Modular Microfluidic Blocks with Precision Locating Features
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Microfluidic systems face challenges in achieving high-volume production while maintaining stringent manufacturing tolerances and customization, with existing techniques often resulting in high costs and limited scalability due to material restrictions and tight sealing requirements, and there is a need for rapid adjustment and reconfiguration without compromising accuracy or causing leaks.
Innovation Solution
The development of modular microfluidic systems using pre-existing or custom-made blocks with precision locating features, such as LEGO-like blocks, that can be easily assembled and reconfigured to form microfluidic paths with precise sealing, allowing for customizable and adaptable systems through the use of channels and seals, enabling efficient fluid handling and analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional microfluidic manufacturing techniques are used, then manufacturing precision can be maintained, but production volume is limited and costs are high
Solution Approach 1:
The microfluidic system is divided into multiple discrete modular blocks that can be independently manufactured using standard injection molding techniques. Each block contains specific microfluidic channels and functions, allowing parallel production and assembly of complete systems at high volume while maintaining precision through standardized manufacturing processes.
Solution Approach 2:
Standardized block interfaces and locating features enable the same manufacturing infrastructure to produce multiple different microfluidic system configurations. A single injection molding setup can produce various block types that are universally compatible, allowing high-volume production across different applications without requiring specialized tooling for each system variant.
2Adaptability or versatility
If microfluidic systems are customized for different applications, then adaptability is improved, but manufacturing precision and sealing reliability deteriorate
Solution Approach 1:
Customization is achieved at the block level rather than the system level. Each modular block is designed with standardized dimensions and locating features that ensure consistent manufacturing precision through injection molding. Different block types with customized channel configurations can be assembled to create adapted systems while maintaining the precision benefits of standardized manufacturing for the common interface features.
Solution Approach 2:
Each modular block is optimized for its specific function with localized channel geometries and features tailored to that block's purpose. The standardized interface regions maintain high manufacturing precision through injection molding, while the internal channel structures can be customized for specific analytical requirements, achieving both adaptability and precision.
3Ease of operation
If rapid reconfiguration of microfluidic systems is enabled, then ease of operation is improved, but sealing reliability and leak prevention worsen
Solution Approach 1:
The system is segmented into discrete blocks with standardized locating features that enable rapid assembly and reconfiguration. Each block contains integrated sealing elements positioned at the interfaces, ensuring that even when quickly assembled, the connections maintain reliable seals. The modular design allows users to reconfigure systems by simply connecting and disconnecting pre-sealed blocks.
Solution Approach 2:
Sealing features are pre-integrated into the block designs during manufacturing, with seals positioned and pre-compressed in their mounting locations. This preliminary preparation of sealing mechanisms ensures that when blocks are rapidly assembled during reconfiguration, the sealing action occurs automatically upon connection, maintaining reliability without requiring complex sealing procedures during rapid reconfiguration.
4Ease of manufacture
If modular blocks with precision locating features are used, then ease of manufacture is improved, but device complexity increases
Solution Approach 1:
The locating and sealing features are segmented into integrated components within each block rather than being separate assemblies. Each block contains molded-in locating protrusions and corresponding recesses, along with integrated sealing elements, that work together as a unified interface. This segmentation into self-contained blocks simplifies assembly while the internal integration manages the complexity of precision features.
Solution Approach 2:
Multiple functions are merged into single block components: locating features, sealing elements, and channel structures are combined into integrated modular blocks. The locating protrusions and sealing features are co-molded as single-piece components rather than separate parts, reducing assembly complexity while maintaining manufacturing precision through injection molding processes.
Data Source
AI summary
The present disclosure is directed to the creation and/or manipulation of microfluidic systems and methods that can be formed in pre-existing modular blocks. Microfluidic paths can be formed in one or more blocks, and when multiple blocks are used, the blocks can be used together to form a path across the blocks. The paths can be sealed to prevent fluid leakage. The modular blocks can be readily available blocks which can then be individually customized to achieve various microfluidic design goals. The paths can be formed in outer surfaces of the blocks and/or disposed through a volume of the blocks. The modular blocks can have a uniform design across various block types, making it easy to reconfigure systems and/or remove and replace blocks and other components of the system. Methods for constructing such systems, and using such systems, are also provided.