic techniques and complex tooling are used to produce microfluidic chips, then manufacturing precision can be achieved, but device complexity and production costs increase significantly
Solution Approach 1:
The patent extracts the channel formation process from the complex photolithographic tooling sequence and implements it directly through laser ablation on the master mold, eliminating the need for separate photolithography equipment, photoresist materials, and multiple development/etching steps while maintaining channel formation precision
Solution Approach 2:
The patent replaces the mechanical and chemical photolithography system with an optical laser ablation system, using focused laser energy to directly remove material and form channels, thereby simplifying the overall device complexity while preserving manufacturing precision
2Shape
If multiple layers are bonded together to form microfluidic chips, then 3D structures can be created, but bonding difficulties lead to seal failures and leaks
Solution Approach 1:
The patent transitions from 2D planar channel designs to 3D volumetric channel structures by utilizing the third dimension (depth) through laser ablation, allowing channels to be formed at various depths and angles within the master mold material, thereby achieving 3D structuring without layer bonding
Solution Approach 2:
The patent removes the layer bonding step entirely from the manufacturing process, creating monolithic 3D microfluidic structures through direct laser ablation of the master mold material, which eliminates seal failures and leaks associated with bonded interfaces
3Ease of operation
If ports are drilled before layer consolidation, then channel connectivity can be established, but design is limited to 2D patterns
Solution Approach 1:
The patent enables 3D channel design and fabrication by using laser ablation to create channels that extend in multiple spatial dimensions within the master mold, allowing complex three-dimensional channel networks, intersections, and vertical connections that cannot be achieved with 2D drilling and layer stacking
4Manufacturing precision
If conventional fabrication processes are used to create closely spaced narrow channels, then microfluidic features can be produced, but production time increases
Solution Approach 1:
The patent implements continuous laser ablation scanning through the master mold material to form channels in a single uninterrupted process, eliminating the discrete steps of photolithography, development, and etching, thereby maintaining precise channel spacing and width while significantly increasing production speed
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 efficient production of microfluidic chips with improved yield and reduced costs by eliminating the need for complex bonding processes, allowing for 3D channel formation and ensuring channel integrity through vented channels and effective ablation product removal.
Implementation Method 1
generating, using a laser source, a laser beam
Implementation Method 2
converging, using a focus optic, the laser beam to a focal region
Implementation Method 3
forming a continuous channel within the transparent material generally along the first scan path
Data Source
AI summary
A system and method for producing continuous channels within a transparent material is disclosed. According to one embodiment, the system and method includes forming a channel with a laser beam, such that the continuous channel has at least one vent from the channel to outside the transparent material.