Microchannel Chip Side Opening Mold Cost Reduction

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Solution Overview

Problem

The complexity of mold structures and high costs associated with forming resin products with recessed parts and flow paths, particularly in micro analysis systems, make it challenging to produce micro flow path chips with side surface openings efficiently.

Innovation Solution

A micro flow path chip design featuring two thin plates with recessed parts and grooves on their joint surfaces, allowing for side openings and flow paths without undercut sections, reducing manufacturing complexity and costs by dividing the components into two plates for easier assembly and mold integration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If a mold structure is used to form recessed parts deeply recessed from an opening or both recessed parts and flow paths in integral forming of resin products, then the desired complex shape is achieved, but the mold structure becomes complex and forming becomes more difficult

Engineering Contradiction:

Improvecomplex shape with recessed parts and flow pathsVSAvoidmold structure complexity and forming difficulty

Core Design Contradiction:

ShapeVSEase of manufacture

Solution Approach 1:

The micro flow path chip is divided into a first plate and a second plate, each containing simplified recessed parts. The first recessed part and second recessed part are formed on separate plates with simpler mold structures, then assembled together to create the complete micro flow path structure. This segmentation avoids the need for complex integral molding while achieving the desired functional shape.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention transitions from three-dimensional integral molding to a two-plate assembly structure. By forming recessed parts on separate plates and assembling them, the manufacturing process moves from complex 3D molding to simpler 2D plate formation followed by assembly, reducing mold complexity while maintaining the functional 3D structure.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Shape

If a connection part with tubular structure having multiple regions of different inner diameters is attached to a flow plate, then the desired flow path configuration is achieved, but the mold structure becomes complex and product cost increases

Engineering Contradiction:

Improveflow path configuration with varying inner diametersVSAvoidmold structure complexity and product cost

Core Design Contradiction:

ShapeVSDevice complexity

Solution Approach 1:

The flow path structure is segmented into the first plate containing the first recessed part and the second plate containing the second recessed part. Each plate is formed with simpler geometry that can be molded more easily, replacing the need for a single complex tubular connection part with multiple diameter variations.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The functional elements that would require a complex tubular connection part are merged into the assembly of two plates with their respective recessed parts. The first recessed part and second recessed part work together to achieve the desired flow path configuration, eliminating the need for a separate complex tubular component.

Inventive Principle:

Principle #5Merging (Combining)

3Shape

If resin products with both recessed parts having large cross-section area openings and flow paths with small cross-section area are integrally formed, then the desired functional structure is achieved, but the mold structure becomes complex and product cost soars

Engineering Contradiction:

Improvefunctional structure with large opening and small flow pathVSAvoidmold structure complexity and product cost

Core Design Contradiction:

ShapeVSEase of manufacture

Solution Approach 1:

The structure is divided into two plates, each handling specific geometric requirements. The first plate contains the first recessed part with its opening, and the second plate contains the second recessed part with the flow path. This segmentation allows each plate to be molded with simpler, less complex mold structures while maintaining the functional relationship between large openings and small flow paths.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention resolves the manufacturing complexity by moving from 3D integral molding to 2D plate assembly. Each plate is formed with simpler geometry suitable for standard molding techniques, then assembled to create the complete structure with both large openings and small flow paths, avoiding the need for complex multi-cavity or progressive molds.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS8945479B2Microchannel chip and microanalysis system

Publication Date: 2015.02.03 ENPLAS CORP

AI summary

Disclosed is a microchannel chip having an opening on the side of a plate with a lowered production cost. In the microchannel chip, a first plate (11), to which a third concavity (17) opening at one side surface (13) and a joining surface (14) is formed on the joining surface (14), is joined to a second plate (21), to which a sixth concavity (26) opening at one side surface (23) is formed on the joining surface and a groove (27′) interconnecting with the sixth concavity (26) is formed. The third concavity (17) and the sixth concavity (26) are aligned facing each other, and by the third concavity (17) and the sixth concavity (26), a glass tube introducing opening (33) is formed having a wider width than that of a duct (27). An adhesive agent is injected into the glass tube introducing opening (33) and a glass tube is inserted.