Monolithic Photonic Crystal Sensor Fluid Integration
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Solution Overview
Problem
Current photonic crystal biosensors face challenges in integration with fluid containment structures, leading to complex and costly fabrication processes due to the need for precise alignment and sealing of submicron photonic crystal features with micron-scale fluid containment structures, which can result in sensing interferences and damage to the photonic crystal structures.
Innovation Solution
The integration of photonic crystal sensors with fluid containment structures in a monolithic structure, where the photonic crystal surface grating is part of the internal surface of the fluid containment structure, allowing for simultaneous fabrication and alignment, reducing the complexity and cost of the fabrication process while preventing fluid leakage and maintaining the integrity of the photonic crystal features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If photonic crystal sensors are integrated with fluid containment structures using separate fabrication processes, then sensing precision and structural integrity are improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the photonic crystal sensor fabrication and fluid containment structure fabrication into a single integrated process. The photonic crystal structure is formed within the fluid containment structure itself, eliminating the need for separate alignment and assembly steps. This merging of processes reduces device complexity while maintaining manufacturing precision through single-step pattern transfer techniques such as replica molding or imprint lithography.
2Manufacturing precision
If photonic crystal sensors are integrated with fluid containment structures using separate fabrication processes, then sensing precision is improved, but ease of manufacture deteriorates
Solution Approach 1:
The patent merges the fabrication of photonic crystal sensors and fluid containment structures into a single integrated process using techniques like replica molding or imprint lithography. This allows both structures to be formed simultaneously in one manufacturing step, greatly improving ease of manufacture while maintaining precise alignment through the single-step pattern transfer process.
3Productivity
If photonic crystal sensors are integrated with fluid containment structures in a monolithic structure, then productivity is improved, but manufacturing precision may deteriorate
Solution Approach 1:
The patent employs advanced imprint lithography or replica molding techniques that enable high-precision feature definition at submicron scales while maintaining high manufacturing throughput. By optimizing parameters such as mold material properties, curing conditions, and release mechanisms, the process achieves both high productivity and high manufacturing precision for the photonic crystal structures.
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 approach enables high-throughput, cost-effective manufacturing of photonic crystal sensors with integrated fluid containment structures, enhancing sensitivity and detection efficiency while minimizing sensing interferences and maintaining the structural integrity of the photonic crystal components.
Implementation Method 1
Photonic crystals, also commonly referred to as photonic bandgap structures, are periodic dielectric or metallic structures exhibiting a spatially periodic variation in refractive index that forbids propagation of certain frequencies of incident electromagnetic radiation.
Implementation Method 2
As diffraction and optical interference processes give rise to the photonic band gap phenomenon
Implementation Method 3
As diffraction and optical interference processes give rise to the photonic band gap phenomenon
Implementation Method 4
The photonic band gap phenomenon may be conceptualized as complete reflection of incident electromagnetic radiation having selected frequencies due to interaction with the periodic structural domains of a photonic crystal.
Data Source
AI summary
Photonic crystal (PC) sensors, and sensor arrays and sensing systems incorporating PC sensors are described which have integrated fluid containment and/or fluid handling structures. The PC sensors are further integrated into a sample handling device such as a microwell plate. Sensors and sensing systems of the present disclosure are capable of high throughput sensing of analytes in fluid samples, bulk refractive index detection, and label-free detection of a range of molecules, including biomolecules and therapeutic candidates. The present disclosure also provides a commercially attractive fabrication platform for making photonic crystal sensors and systems wherein an integrated fluid containment structure and a photonic crystal structure are fabricated in a single molding or imprinting processing step amendable to high throughput processing.