Thermoformed, injection molded, and/or overmolded microfluidic structures and techniques for making the same
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Solution Overview
Problem
Microfluidic structures face challenges with reagent storage due to limited free volume and structural constraints, leading to potential leaks at fluidic interfaces and the need for robust off-structure storage solutions.
Innovation Solution
The development of laminated microfluidic structures with integrated wells formed through thermoforming or injection molding, incorporating sipper ports and channels, and overmolding or co-molding processes to create leak-resistant, compact designs for reagent storage and fluidic connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If reagents are stored in external reservoirs connected to the microfluidic structure, then the microfluidic structure maintains its leak-free integrity, but the overall system complexity increases and additional sealing interfaces are required
Solution Approach 1:
The patent integrates reagent storage wells directly into the microfluidic structure by forming distended regions that create volume expansion within the existing structure. This merging of storage and fluidic functions eliminates the need for separate external reservoirs and their associated sealing interfaces, thereby reducing system complexity while maintaining leak-free integrity through the integrated design
2Volume of moving object
If the microfluidic structure is made more compact to reduce size, then the device becomes more portable and efficient, but the available free volume for reagent storage decreases
Solution Approach 1:
The patent addresses the volume-capacity contradiction by creating distended regions that expand in the third dimension (depth) while maintaining a compact footprint in the planar view. The wells are formed by distending specific regions of the microfluidic structure, allowing vertical expansion to accommodate reagent storage volume without increasing the overall device area, thus achieving compactness with adequate storage capacity
3Quantity of substance
If wells are formed by distending regions of the microfluidic structure, then reagent storage capacity increases, but the structural integrity and sealing may be compromised
Solution Approach 1:
The patent applies local quality by selectively distending specific regions of the microfluidic structure to form wells while maintaining the original structural integrity in other areas. The distended regions are created through controlled formation processes that preserve the strength and sealing properties of the undistended portions, allowing localized volume expansion without compromising overall structural integrity
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
Enhances reagent storage capacity and reduces leakage risks by integrating wells and sipper ports within the microfluidic structure, providing a more reliable and efficient fluid handling system.
Implementation Method 1
heating at least the first region to a first temperature above a glass transition temperature of the polymeric material or materials of the at least two layers
Implementation Method 2
applying a pressure differential to the laminated microfluidic structure while the first region is heated above the glass transition temperature... to cause the first region to distend
Data Source
AI summary
Laminated microfluidic structures and methods for manufacturing the same are provided. In some instances, a laminated microfluidic structure is provided which includes a distended region having a sipper port at the bottom and an internal channel that fluidically connects the sipper port to a location outside of the distended region. Thermoforming and/or injection molding techniques for manufacturing such laminated microfluidic structures are provided. In other instances, a laminated microfluidic structure may be co-molded with a polymeric material to produce an integrated laminated microfluidic structure and housing.