Patterned Membrane Structural Conformity
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Solution Overview
Problem
Existing patterned membranes for lateral flow assays lack structural conformity, leading to variability in manufacturing conditions and compromised reproducibility and comparability across different lots and manufacturers.
Innovation Solution
A patterned membrane structure in the form of an industrial-scale roll or sheet with a microporous membrane layer featuring multiple flow lanes separated by hydrophobic channels, allowing for precise and uniform production of large quantities of patterned membranes using industrial-scale equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional small-scale production methods are used for patterned membranes, then flexibility in manufacturing is maintained, but structural conformity and reproducibility across different lots and manufacturers are compromised
Solution Approach 1:
The membrane is divided into multiple flow lanes separated by hydrophobic separation channels, creating distinct functional zones that can be consistently manufactured. This segmentation allows each lane to be produced with uniform structural characteristics while maintaining overall membrane integrity across industrial-scale production
Solution Approach 2:
The invention changes the manufacturing approach from small-scale to industrial-scale production, utilizing controlled parameters such as membrane thickness (80-200 μm), pore size, and hydrophobic channel dimensions to achieve consistent structural conformity across large quantities of membranes produced by different manufacturers
2Productivity
If industrial-scale equipment is used for production, then productivity and quantity output increase, but achieving high structural conformity and pattern precision becomes more difficult
Solution Approach 1:
The patterned membrane structure with standardized flow lanes and separation channels serves multiple functions: it enables high-volume industrial production while maintaining consistent structural conformity, and can be used across different lateral flow assay applications. The universal design allows industrial-scale equipment to produce membranes with reproducible patterns that meet precision requirements
3Adaptability or versatility
If multiple flow lanes are integrated into a single membrane, then multiparameter testing capability is achieved, but manufacturing complexity increases
Solution Approach 1:
The membrane is segmented into multiple flow lanes separated by hydrophobic channels, with each lane capable of performing a different test parameter. This segmentation enables multiparameter testing while maintaining relatively simple manufacturing processes, as each lane can be produced with consistent structural characteristics using standardized industrial-scale methods
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 the production of patterned membranes with high structural conformity, improving reproducibility and comparability of results, and enabling the efficient manufacturing of large quantities with precise control over the pattern, addressing the limitations of conventional small-scale production methods.
Implementation Method 1
the flow lanes are separated by hydrophobic separation channels
Implementation Method 2
a fluid to be tested for the presence of a ligand is applied to one end of a porous membrane layer and flows in lateral direction through the membrane under the action of capillary forces
Data Source
AI summary
The present invention relates to a patterned membrane structure comprising a microporous membrane layer, wherein the microporous membrane layer includes a plurality of flow lanes, the flow lanes are separated by hydrophobic separation channels, and the flow lanes and hydrophobic separation channels form a repetitive pattern; and a method for manufacture of the patterned membrane structure. The patterned membrane structure according to the present invention represents an industrial scale precursor of membranes such as a multiparameter lateral flow membrane comprising separated flow lanes.