Multiplexed Electrospray Deposition Apparatus with Planar Dispenser
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Solution Overview
Problem
Existing electrospray deposition (ESD) apparatuses face challenges in multiplexing capabilities due to misalignment of source tips, requiring collimating masks that add complexity and limit the ability to deposit small volumes of substances reliably and efficiently on planar microfabrication schemes in lab-on-a-chip technologies.
Innovation Solution
A multiplexed ESD apparatus with a unitary planar dispenser etched from a silicon wafer through microfabrication, featuring equidistant dispensing legs with single-edged tips to prevent charge accumulation and corona discharge, allowing direct dispensing onto substrates with microhydrogel features functionalized with anchoring agents for immobilization of substances without the need for collimating masks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a collimating mask is used in ESD apparatus, then deposition pattern control is improved, but device complexity increases
Solution Approach 1:
The patent removes the collimating mask component entirely from the ESD apparatus. Instead of using a mask to control deposition patterns, the invention uses directly addressable individual dispensing tips that can be independently activated to deposit materials only where needed, eliminating the mask and its associated alignment complexity
Solution Approach 2:
The planar dispenser array serves multiple functions: it provides both the dispensing function and the pattern control function that previously required separate components (mask and dispenser). Each tip in the array can be independently controlled to create various deposition patterns without requiring physical masks
2Productivity
If multiple source tips are used in ESD apparatus, then productivity is improved, but reliability deteriorates due to misalignment
Solution Approach 1:
The patent integrates multiple dispensing tips into a single planar dispenser array structure fabricated from one silicon wafer. This monolithic integration ensures that all tips are inherently aligned relative to each other and to the substrate, eliminating the misalignment problems that occur when multiple separate tips or masks are used
Solution Approach 2:
The patent replaces mechanical alignment systems (such as mask alignment mechanisms) with a microfabricated planar array where alignment is achieved through the fabrication process itself. The tips are positioned with precise control through semiconductor manufacturing techniques, eliminating mechanical alignment errors
3Ease of operation
If conventional spotting or ink-jet methods are used, then ease of operation is maintained, but manufacturing precision deteriorates
Solution Approach 1:
The electrospray deposition process is self-aligning due to the electrostatic field geometry. The electric field naturally guides the spray from each tip to the corresponding location on the substrate, eliminating the need for complex mechanical alignment systems while maintaining high precision. This makes the system as easy to operate as conventional methods but with superior precision
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
Enables reliable and efficient deposition of picoliter volumes of substances onto substrates, improving biochip manufacturing by ensuring consistent dispensing and immobilization of proteins and other biomolecules, thereby enhancing the throughput and precision of lab-on-a-chip applications.
Implementation Method 1
Electrospray Deposition (ESD) has lately emerged as an important technology for dispensing a small volume of a liquid composition by transforming it into a fine mist of droplets
Implementation Method 2
a high voltage electric field is applied to a capillary through which the liquid composition passes. In application, ESD may be used to spray or dispense various kinds of biomacromolecules
Implementation Method 3
allow the biomacromolecules and/or synthetic polymers to accumulate and adhere on a substrate using electrostatic force
Implementation Method 4
charged nano-particles may be formed, which may be subsequently attracted to the counter-electrode by electrostatic force
Implementation Method 5
when the electrostatic force becomes stronger than surface tension, the liquid erupts from the tip of the capillary to form a fine jet
Implementation Method 6
Because the droplets formed by means of electrospray are tiny, the solvent evaporates and dries in a very short period of time
Data Source
AI summary
Multiplexed electrospray deposition apparatus capable of delivering picoliter volumes of one or more substances is disclosed. The apparatus may include a unitary planar dispenser etched from a silicon wafer through microfabrication or micromachining technology. The apparatus may be used as a deposition tool for making protein microarrays in a noncontact mode. Upon application of potential difference in the range of 7-9 kV, the substances may be dispensed directly, not through a collimating mask, onto a substrate with microhydrogel features functionalized with an anchoring agent.