Laser Welding Fluidic Device Manufacturing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing fluidic devices for Micro-Total Analysis Systems (μ-TAS) face challenges in efficiently manufacturing devices with complex flow channel patterns and multi-layer structures, which are essential for precise sample analysis and reagent mixing.
Innovation Solution
The development of a fluidic device manufacturing method involving a three-layer structure formed by laser welding, where a resin intermediate layer absorptive to laser light is sandwiched between two resin substrates transmissive to laser light, allowing for simultaneous bonding of all layers with a single laser irradiation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional multi-step bonding methods are used to assemble fluidic devices with complex flow channel patterns and multi-layer structures, then manufacturing precision can be achieved, but manufacturing time and complexity increase significantly
Solution Approach 1:
The patent combines multiple bonding operations into a single laser irradiation process that simultaneously bonds multiple layers together. The laser beam irradiates the intermediate layer from one side, causing it to melt and bond with adjacent layers all at once, eliminating the need for sequential bonding steps and significantly reducing manufacturing time while maintaining precision.
Solution Approach 2:
The patent introduces an intermediate layer made of resin material that is absorptive to laser light as a mediator between substrate layers. This intermediate layer absorbs laser energy, converts it to heat, and facilitates bonding between layers without requiring direct contact or complex alignment mechanisms, thereby simplifying the manufacturing process.
2Strength
If conventional bonding methods are used to join multiple substrate layers, then structural integrity can be maintained, but the process requires multiple steps and increases device complexity
Solution Approach 1:
The patent replaces complex mechanical assembly and bonding operations with a single laser irradiation process. The laser beam provides localized heating that melts the intermediate layer and bonds layers together through thermal energy, eliminating the need for mechanical clamping, alignment, and sequential bonding operations that would otherwise be required.
Solution Approach 2:
The patent changes the physical state of the intermediate layer from solid to molten during laser irradiation, enabling bonding. By controlling laser parameters (intensity, duration, scan speed) and material properties (melting point, thermal conductivity), the process achieves strong bonds without requiring complex multi-step procedures or additional bonding agents.
3Ease of manufacture
If traditional manufacturing methods are used for fluidic devices, then existing processes can be maintained, but manufacturing costs and time increase due to multiple processing steps
Solution Approach 1:
The patent prepares substrate layers and intermediate layers in advance with pre-formed flow channel patterns and appropriate material selection. The intermediate layer is specifically designed with laser-absorbing properties and positioned between substrate layers before final assembly, so that when laser irradiation occurs, all bonding actions happen simultaneously without requiring subsequent processing steps.
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 enables the efficient fabrication of fluidic devices with fine flow channel patterns and multi-layer structures, reducing manufacturing time and costs while ensuring leak-free and uniform flow channels for smooth liquid circulation.
Implementation Method 1
a resin intermediate layer absorptive to laser light is sandwiched between two resin substrates transmissive to laser light
Implementation Method 2
allowing for simultaneous bonding of all layers with a single laser irradiation process
Implementation Method 3
the respective layers are bonded with adjacent layers by laser welding
Data Source
AI summary
A method for manufacturing a fluidic device comprises: forming a laminate including a first substrate made from resin material transmissive to laser light, an intermediate layer stacked on the first substrate and made from resin material absorptive to the laser light, and a second substrate stacked on the intermediate layer and made from resin material transmissive to the laser light; and welding the first substrate and the intermediate layer, and the intermediate layer and the second substrate, by irradiating the laminate with laser light from the direction of the first or the second substrate and melting the intermediate layer over the entire thickness direction in an area irradiated with the laser light, wherein the forming includes forming a flow channel in a contact surface of the first or the second substrate with the intermediate layer; or forming a penetration area penetrating in the stacked direction in the intermediate layer.