Microfluidic Diagnostic Device Printed Adhesive Channels
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Solution Overview
Problem
Existing microfluidic diagnostic devices face limitations in creating smaller channel widths due to the contact-based die-cutting method, which results in undesirable adhesive carryover and requires more fluid sample for accurate testing, hindering rapid and less invasive blood testing.
Innovation Solution
A microfluidic diagnostic device is developed using printed adhesive channels with a mean width less than 1.0 mm, where the adhesive is applied in a specific pattern on a base sheet and covered with a sheet, allowing for capillary flow without pumps or vacuum sources, and featuring hydrophilic or non-hydrophilic surfaces for enhanced fluid transport.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If die-cutting method is used to create channels, then channels can be formed, but adhesive carryover occurs and channel width cannot be reduced below 1.0 mm
Solution Approach 1:
The patent extracts the adhesive application step from the channel formation process. Instead of using die-cutting that contacts and carries over adhesive, the invention applies adhesive only in specific patterns using printing methods, separating the adhesive application from the channel definition process. This eliminates adhesive carryover and enables precise channel width control below 1.0 mm.
Solution Approach 2:
The patent replaces the mechanical die-cutting system with a printing-based adhesive application system. Instead of mechanically cutting through adhesive layers with a die, the invention uses printing methods (such as screen printing, inkjet printing, or gravure printing) to deposit adhesive in precise patterns, eliminating mechanical contact and adhesive carryover while achieving sub-1.0 mm channel widths.
2Quantity of substance
If larger channel widths are used, then adhesive carryover is reduced, but more fluid sample is required for accurate testing
Solution Approach 1:
The patent replaces mechanical die-cutting with printing-based adhesive application, enabling precise control of channel width at sub-1.0 mm scales. This substitution allows creation of narrow channels that minimize fluid sample volume requirements while maintaining manufacturing feasibility through non-contact adhesive deposition.
3Manufacturing precision
If printed adhesive method is used, then smaller channel widths are achieved, but new manufacturing process is required
Solution Approach 1:
The patent substitutes mechanical die-cutting with printing technology, which is a well-established manufacturing process. The printing method (screen printing, inkjet printing, or gravure printing) uses conventional printing equipment and materials, making the manufacturing process accessible and scalable without requiring entirely new manufacturing capabilities.
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
The solution enables the creation of smaller channels that require less fluid sample, facilitating faster and more convenient testing, suitable for frequent monitoring and medication adjustments in medical conditions like diabetes, with improved fluid flow and reduced adhesive usage.
Implementation Method 1
The devices may be used with or without pumps or vacuum sources and may rely on capillary flow for moving liquid samples
Implementation Method 2
either the base sheet or the cover sheet or both comprise a hydrophilic surface in contact with the at least one channel
Data Source
AI summary
A method of making a microfluidic diagnostic device for use in the assaying of biological fluids, whereby a layer of adhesive in a channel pattern is printed onto a surface of a base sheet and a cover sheet is adhered to the base sheet with the adhesive. The layer of adhesive defines at least one channel, wherein the channel passes through the thickness of the adhesive layer.