Laser-Welded Microfluidic Membranes for Precise Dosing

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Solution Overview

Problem

Current microfluidic pump systems with flexible cover films face challenges in achieving precise dosing due to structural deformation and variance in valve chamber volumes, leading to inconsistent delivery rates and reduced reproducibility, especially when handling small volumes and sensitive culture conditions in biotechnological processes.

Innovation Solution

The use of laser beam welding to attach a flexible membrane to the valve body, with precise guidance and controlled energy input to create a strong, reproducible weld seam, reducing mechanical interactions and adhesion issues, and employing surface smoothing and hydrophilic coatings to enhance precision and reduce adhesion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional thermal welding or adhesive bonding is used to attach the flexible membrane to the valve body, then the membrane can be attached to the valve body, but structural deformation and variance in valve chamber volumes occur, leading to inconsistent delivery rates

Engineering Contradiction:

Improvedosing precisionVSAvoidvalve chamber volume consistency

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent replaces conventional mechanical bonding methods (thermal welding, adhesive bonding) with laser beam welding. This substitution eliminates the mechanical deformation and volume variance caused by heat-pressing and clamping processes, achieving consistent valve chamber volumes and reliable dosing precision through a non-contact welding process that precisely controls energy input without mechanical stress on the membrane or valve body

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent controls the laser beam parameters (power, speed, focal point) to achieve optimal welding conditions. By precisely adjusting these parameters, the process achieves strong bonding between the membrane and valve body while minimizing heat-affected zone and preventing structural deformation, thereby maintaining consistent valve chamber volumes across production batches

Inventive Principle:

Principle #35Parameter changes

2Strength

If higher energy input is used in thermal welding to ensure strong bonding, then the membrane attaches more securely, but structural deformation increases, reducing dosing precision

Engineering Contradiction:

Improveweld seam strengthVSAvoidvalve chamber geometry

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The patent replaces conventional thermal welding with laser beam welding, which delivers energy through radiation rather than conductive heat transfer. This allows precise localization of energy input to the weld seam area only, achieving strong bonding without the widespread heat diffusion that causes structural deformation in conventional thermal welding processes

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The laser beam welding process applies energy locally and selectively to the interface between the membrane and valve body. The highly focused energy input creates a strong weld seam precisely where needed, while the surrounding areas remain unaffected, preserving the original geometry and volume of the valve chamber

Inventive Principle:

Principle #3Local quality

3Ease of manufacture

If conventional bonding methods are used to reduce costs, then manufacturing is more economical, but adhesion issues and mechanical interactions reduce system reliability

Engineering Contradiction:

Improvemanufacturing costVSAvoiddosing reproducibility

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent replaces adhesive bonding and mechanical clamping with laser beam welding, eliminating the adhesion issues and mechanical interactions that compromise reliability. The direct fusion bonding created by laser welding provides superior connection strength and consistency, ensuring reproducible dosing performance while maintaining manufacturing efficiency through a streamlined, single-step process

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 significantly reduces variance in pump performance, improving the precision and reproducibility of the dosing process, enabling more accurate and consistent delivery of small liquid volumes, especially in the range of 0.01 to 80 µL/h, and enhancing the reliability of microfluidic systems in biotechnological applications.

Implementation Method 1

The surface of the membrane facing the valve trough is heated with a laser beam during production

Methodology Applied

Scientific EffectLaser beam heating: Laser

Implementation Method 2

The surface of the membrane facing the valve trough is heated by radiation impinging on the membrane

Methodology Applied

Scientific EffectRadiation absorption: Absorption (EM radiation)

Data Source

PatentEP3807537B1Method for improving the dosing precision of microfluidic pumps or valves and welding device and clamping device for carrying out the method

Publication Date: 2023.12.20 M2P LABS

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AI summary

The invention relates to a method for increasing the metering precision of microfluidic pumps and valves based on a flexible cover film/membrane and a valve trough, in which the surface of the membrane, which faces the valve trough, is heated using a laser beam.